Vehicle Seat Padding Assembly With Recyclable 3D Fiber Structure
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Solution Overview
Problem
Current vehicle seat padding materials, such as polyurethane foam, contribute to environmental issues due to high CO2 emissions during production, are not recyclable, and can retain moisture, leading to discomfort and increased weight in vehicle seats.
Innovation Solution
A vehicle seat element featuring a metallic structure, a padding made of solidified 3D entanglement of continuous thermoplastic fibers arranged irregularly, and an interface with fastening elements that secure the padding regardless of occupant posture or movement, using a recyclable plastics material that reduces CO2 emissions and enhances breathability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If polyurethane foam is used for padding, then comfort and support are provided, but CO2 emissions increase and recyclability is lost
Solution Approach 1:
The patent changes the material parameters from polyurethane foam to thermoplastic fibers, altering the physical and chemical properties to achieve both environmental benefits and functional performance. The fiber composition, density, and thermal properties are specifically tuned to match or exceed foam performance while enabling recyclability and reducing emissions.
Solution Approach 2:
The invention uses composite construction by combining thermoplastic fibers with a polymeric foam layer. This multi-material approach allows the fiber layer to provide breathability and recyclability while the foam layer maintains comfort and support properties, effectively resolving the contradiction between environmental impact and functional performance.
2Weight of moving object
If polyurethane foam is used for padding, then comfort is provided, but weight increases
Solution Approach 1:
The patent modifies the density and composition parameters of the padding material. By using thermoplastic fibers with controlled linear density and combining them in a specific entanglement structure, the overall padding weight is reduced while maintaining the necessary comfort characteristics through the composite foam layer.
3Object-affected harmful factors
If polyurethane foam is used for padding, then structure is provided, but breathability decreases
Solution Approach 1:
The patent applies local quality by creating a multi-layer structure where different materials perform different functions. The thermoplastic fiber layer provides breathability and moisture management in the outer region, while the polymeric foam layer provides structural support and comfort in the inner region, allowing each material to optimize its local function.
Solution Approach 2:
The composite construction combines the breathability advantages of thermoplastic fibers with the structural properties of polymeric foam. This allows the padding to simultaneously achieve high breathability for moisture management and adequate structural support, resolving the contradiction between these two properties.
4Reliability
If fastening elements pass through padding and interface, then security is improved, but padding integrity may be compromised
Solution Approach 1:
The patent uses a flexible polymeric foam layer that can accommodate the passage of fastening elements without compromising overall structural integrity. The foam's viscoelastic properties allow it to deform around the fasteners and maintain cushioning performance, while the thermoplastic fiber layer provides additional structural reinforcement.
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 lighter, more breathable, and ecologically friendly padding that maintains security and comfort across various postures and movements, while reducing environmental impact and allowing for easier recycling.
Implementation Method 1
a padding comprising a solidified 3D entanglement of continuous thermoplastic fibers
Implementation Method 2
a plurality of fastening elements for fastening the padding to the interface, each fastening element passing through at least a part of the padding and the receiving surface of the interface
Data Source
AI summary
A vehicle seat element, in particular a motor vehicle seat element, comprising a structure, typically metallic, a padding comprising a solidified 3D entanglement of continuous thermoplastic fibers arranged irregularly forming loops welded together, an interface located between the structure and the padding, the interface comprising a receiving surface covered at least in part by the padding, and a plurality of fastening elements for fastening the padding to the interface, each fastening element passing through at least a part of the padding and the receiving surface of the interface, transversely thereto.