Vehicle Interior Skin Material Fraying Suppression
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Solution Overview
Problem
Conventional optical fiber woven fabrics for vehicle interiors face issues with fraying at cut edges due to the sliding nature of monofilament optical fibers, which are not adequately fixed by traditional heat fusible yarns when woven with high fineness heat fusible fibers.
Innovation Solution
A woven fabric using synthetic resin fibers and side emission type optical fibers, where heat fusible fibers are twisted with multifilaments and heat fusion yarns to bond adjacent optical fibers in longitudinal directions, effectively suppressing fraying during cutting without compromising strength or increasing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If heat fusible fibers with high fineness are used to bond optical fibers, then the fabric can be woven with finer threads, but the optical fibers are not sufficiently fixed and fraying occurs during cutting
Solution Approach 1:
The patent uses a composite structure consisting of heat fusible fibers (for bonding) and reinforcement fibers (for mechanical strength) working together to fix the optical fibers. The heat fusible fibers provide initial bonding through heat fusion, while the reinforcement fibers provide additional mechanical strength to prevent fraying during cutting, resolving the contradiction between fineness and fixing strength.
2Reliability
If more heat fusible fibers are woven to suppress fraying, then the optical fibers are better fixed, but the material cost and fabric complexity increase
Solution Approach 1:
The patent divides the fixing function into two distinct components: heat fusible fibers that provide bonding through heat fusion, and reinforcement fibers that provide mechanical strength. This segmentation allows each component to be optimized for its specific function, achieving reliable optical fiber fixation without requiring excessive amounts of heat fusible fibers, thus reducing fabric complexity.
3Ease of manufacture
If traditional heat fusible yarns are used, then the weaving process is simple, but the optical fibers slide and fray at cut edges
Solution Approach 1:
The patent introduces reinforcement fibers as an intermediary element that works in conjunction with heat fusible fibers to provide additional mechanical strength. This intermediary component specifically addresses the fraying problem at cut edges without complicating the weaving process, as both fiber types can be integrated into the existing woven fabric 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 solution ensures that side emission type optical fibers are sufficiently fixed and fraying is suppressed when cut, maintaining the fabric's strength and appearance while reducing the need for excessive heat fusible fibers, thus offering a cost-effective and efficient solution for vehicle interior materials.
Implementation Method 1
heat fusible fibers as warps or wefts, wherein the synthetic resin fibers and the side emission type optical fibers adjacent to the synthetic resin fibers are bonded in respective longitudinal directions
Data Source
AI summary
A skin material for vehicle interior is bonded to a resinous vehicle interior base. The skin material for vehicle interior includes a woven fabric woven by using synthetic resin fibers, side emission type optical fibers, and heat fusible fibers as warps or wefts. The synthetic resin fibers and the side emission type optical fibers adjacent to the synthetic resin fibers are bonded in respective longitudinal directions thereof by the heat fusible fibers. Even when a plurality of the side emission type optical fibers are woven between the adjacent synthetic resin fibers, the adjacent side emission type optical fibers may be bonded to each other in the longitudinal direction by the heat fusible fibers. The heat fusible fibers may be obtained by twisting multifilaments and heat fusion yarns having a melting point lower than that of the multifilaments, and the multifilaments remain as constituent yarns after the bonding.