3D mesh structure
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Solution Overview
Problem
Three-dimensional net-like structures made from high surface density materials like polyethylene experience unnatural deformation and wrinkles when bent, making them difficult to shape according to care beds or sofa beds, and there is a need for lighter, more durable materials to alleviate nurse and care staff workload.
Innovation Solution
A three-dimensional net-like structure made from polyethylene with a specific swelling ratio dependent on shear rate, featuring a curled spring structure and a three-dimensional striped sparse-dense configuration, allowing for adequate flexibility and smooth bendability, achieved by extruding polyethylene filaments with a controlled diameter and density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high surface density material like polyethylene is used to make three-dimensional net-like structure, then durability is improved, but bendability deteriorates causing wrinkles and folds during bending
Solution Approach 1:
The patent changes the physical parameters of polyethylene by controlling its swelling ratio at specific shear rates (24.3 sec^-1) to be within 0.93 to 1.16, and controlling filament diameter to 0.2-1.3mm. This parameter optimization allows the material to maintain durability while achieving adequate flexibility for bending applications in care beds and sofa beds.
2Strength
If high surface density material is used, then structural strength is improved, but weight increases making it difficult to handle
Solution Approach 1:
The patent optimizes the bulk density parameter to be within 0.01 to 0.2 g/cm³ and controls the three-dimensional striped sparse-dense configuration. This parameter optimization achieves adequate structural strength while reducing weight to 1/3 or less of conventional materials, making the mattress easier to handle for nurses and care staff.
3Strength
If uniform dense structure is used, then material strength is improved, but flexibility and bendability deteriorate
Solution Approach 1:
The patent creates a three-dimensional striped sparse-dense configuration where sparse areas and dense areas appear alternately in the extrusion direction. This local quality variation provides both strength from dense areas and flexibility from sparse areas, enabling the material to bend smoothly without wrinkles while maintaining 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 structure achieves enhanced bendability and durability, reducing wrinkles and improving usability, while maintaining production efficiency and allowing for lighter weight, making it suitable for medical and nursing applications.
Implementation Method 1
made from polyethylene having a swelling ratio dependent on a shear rate and configured to have a curled spring structure of filaments randomly brought into contact with and tangled with each other
Data Source
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AI summary
By taking into account the difficulty in smoothly bending along the shape of, for example, a care bed, there is provided a three-dimensional net-like structure made from polyethylene having a swelling ratio dependent on a shear rate such as to be 0.93 to 1.16 at a shear rate of 24.3 sec-1 and 1.15 to 1.34 at a shear rate of 608 sec-1 and having an MFR of 3 to 35 g/ 10 min and a density of 0.82 to 0.95 g/cm3 and configured to have a spring structure of filaments randomly brought into contact with and tangled with one another, have a three-dimensional striped sparse-dense configuration in a lateral direction relative to an extrusion direction. The swelling ratio is shown as D2/D1 against shear rate when a molten thermoplastic resin is extruded to filaments from a capillary having a tube inner diameter D1 of 1.0 mmφ and a length of 10 mm and D2 denotes a diameter of cross section of the filaments extruded and cooled down.