Needled Nonwoven Foam Lamination for Seat Covers
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Solution Overview
Problem
Existing seat cover lamination textile composite materials lack a firm connection between nonwoven and foam components, leading to potential separation and inadequate drapability, particularly wrinkle-free arrangement, without the need for additional adhesive media.
Innovation Solution
A seat cover lamination textile composite material with a nonwoven component and foam component mechanically connected through needling, where binding fibers with specific fineness values and melting temperatures, and functional fibers with high resilience, are used to create a strong and secure connection, preventing foam/fleece separation forces, and allowing for adaptability to surface shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive process is used to connect nonwoven and foam components, then connection strength is improved, but device complexity and environmental harm increase due to additional adhesive media
Solution Approach 1:
The patent removes the adhesive component from the lamination process, connecting nonwoven and foam components directly through mechanical interlocking via loop fibers and needle punching, thereby eliminating the need for additional adhesive media and simplifying the overall structure
Solution Approach 2:
Loop fibers serve as an intermediary mechanical element that physically interlocks with the foam component through needle punching, creating a direct mechanical bond that replaces the chemical bond previously provided by adhesives
2Device complexity
If mechanical connection through needling is used, then device complexity is reduced, but connection strength deteriorates
Solution Approach 1:
The patent combines loop fibers with binding fibers to create a composite nonwoven structure where loop fibers provide mechanical interlocking with foam and binding fibers provide structural stability, achieving both strong connection and structural integrity through material composition
Solution Approach 2:
The patent specifies precise parameters for loop fiber fineness (1.5-24 dtex) and binding fiber fineness (1-9 dtex) to optimize the mechanical interlocking strength, ensuring that the needled connection achieves sufficient holding force without requiring complex additional processes
3Ease of operation
If binding fiber fineness is increased (thinner fibers), then drapability is improved, but connection strength deteriorates
Solution Approach 1:
The patent assigns different fiber fineness ranges to different functional requirements: loop fibers (1.5-24 dtex) provide drapability and comfort contact, while binding fibers (1-9 dtex) provide structural stability and connection strength, with each fiber type optimized for its specific local function within the nonwoven structure
Solution Approach 2:
The combination of loop fibers and binding fibers with different fineness values creates a composite nonwoven material that simultaneously achieves good drapability through the softer loop fibers and sufficient connection strength through the stronger binding fibers, resolving the trade-off between these two properties
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 solution provides a firm, secure connection between nonwoven and foam components, ensuring wrinkle-free drapability and high stability, while eliminating the need for additional adhesives, allowing the material to adapt to complex surfaces and maintain elasticity and durability.
Implementation Method 1
the binding fiber having a melting temperature which corresponds to a value from a value range of 100.degree. C. to 190.degree. C.
Data Source
Figure 1~3
AI summary
The invention relates to a laminated textile composite material, in particular a laminated textile composite material for a seat cover, the material comprising at least one non-woven fabric component (12) and at least one foam component (14) which is connected to the non-woven fabric component (12). The non-woven fabric component (12) and the foam component (14) are mechanically interconnected. According to the invention, the non-woven fabric component (12) and the foam component (14) are needled together, a holding force between the non-woven fabric component (12) and the foam component (14) being greater than 1 N, said force acting in opposition to a foam-non-woven separation force.