Vehicle Seatback Cover Lightweight Composite Manufacturing
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Solution Overview
Problem
Existing vehicle seatback covers either lack a protective cover, leading to carpet damage, or use heavy materials like woodstock for rigidity, which increases weight and compromises lightweight design goals.
Innovation Solution
A manufacturing method for a vehicle seatback cover using a lightweight composite material, such as a dry laid composite made from maleic anhydride modified polypropylene (MAPP) and reinforcing fibers, which is formed into a specific shape and bonded with a carpet for enhanced strength and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard material such as woodstock is used for a vehicle seatback cover, then rigidity and strength are ensured, but the product weight increases
Solution Approach 1:
The patent uses a composite material consisting of a porous base layer (replacing traditional hard materials like woodstock) combined with a reinforcing fiber layer. This composite structure provides the necessary rigidity and strength while significantly reducing weight compared to solid hard materials.
Solution Approach 2:
The patent employs a porous material for the seatback cover base layer, which reduces weight while maintaining structural integrity. The porous structure allows for weight reduction without completely sacrificing strength, as the reinforcing fiber layer compensates for the reduced density.
2Weight of moving object
If a lightweight plastic material is used for a vehicle seatback cover, then product weight is reduced, but required physical properties and strength are hardly ensured
Solution Approach 1:
The patent creates a composite structure where a lightweight porous base layer is combined with a reinforcing fiber layer. This combination allows the use of lightweight materials while restoring and enhancing strength properties through the reinforcing fibers, solving the problem of insufficient physical properties in lightweight plastics.
Solution Approach 2:
The patent changes the structural parameters of the material by creating a layered composite structure with specific porosity levels and fiber orientations. This allows optimization of both weight and strength parameters simultaneously, rather than being constrained by single-material limitations.
3Weight of moving object
If no vehicle seatback cover is used, then product weight is reduced, but the carpet finish material can be torn and durability is compromised
Solution Approach 1:
The patent uses a porous material that provides protective functions while maintaining lightweight characteristics. The porous structure offers sufficient durability to protect the carpet underneath without requiring a solid, heavy cover, thus balancing protection needs with weight reduction goals.
Solution Approach 2:
The composite structure with reinforcing fibers provides enhanced durability and protection for the carpet while keeping the overall weight low. The fiber reinforcement specifically addresses the protective function needed to prevent carpet damage without adding excessive weight.
Data Source
AI summary
The present disclosure relates to a manufacturing method of a vehicle seatback cover, comprising a lightweight composite manufacturing step of manufacturing a lightweight composite using a reinforcing fiber and a thermoplastic resin fiber, a lightweight composite forming step of forming the lightweight composite into a vehicle seatback cover shape and preparing a vehicle seatback cover material, and a carpet bonding step of bonding the vehicle seatback cover material and a carpet material.