Profiled Foam Upholstery Support for Breathable Sound Insulation
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Solution Overview
Problem
Conventional methods for producing fabrics for upholstery and soundproofing applications face challenges in achieving sufficient air permeability, breathability, and sound insulation while being cost-effective and simple to manufacture.
Innovation Solution
A method involving a first layer with a profiled surface, where elevations, depressions, and thin-layer areas are formed, and then bonded to a second layer through thermal decomposition and pressure, creating adhesive areas that enhance air permeability and sound absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If foam layers are made of closed-cell foam and plastic films to provide structural integrity, then strength is improved, but air permeability and breathability deteriorate because they have a blocking effect and do not allow moisture or heat transport
Solution Approach 1:
The patent uses open-cell foam structures instead of closed-cell foam to create inherent porosity that allows air and moisture transport while maintaining structural integrity. The profiling process further enhances this by creating additional pathways through the foam layer.
Solution Approach 2:
The foam layer is segmented through profiling into regions of different thickness, creating elevations and depressions that form channels for air and moisture flow. This segmentation maintains overall structural strength while providing localized pathways for transport.
2Object-affected harmful factors
If the foam layer is reticulated in a post-treatment process to eliminate membranes in the cell structure, then air and moisture transport is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent performs preliminary action by selecting open-cell foam with appropriate porosity before lamination, and uses profiling during the manufacturing process itself to create air channels, rather than requiring a separate post-treatment reticulation step.
Solution Approach 2:
The profiling process that creates the surface structure for aesthetic and ergonomic purposes is merged with the function of creating air and moisture transport channels, combining structural formation with functional enhancement in a single process step.
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 method results in a fabric with improved breathability and sound insulation properties, suitable for upholstery and soundproofing applications, while maintaining rigidity for ease of handling during manufacturing.
Implementation Method 1
the first layer is heated at least in regions, thereby at least partially thermally decomposing to form an adhesive layer and bonded to the second layer under the action of pressure
Data Source
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AI summary
The method involves profiling an upper side and/or a lower side of a perforated foam coating (20) formed from rubber foam and/or plastic foil such that an elevation section (24), a slot section (26) and a thin film section (30) are formed. The thin film section has a thickness that is smaller than a thickness of the perforated foam coating. The perforated foam coating is partially heated and connected with a textile coating (50) by material engagement. The thickness of the thin film section is reduced by the heating effect, and/or openings are formed in the thin film section. An independent claim is also included for a textile sheet including a perforated foam coating.