Seat Padding With Hot-Pressed 3D Fiber Borders for Edge Durability
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Solution Overview
Problem
Existing seat padding materials, typically made of urethane polymer foam, retain moisture in humid conditions and lack effective reinforcement at the edges, leading to potential issues with comfort and durability.
Innovation Solution
A method involving the use of a 3D tangle of continuous thermoplastic fibers arranged irregularly, forming loops, with a densified and stiffened edge created by hot pressing, which enhances edge reinforcement and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If urethane polymer foam is used for seat padding, then the padding provides softness and comfort, but it retains moisture in humid conditions
Solution Approach 1:
The patent uses a nonwoven fabric made of thermoplastic polymer filaments with inherent porosity that allows moisture to pass through, preventing moisture retention while maintaining comfort. The porous structure enables breathability and drainage, directly addressing the moisture retention issue of traditional foam materials.
Solution Approach 2:
The invention creates a composite structure by combining the nonwoven fabric padding with a foam insert and waterproof cover. This composite approach allows the padding to provide comfort through the foam while the nonwoven fabric layer prevents moisture retention, achieving both comfort and moisture resistance simultaneously.
2Productivity
If conventional stamping techniques are used to manufacture seat structure, then the structure is obtained efficiently, but the edges lack reinforcement and durability
Solution Approach 1:
The patent applies local quality by creating a densified and stiffened border around the periphery of the padding through selective hot pressing. This localized treatment reinforces only the edge areas that require durability while maintaining the overall manufacturing efficiency and comfort properties of the central padding region.
Solution Approach 2:
The densified border is created during the manufacturing process itself through hot pressing before final assembly, providing preliminary reinforcement to the edges. This preliminary action ensures edge durability is built into the structure during production rather than requiring additional reinforcement steps later.
3Reliability
If hot pressing is applied to create densified edge, then edge reinforcement and stability are enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the hot pressing operation with the existing manufacturing process for creating the padding. By integrating the densification step into the overall production flow and using the same thermoplastic material properties, the process complexity is minimized while achieving reliable edge 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 method produces a padding with improved edge reinforcement, ensuring better moisture resistance and enhanced durability while maintaining comfort, addressing the limitations of traditional urethane foam.
Implementation Method 1
Hot pressing of the 3D tangle of fibers, in all or part of the periphery of the padding, so as to produce a densified and stiffened edge
Implementation Method 2
Hot pressing of the 3D tangle of fibers... so as to produce a densified and stiffened edge
Implementation Method 3
Extrusion of a thermoplastic polymer in an extrusion die comprising extrusion nozzles distributed along a lengthwise direction and along a widthwise direction of the extrusion die, generating a curtain of continuous molten fibers, falling by gravity
Implementation Method 4
solidification of the 3D entanglement of fibers by immersion in a cooling liquid
Data Source
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AI summary
This disclosure relates to a method for manufacturing seat padding (3) comprising: - /A/ Providing padding (3) comprising a 3D entanglement of continuous thermoplastic fibers (5), irregularly arranged in loops welded together, the padding having a longitudinal direction, a widthwise direction, and a thickness direction, as well as a border, at the periphery extending along the edges of the padding; - /B/ Hot pressing the 3D fiber entanglement, in all or part of the periphery of the padding, so as to produce a densified and stiffened border (Bdr) of the padding, relative to a central area of the padding of lesser density and lesser stiffness. This disclosure further relates to padding as such, as well as to a vehicle seat comprising such padding.