Multilayer comfortable air fiber structure and preparation method therefor, and seat cushion, backrest and seat prepared therefrom
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Solution Overview
Problem
Existing seat cushions and backrests formed from single-layer air fiber sheets exhibit uneven density and hardness, leading to inconsistent comfort and material waste due to excessive compression during the forming process.
Innovation Solution
A multi-layer air fiber structure comprising a comfortable upper layer and a supportive lower layer, formed by hot-pressing air fiber sheets with different spinning directions, where the bottom surface of the upper layer is mechanically connected to the upper surface of the lower layer, using materials like thermoplastic elastomer and various connection methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single-layer air fiber sheets are used for seat cushion and backrest, then the manufacturing process is simple, but the density and hardness are uneven leading to poor comfort
Solution Approach 1:
The single-layer air fiber sheet is divided into multiple layers with different spinning directions. The patent uses at least two layers where adjacent layers have perpendicular spinning directions, allowing each layer to contribute differently to the overall structure, thereby achieving uniform density and hardness while maintaining manufacturing simplicity
Solution Approach 2:
The patent creates a composite structure by combining multiple air fiber sheets with different spinning directions. This composite approach allows the layers to work together synergistically, where the perpendicular spinning directions complement each other to achieve uniform physical properties that neither layer could achieve alone
2Ease of manufacture
If single-layer air fiber sheets are compressed to achieve desired thickness, then the forming process is straightforward, but material waste occurs due to excessive compression
Solution Approach 1:
The desired thickness and density are achieved through the preliminary arrangement of multiple layers with different spinning directions before the final compression step. Each layer is pre-configured to contribute to the target dimensions, reducing the need for excessive compression and minimizing material waste
3Device complexity
If single-layer air fiber sheets are used, then the structure is simple, but the compression ratio is inconsistent leading to uneven density and hardness
Solution Approach 1:
Different layers are assigned different spinning directions to create local variations in fiber orientation. The first layer has fibers oriented in one direction while the second layer has fibers oriented perpendicularly, allowing each local region to contribute differently to the overall uniformity of density and hardness
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The multi-layer structure achieves consistent density and hardness, enhancing comfort while reducing material waste and assembly complexity, with a weight reduction of over 25% compared to single-layer structures.
Implementation Method 1
the comfortable upper layer and the supportive lower layer are respectively formed by hot-pressing single-layer air fiber sheets
Implementation Method 2
formed by hot-pressing single-layer air fiber sheets... with the compression amount exceeding 30mm
Implementation Method 3
Thermoplastic elastomer... has the elasticity of rubber at normal temperature and has plasticity at high temperature
Implementation Method 4
the resin segments form physical cross-linking points by virtue of the force between chains... changes reversibly with the change of temperature
Implementation Method 5
a bottom surface of the comfortable upper layer is mechanically connected with an upper surface of the supportive lower layer
Data Source
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AI summary
The multi-layer comfortable air fiber structure disclosed in the present invention comprises a comfortable upper layer and a supportive lower layer, wherein the comfortable upper layer and the supportive lower layer are respectively prepared by hot pressing single-layer air fiber sheets formed from air fibers with different spinning directions, and a bottom surface of the comfortable upper layer is mechanically connected with an upper surface of the supportive lower layer. The present invention also discloses a preparation method for the multi-layer comfortable air fiber structure. The backrest or the backrest disclosed in the present invention is prepared from the above-mentioned multi-layer comfortable air fiber structure. The seat disclosed in the present invention is formed by the above seat cushion and backrest. The present invention meets the demand for comfort by adjusting the density and hardness of the comfortable upper layer and the supportive lower layer, and meanwhile achieves the purpose of saving materials.