Three-Layer Reinforcing Fabric for Urethane Foam Noise Control
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Solution Overview
Problem
Existing reinforcing base fabrics for urethane-foamed products face issues with noise generation due to urethane material permeation and crease formation when used in vehicle seats, particularly due to uneven fiber density in nonwoven fabrics, which affects durability and shape retention.
Innovation Solution
A three-layered reinforcing base fabric with a front surface layer and rear surface layer formed of thermoplastic resin fiber integration, and an intermediate foam layer, where the total weight per unit area ranges from 90 g/m2 to 260 g/m2, with the front surface layer having a weight per unit area of at least 20 g/m2, the rear surface layer at least 30 g/m2, and the intermediate layer between 30 g/m2 to 100 g/m2, preventing urethane material permeation and noise generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the thickness of the nonwoven fabric intermediate layer is increased to prevent permeation of urethane material, then noise prevention is improved, but mold shape followability degrades and breakage or crease formation occurs
Solution Approach 1:
The patent changes the physical parameters of the intermediate layer by using foam material with specific density (0.03 to 0.10 g/cm³) and weight per unit area (30 to 100 g/m²), which provides effective permeation resistance while maintaining thin profile and mold followability
Solution Approach 2:
The patent creates a composite structure by integrating foam material with nonwoven fabric, combining the permeation resistance of foam with the friction-reducing properties of fabric to achieve both noise prevention and mold followability
2Object-affected harmful factors
If the fiber density of the nonwoven fabric intermediate layer is increased to prevent permeation, then noise prevention is improved, but manufacturing complexity increases and uniformity becomes difficult to maintain
Solution Approach 1:
The patent simplifies the structure by changing to foam material with controlled density parameters, achieving uniform permeation resistance without the complexity of varying fiber densities in nonwoven fabric
Solution Approach 2:
The foam material provides homogeneous structure and uniform density throughout the intermediate layer, ensuring consistent permeation resistance across the entire surface without the unevenness inherent in nonwoven fabric
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 effectively prevents urethane material permeation, reduces noise, and maintains shape retention, while allowing for mold shape followability and preventing crease formation, enhancing the durability and performance of urethane-foamed products in vehicle seats.
Implementation Method 1
an intermediate layer formed of a foam and interposed between the front surface layer and the rear surface layer
Data Source
AI summary
A reinforcing base fabric for an urethane-foamed product includes: a front surface layer and a rear surface layer formed of a fiber integration of a thermoplastic resin; and an intermediate layer formed of a foam and interposed between the front surface layer and the rear surface layer. The total weight per unit area ranges from 90 g/m2 to 260 g/m2. The front surface layer is formed of a fiber integration having a weight per unit area of equal to or greater than 20 g/m2. The rear surface layer is formed of a fiber integration having a weight per unit area of equal to or greater than 30 g/m2. The intermediate layer is formed of a foam layer having a weight per unit area of 30 g/m2 to 100 g/m2.