Textile Product with High Tg Polymer Blend for Automotive Cushioning
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Solution Overview
Problem
Polyurethane (PUR) foams used in the automotive sector have drawbacks such as the use of isocyanates, which are problematic during manufacturing, storage, processing, and transport, and their replacement materials do not meet the required compressive elasticity standards, especially at elevated temperatures.
Innovation Solution
A textile product composed of carrier fibers with a polymer blend having a glass transition temperature greater than 75 °C and binding fibers that contribute to compressive elasticity without the need for additional binding agents, forming a thermally stable and pressure-elastic fiber fleece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyurethane (PUR) foams are used for cushioning materials, then compressive elasticity and cushioning performance are achieved, but harmful factors arise from isocyanate off-gassing and manufacturing risks
Solution Approach 1:
The invention extracts and removes the harmful isocyanate component from the cushioning material system entirely. Instead of using PUR foam chemistry, the patent employs a purely textile-based solution with polyester fibers and binding elements that achieve cushioning performance without any isocyanates, eliminating the harmful off-gassing and manufacturing risks associated with PUR foams
Solution Approach 2:
The invention creates a composite textile structure combining different fiber types (polyester fibers with specific properties) and binding elements (meltable or dissolvable binding agents) to achieve the cushioning performance previously provided by PUR foams. This composite textile material replicates the functional properties of PUR foam while avoiding its harmful chemical components
2Object-affected harmful factors
If alternative materials replace PUR foams, then harmful factors are eliminated, but compressive elasticity at elevated temperatures deteriorates
Solution Approach 1:
The invention carefully selects and controls the glass transition temperature (Tg) parameter of the polyester fibers used in the textile product. By choosing fibers with Tg > 75°C, the material maintains its structural integrity and compressive elasticity at elevated temperatures (up to 70°C testing conditions) while still being free from isocyanates. This parameter optimization ensures the alternative material meets automotive sector temperature requirements
Solution Approach 2:
The invention develops a composite textile structure combining polyester fibers with specific thermal properties and binding elements that maintain compressive elasticity at elevated temperatures. The composite nature of the textile product, with its specific fiber arrangement and binding mechanism, enables it to match the thermal stability and elastic recovery of PUR foams without using harmful chemicals
3Strength
If additional binding agents are used in textile products, then fiber bonding and structural integrity are improved, but manufacturing complexity and processing steps increase
Solution Approach 1:
The invention employs binding elements that are integrated directly into the textile product structure during the fabric formation process itself. The binding agents (meltable or dissolvable) are incorporated into the nonwoven fabric as it is being manufactured, allowing the fibers to bond to each other as part of the normal production process. This eliminates the need for separate post-manufacturing bonding steps, reducing overall manufacturing complexity while maintaining strong fiber bonding
Solution Approach 2:
The invention merges the binding function with the fabric formation process. The binding agents are combined with the polyester fibers during nonwoven fabric production, so that the bonding action occurs simultaneously with fabric creation rather than as a separate subsequent step. This integration simplifies the overall manufacturing process while ensuring adequate fiber bonding and structural integrity
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 textile product exhibits stable restoring forces at elevated temperatures, meeting the automotive sector's thermal stability and compressive elasticity requirements, and eliminates the need for additional binding agents, making it a suitable replacement for PUR foams.
Implementation Method 1
the carrier fibers comprise a polymer blend with a glass transition temperature (Tg) > 75 °C
Implementation Method 2
the fibers are mixed, pressed together to form a fabric, and the fabric is then thermoformed
Data Source
Figure 1
AI summary
The invention relates to a textile product comprising support fibres and binding fibres, said support fibres comprising a polymer blend having a glass transition temperature > 70°C. The invention also relates to a method for producing a textile product, comprising the following steps: support and binding fibres are provided; said support and binding fibres are processed to form a textile product, said support fibres having a polymer blend with a glass transition temperature > 70 °C. The invention also relates to the use of a textile product for producing textile objects, preferably interior textiles, semi-technical textiles, technical textiles, home textiles, clothes and/or textiles for medical use.