Needle punched carpet

Solution Overview

Problem

Automotive needle punched carpets face challenges in abrasion resistance and weight, with traditional solid fibers prone to fibrillation and whitening due to wear, limiting their use in high-end vehicles where lightweight and durable flooring is required.

Innovation Solution

Incorporating staple fibers with a hollow cross-section in the needle punched carpet face layer, which increases abrasion performance and allows for a lighter weight while maintaining visual appeal, by using up to 100% hollow fibers and optionally combining with binding fibers for enhanced durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional solid fibers are used in needle punched carpet face layer, then abrasion resistance is improved, but weight increases and whitening occurs due to wear

Engineering Contradiction:

Improveabrasion resistanceVSAvoidcarpet weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The invention changes the cross-sectional geometry parameter of the fibers from solid to hollow. This parameter change reduces the weight of the carpet while maintaining or improving abrasion resistance, as the hollow structure provides both weight reduction and enhanced mechanical properties through the air cavity reinforcement

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses hollow fibers as a composite material structure where the air cavity within the fiber acts as a lightweight reinforcement element. This composite approach (fiber material + air cavity) reduces overall density and weight while maintaining structural integrity and abrasion resistance

Inventive Principle:

Principle #40Composite materials

2Strength

If traditional solid fibers are used in needle punched carpet face layer, then structural strength is maintained, but whitening effect occurs due to fibrillation under wear

Engineering Contradiction:

Improvestructural strengthVSAvoidwhitening effect

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The invention changes the cross-sectional geometry parameter of the fibers from solid to hollow. This parameter change reduces the weight of the carpet while maintaining or improving abrasion resistance, as the hollow structure provides both weight reduction and enhanced mechanical properties through the air cavity reinforcement

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts the potential weakness of hollow fibers (perceived susceptibility to breakage) into a benefit by demonstrating that the hollow structure actually reduces fibrillation and whitening. The air cavity within the hollow fiber acts as a stress distribution element that prevents the propagation of micro-cracks, thereby converting the perceived vulnerability into improved wear resistance and aesthetic durability

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If area weight is increased to improve abrasion performance, then abrasion resistance is improved, but weight increases contradicting lightweight trends

Engineering Contradiction:

Improveabrasion performanceVSAvoidcarpet weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The invention changes the cross-sectional geometry parameter of the fibers from solid to hollow. This parameter change reduces the weight of the carpet while maintaining or improving abrasion resistance, as the hollow structure provides both weight reduction and enhanced mechanical properties through the air cavity reinforcement

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention utilizes hollow fibers which can be considered as porous materials with internal cavities. These porous structures reduce the overall density and weight of the carpet while the cavity walls provide reinforcement that maintains or enhances abrasion resistance, eliminating the need to increase area weight to achieve better wear performance

Inventive Principle:

Principle #31Porous materials

Data Source

PatentUS10465320B2Needle punched carpet

Publication Date: 2019.11.05 AUTONEUM MANAGEMENT AG

AI summary

A needle punched carpet for use in a car is disclosed. The needle punched carpet comprises at least a needle punched facing layer defining a top layer and made of staple fibers. The staple fibers comprise hollow fibers having a hollow fiber content that is at least more than 45 weight % of the total staple fibers.