Vehicle Bubble Sheet Fabrication via Patterned Polymer Bonding
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Solution Overview
Problem
Conventional luggage covering mats for vehicles, such as those using wood flour reinforced boards or single-layer polymer sheets, face issues with odor generation, low rigidity, and complex fabrication processes, while existing air bubble sheets do not achieve weight reduction effectively.
Innovation Solution
A method involving preheating a polymer sheet, forming patterns using a pattern forming machine, and bonding the patterned sheet with a non-woven fabric using an adhesive layer, which simplifies the process and enhances rigidity and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a wood flour reinforced board or natural fiber reinforced board is used for luggage covering mats, then the sheet provides structural support, but odor is generated when components are carbonized or oxidized
Solution Approach 1:
The invention extracts and removes the harmful natural fiber components (wood flour, natural fibers) from the polymer sheet composition. By using only synthetic polymer materials without natural fiber reinforcements, the source of odor generation through carbonization and oxidation is eliminated, while structural support is maintained through the polymer matrix and bubble structure.
Solution Approach 2:
The invention changes the material composition parameters by eliminating natural fiber content and using exclusively synthetic polymer materials. This parameter change prevents the chemical reactions (carbonization and oxidation) that occur with natural fibers, thereby preventing odor generation while maintaining structural integrity through alternative design features.
2Weight of moving object
If a single-layer polymer sheet is used for luggage covering mats, then the sheet is lightweight and simple to manufacture, but the rigidity is low
Solution Approach 1:
The invention introduces a bubble structure (porous configuration) within the single-layer polymer sheet. These bubbles act as internal support elements that significantly enhance the rigidity and load-bearing capacity of the sheet without adding substantial weight. The porous structure provides structural reinforcement while maintaining the lightweight characteristic of the polymer material.
Solution Approach 2:
The invention creates a composite structure by incorporating bubbles (air pockets) within the polymer matrix. This composite configuration combines the lightweight polymer material with the structural support provided by the bubble network, achieving both weight reduction and improved rigidity simultaneously.
3Strength
If a separate filler is included within air bubbles to create an air bubble sheet, then the sheet achieves improved structural properties, but the fabricating process becomes complicated and weight reduction is not achieved
Solution Approach 1:
The invention extracts and removes the separate filler material from the bubble structure. By leaving the bubbles filled only with air (without additional fillers), the fabrication process is simplified significantly, and weight reduction is achieved since no extra filler materials need to be incorporated, processed, or bonded within the bubble structures.
Solution Approach 2:
The invention segments the bubble structure into independent, discrete bubbles distributed throughout the polymer sheet. Each bubble acts as an independent structural element, and the segmentation allows for simpler fabrication where bubbles are formed individually within the polymer matrix rather than requiring complex assembly of filler-containing structures.
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 resulting bubble sheet for vehicles achieves improved rigidity and reduced weight, with patterns formed efficiently through a simplified fabrication process, outperforming comparative examples in terms of weight and maximum load capacity.
Implementation Method 1
bonding the pattern polymer sheet and a non-woven fabric sheet
Implementation Method 2
preheating a first polymer sheet; preheating the first polymer sheet may be performed at a temperature of 180 to 260° C. for 50 to 120 seconds
Data Source
AI summary
A method of fabricating a bubble sheet for vehicles includes steps of: preheating a first polymer sheet; providing the first polymer sheet to a partially preheated pattern forming machine to form a pattern polymer sheet including a plurality of patterns having a prominent or depressed shape; and bonding the pattern polymer sheet and a non-woven fabric sheet.