Thermoplastic Fiber Seat Padding With a Densified Support Border
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Solution Overview
Problem
Current seat padding manufacturing methods fail to create a durable and comfortable seat with a consistent surface finish, as existing methods result in irregular edges and inadequate support due to the use of polyurethane foam that retains moisture and lacks a uniform stiffness distribution.
Innovation Solution
A method involving a 3D entanglement of continuous thermoplastic fibers arranged irregularly, with hot pressing to create a densified and stiffened border around the perimeter, providing enhanced support and comfort by folding the border against the central zone, while using thermoplastic polymers like PET for the fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If polyurethane foam is used for seat padding, then comfort is provided, but moisture retention occurs and edges become irregular
Solution Approach 1:
The patent changes the material parameter from polyurethane foam to thermoplastic polymer fibers, which fundamentally alters the moisture retention property. The fibrous structure allows moisture to pass through rather than being retained, eliminating the harmful effect while maintaining durability through the inherent stability of thermoplastic materials.
Solution Approach 2:
The patent uses a composite structure of thermoplastic polymer fibers forming a 3D entanglement network. This composite fibrous material combines the benefits of moisture permeability with structural durability, creating a padding that resists degradation while providing comfort.
2Manufacturing precision
If hot pressing is applied to create a stiffened border, then support and surface finish are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies hot pressing only to the peripheral region of the padding to create a stiffened border, while leaving the central region with its original soft, compliant properties. This localized treatment achieves consistent surface finish and edge support without requiring complex manufacturing equipment, as the same hot press can selectively treat different zones.
Solution Approach 2:
The padding is functionally segmented into a stiffened peripheral border and a soft central zone. The hot pressing process creates this segmentation by selectively densifying the perimeter fibers, providing structural support at the edges while maintaining comfort in the center, thereby improving surface finish consistency through functional zoning.
3Object-affected harmful factors
If thermoplastic polymer fibers are used instead of polyurethane foam, then moisture retention is reduced, but manufacturing precision is required for fiber entanglement
Solution Approach 1:
The thermoplastic polymer fibers utilize their own thermal properties to achieve entanglement and bonding. During the hot pressing process, the fibers are heated to their melting point, causing them to soften and entangle with each other, then cool and solidify to form a stable 3D structure. This self-bonding mechanism eliminates the need for external adhesives or complex weaving equipment, reducing manufacturing precision requirements while effectively reducing moisture retention through the fibrous 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 method produces a seat padding with improved durability and comfort by creating a stiffened border that enhances support and maintains a consistent surface finish, addressing the issues of irregular edges and moisture retention in traditional polyurethane foam paddings.
Implementation Method 1
Extruding a thermoplastic polymer in an extrusion die comprising extrusion nozzles distributed in a lengthwise direction and along a widthwise direction of the extrusion die, generating a curtain of continuous molten fibers, falling by gravity
Implementation Method 2
Hot pressing of the 3D entanglement of fibers at all or part of the periphery of the padding, so as to produce a densified and stiffened border of the padding
Implementation Method 3
Hot pressing of the 3D entanglement of fibers at all or part of the periphery of the padding
Implementation Method 4
optionally solidifying the 3D entanglement of fibers by immersion in a cooling liquid
Data Source
AI summary
The present disclosure relates to a method for manufacturing a seat padding comprising:—/A/ providing a padding comprising a 3D entanglement of continuous thermoplastic fibers arranged irregularly forming loops welded together, the padding having a length direction, a width direction, and a thickness direction, as well as a border on the periphery extending along the edges of the padding—/B/ Hot pressing of the 3D entanglement of fibers, at all or part of the periphery of the padding, so as to produce a densified and stiffened border of the padding, relative to a central zone of the padding of less density and of less rigidity. The present disclosure also relates to padding as such, as well as to a vehicle seat comprising such padding.