Seat Padding Fastening Structure for Breathable Recyclable Covers
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Solution Overview
Problem
Existing fastening systems for vehicle seat covers are inefficient and environmentally unfriendly, particularly when using polyurethane foam padding, which is not breathable and generates high CO2 emissions during production, and lacks effective recycling options.
Innovation Solution
A padding system with a groove and hole design integrated with a fastening device, comprising a clip-on part, base part, and attachment rods with a stop collar, made from recyclable thermoplastic polymer, allowing easy attachment and detachment of covers while reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If polyurethane foam padding is used for vehicle seats, then the padding provides good cushioning and support, but it is not breathable and generates high CO2 emissions during production with no effective recycling options
Solution Approach 1:
The padding is constructed from a three-dimensional entanglement of continuous thermoplastic fibers with controlled porosity, creating a breathable structure that allows air circulation while maintaining cushioning properties. This porous fiber network replaces the non-breathable polyurethane foam, solving the breathability issue without compromising support.
Solution Approach 2:
The invention changes the material parameter from polyurethane foam to thermoplastic polymer fibers, fundamentally altering the environmental characteristics. This material substitution reduces CO2 emissions during production and enables recyclability, while the fiber entanglement structure provides the necessary mechanical properties for seat padding.
2Reliability
If traditional fastening systems are used to attach covers to padding, then the covers can be secured, but the systems are inefficient and environmentally unfriendly with difficult recycling
Solution Approach 1:
The fastening device is integrated directly into the padding structure through ultrasonic welding, merging two previously separate components (padding and fastening mechanism) into a single unified assembly. This integration ensures reliable cover attachment while simplifying end-of-life recycling, as the entire assembly can be processed together without separation requirements.
Solution Approach 2:
The fastening device and padding are made from compatible thermoplastic materials that can be processed together. This material homogeneity allows the entire assembly to be recycled through the same process, eliminating the need to separate different material types and significantly improving recycling efficiency.
3Strength
If a fastening device is inserted into the padding before melting, then the fastening device can be securely integrated, but the manufacturing process requires precise positioning and alignment
Solution Approach 1:
The fastening device is inserted into the padding in its initial state before the ultrasonic welding process. This preliminary positioning action allows the device to be correctly aligned with the padding structure before the melting and bonding operation occurs, ensuring proper integration while maintaining manufacturing simplicity.
Solution Approach 2:
The mechanical insertion and positioning of the fastening device is replaced by ultrasonic vibration-based welding. The ultrasonic energy facilitates the bonding process without requiring complex mechanical alignment systems, reducing manufacturing precision requirements while ensuring strong integration between the fastening device and padding.
4Strength
If the rod is melted to form a stop collar, then the fastening device is securely retained in the padding, but the melting process requires controlled heat application to avoid damage
Solution Approach 1:
The ultrasonic welding process uses high-frequency periodic vibrations to generate localized heat at the contact interface between the rod and padding. This periodic action melts the thermoplastic materials only where needed to form the stop collar, creating strong retention while preventing excessive heat spread that could damage surrounding areas.
Solution Approach 2:
The ultrasonic welding process exploits phase transitions of the thermoplastic materials, melting them locally at the bonding interface through vibrational energy. The controlled melting and subsequent cooling create a strong mechanical interlock forming the stop collar, while the localized nature of the phase transition prevents overheating and damage to the broader structure.
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 system provides a breathable, lightweight, and recyclable solution for attaching vehicle seat covers, reducing CO2 emissions and enabling simultaneous recycling of padding and fastening components.
Implementation Method 1
The stop collar is, for example, obtained by ultrasonic fusion. In this case, the melting operation consists of using at least one sonotrode and an anvil to melt the end of the rod in order to obtain the stop collar
Implementation Method 2
The stop collar may be welded to the padding. In this case, the melting operation includes a welding operation. The stop collar is then thus obtained by melting material from a free end of the rod, causing the stop collar to be welded to the bottom wall of the groove in the padding
Data Source
AI summary
A padding system comprising a padding comprising a groove on a surface of the padding intended to receive an occupant, a hole extending along an axis and traversing the padding from a bottom wall of the groove, a fastening device integral to the padding, configured to provide the attachment of a cover to the padding, the fastening device comprising: a fastening part comprising a portion configured to allow attaching the cover, the fastening part being retained so as to project into the groove, a base part extending under the fastening part into the hole, at least one attachment part connected to the base part, comprising a rod traversing the padding at a distance from the hole and a stop collar projecting from the bottom wall of the groove, the stop collar being obtained by an operation of melting material from a free end of the rod.