Polypropylene Composite with Penetrating Apertures for Aesthetic Durability
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Solution Overview
Problem
Existing composite materials used in rigid products like chair seats and backrests lack both structural durability and aesthetic appeal, particularly when exposed to outdoor conditions, and current manufacturing methods are costly and complex.
Innovation Solution
A composite material is produced by combining a first rigid polymeric layer with a second layer featuring alternating solid areas and openings, where the first layer penetrates the second layer's openings, creating a mechanical and adhesive bond while exposing the second layer's surface, mimicking fabric or weave patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If molded plastic materials are used to fabricate chair seats and backrests, then manufacturing efficiency and structural consistency are improved, but aesthetic appearance deteriorates
Solution Approach 1:
The patent combines a plastic base layer with a fabric-like top layer to create a composite material that integrates the manufacturing advantages of molded plastic with the aesthetic qualities of fabric. The plastic layer provides structural integrity while the fabric layer contributes visual appeal, resolving the contradiction between productivity and aesthetic appearance.
Solution Approach 2:
The invention merges two distinct materials (molded plastic and fabric) into a single integrated composite structure. The fabric layer is bonded to the plastic base layer, combining the structural benefits of molded plastic with the aesthetic benefits of fabric, thereby achieving both manufacturing efficiency and visual appeal simultaneously.
2Shape
If upholstery fabrics or cane are used for seats and backrests, then aesthetic appearance is improved, but durability and wear resistance deteriorate
Solution Approach 1:
The composite structure pairs a durable plastic base layer with an aesthetic fabric top layer. The plastic layer provides wear resistance and structural support, while the fabric layer delivers visual appeal. This combination resolves the contradiction by assigning different functional roles to each material layer.
Solution Approach 2:
The invention applies different material properties to different layers: the plastic base layer is optimized for durability and structural support, while the fabric top layer is optimized for aesthetic appearance. This local differentiation of material qualities allows each layer to excel at its specific function, resolving the durability-aesthetic contradiction.
3Shape
If plastic woven or knitted fabrics are used to form structural parts, then aesthetic appearance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent uses a composite of molded plastic and fabric layers, where the plastic layer can be manufactured using standard molding techniques and the fabric layer is subsequently bonded to it. This approach achieves fabric-like aesthetics without requiring the complexity of weaving or knitting plastic into three-dimensional structures, thereby reducing manufacturing complexity.
Solution Approach 2:
The invention segments the structure into two separate layers (plastic base layer and fabric top layer) that can be manufactured independently and then combined. This segmentation allows each layer to be produced using simpler, more cost-effective processes rather than requiring complex integrated manufacturing of plastic woven fabrics.
4Strength
If fibers are entirely embedded in composite material, then structural integrity is improved, but aesthetic appearance deteriorates
Solution Approach 1:
The invention applies different fiber embedding strategies to different layers: the plastic base layer contains entirely embedded fibers for structural integrity, while the fabric top layer has visible fiber patterns for aesthetic appeal. This local differentiation resolves the contradiction between strength and appearance.
Solution Approach 2:
The composite structure allows the plastic layer to provide structural reinforcement through embedded fibers while the fabric layer provides aesthetic surface patterns. The combination of these two layers with different fiber configurations resolves the contradiction between structural integrity and visual appearance.
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 composite material achieves enhanced durability and aesthetic appeal by integrating a visible fabric-like surface while maintaining structural integrity, suitable for various rigid and semi-rigid applications.
Implementation Method 1
heating said first rigid layer, to cause a surface portion of predetermined thickness s1 of said first rigid layer to be softened
Implementation Method 2
cause a surface portion of predetermined thickness s1 of said first rigid layer to be softened from a first side of said first rigid layer
Implementation Method 3
pressing said second layer on said first layer to cause portions 2a of said softened surface portion of said first layer to fit into the through openings 3c of said second layer
Data Source
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AI summary
A composite material comprises a first rigid layer (2) of polypropylene penetrated by a second layer (3) of polypropylene to form a composite layer of predetermined thickness (S) with said first layer (2), wherein said second layer (3) comprises an alternation of solid areas (3a, 3b) and through apertures (3c) throughout the thickness of said second layer (3), whereas portions (2a) of said first layer (2) fit into the through holes (3c) of said second layer (3).