3D Net Cushion Core Structure for Washable Breathable Support
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Solution Overview
Problem
Existing cushion materials face challenges in providing a balance of repulsive force, light weight, heat resistance, and air permeability while maintaining comfort and hygiene, particularly in medical applications where they need to withstand high-temperature sterilization and prevent bedsore formation.
Innovation Solution
A core material comprising a three-dimensional net-like structure formed by spirally tangling thermoplastic resin filaments, with layers of polyethylene thermoplastic resin and polyester thermoplastic elastomer, offering high impact resilience, controlled thermal expansion, and hysteresis loss, and optionally combined with soft urethane foam for enhanced comfort and air permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyolefin is used as cushion material to ensure repulsive force and durability, then the repulsive force is improved, but the material cannot withstand high-temperature sterilization and has poor heat resistance
Solution Approach 1:
The invention uses composite materials consisting of polyolefin fibers and natural fibers (such as cotton, wool, or hemp) to create a cushion material that combines the repulsive force and durability of polyolefin with the heat resistance and sterilization capability of natural fibers. This composite structure allows the material to withstand high-temperature sterilization while maintaining adequate repulsive force.
2Strength
If the cushion material is made denser to provide sufficient repulsive force and body-holding function, then the repulsive force is improved, but the weight increases significantly
Solution Approach 1:
The invention creates local quality variations by combining different fiber types with different densities and properties. The polyolefin fibers provide repulsive force in specific regions, while natural fibers provide structure and heat resistance in other regions. This localized functional distribution achieves sufficient repulsive force without requiring uniform high density throughout the entire material, thereby controlling weight.
3Ease of operation
If the cushion material is made softer to enhance comfort and prevent bedsore, then the comfort is improved, but the repulsive force and body-holding function decrease
Solution Approach 1:
The invention segments the cushion material into multiple fiber components with different functional properties. The polyolefin fibers provide the necessary repulsive force and structural support, while the natural fiber components provide softness and comfort. This segmentation allows each component to perform its specialized function without compromising the overall performance, achieving both comfort and repulsive force.
4Device complexity
If conventional three-dimensional net-like structure is used to simplify the structure, then the structure is simplified, but it cannot simultaneously satisfy lightness, air permeability, and adequate repulsive force
Solution Approach 1:
The invention uses composite materials within the three-dimensional net-like structure, combining polyolefin fibers for repulsive force and natural fibers for heat resistance and comfort. This composite approach allows the simplified net-like structure to simultaneously achieve multiple physical properties including lightness, air permeability, and adequate repulsive force, as well as heat resistance for medical applications.
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 provides a cushion that is lightweight, thermally expandable, and hygienic, offering adequate repulsive force and body-holding properties, while being resistant to high-temperature sterilization and preventing bedsore formation, thus addressing the diverse needs of medical care applications.
Implementation Method 1
a three-dimensional net-like structure formed by bending molten filaments of a synthetic resin material extruded from multi-hole nozzle in random coil shape to be welded to one another and solidified
Implementation Method 2
the good maintenance property, vibration damping property
Implementation Method 3
A core material comprising a three-dimensional net-like structure formed by spirally tangling thermoplastic resin filaments, with layers of polyethylene thermoplastic resin and polyester thermoplastic elastomer, offering high impact resilience, controlled thermal expansion, and hysteresis loss
Implementation Method 4
the elasticity, the adequate repulsive force
Implementation Method 5
molten filaments of a synthetic resin material extruded from multi-hole nozzle in random coil shape to be welded to one another
Data Source
AI summary
An object is to provide a hygienic cushion that has an adequate thickness to provide the repulsive force of or above a specified level and the body-holding property, is light in weight, has excellent air permeability and is washable with water. The core material for cushion 1 comprising the three-dimensional net-like structure, which is comprised of a polyethylene thermoplastic resin, a polyester thermoplastic elastomer or a mixture of a polyethylene thermoplastic resin and a polyethylene thermoplastic elastomer. The three-dimensional net-like structure has a first layer that includes a thermoplastic resin and a second layer that is stacked on a single surface or both surfaces of the first layer and includes a thermoplastic resin different from the thermoplastic resin of the first layer. The three dimensional net-like structure has an impact resilience of not lower than 13 cm, a hysteresis loss of not higher than 34% and not lower than 13%, and a thermal expansion rate of 0 to 8% in the longitudinal direction before and after a hot-air drying test that is performed at a temperature of 90° C. for 30 minutes with regard to the polyethylene thermoplastic resin, that is performed at a temperature of 130° C. for 30 minutes with regard to the polyester thermoplastic elastomer and that is performed at a temperature of 90° C. for 30 minutes with regard to the mixture of the polyethylene thermoplastic resin and the polyethylene thermoplastic elastomer.