3D Striped Filament Structure for Sterilization-Stable Cushioning
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Solution Overview
Problem
Existing three-dimensional net-like structures used in mattresses and cushions suffer from random loop formation leading to shrinkage and wrinkles upon high-temperature sterilization, inadequate adaptation to human body posture, and insufficient elastic properties, failing to meet diverse needs for comfort and quality.
Innovation Solution
A three-dimensional striped structure formed by bonding continuous filaments randomly in loops, using polyethylene thermoplastic resin or polyester thermoplastic elastomer, with specific thermal expansion and hysteresis loss characteristics, providing anisotropic thermal expansion and high impact resilience, suitable for various applications including mattresses and cushions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a three-dimensional net-like structure is formed by conventional extrusion molding with random loop formation, then air permeability is achieved, but shrinkage and wrinkles occur during high-temperature sterilization
Solution Approach 1:
The patent applies parameter changes by controlling the thermal expansion rate of the three-dimensional net-like structure to be 0 to 8% in the longitudinal direction and 0 to 10% in the lateral direction after hot-air drying at 90°C for 30 minutes. This controlled parameter change prevents excessive shrinkage and wrinkle formation during high-temperature sterilization while maintaining air permeability
Solution Approach 2:
The patent utilizes thermal expansion characteristics by specifying that the structure exhibits controlled expansion behavior when exposed to hot air drying conditions. The thermal expansion rate is engineered to be within specific ranges (0-8% longitudinal, 0-10% lateral), allowing the material to accommodate temperature changes during sterilization without developing wrinkles or excessive shrinkage
2Ease of operation
If the three-dimensional net-like structure has high elastic property, then comfort for human body is improved, but hysteresis loss increases reducing energy efficiency
Solution Approach 1:
The patent applies parameter changes by optimizing the hysteresis loss to be within 13% to 34% and impact resilience to be 13 cm or higher. These parameter specifications balance the elastic properties for human comfort while controlling energy loss, allowing the material to provide cushioning and support without excessive energy dissipation
3Adaptability or versatility
If the three-dimensional net-like structure is designed for diverse applications, then adaptability to human body characteristics is improved, but product quality consistency becomes difficult to maintain
Solution Approach 1:
The patent applies universality by designing a three-dimensional net-like structure with standardized key parameters (thermal expansion rate: 0-8% longitudinal, 0-10% lateral; hysteresis loss: 13-34%; impact resilience: ≥13 cm) that can be universally applied across different applications including mattresses, cushions, and nursing care products. This standardized design maintains product quality consistency while adapting to diverse human body characteristics and application requirements
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 offers improved thermal stability, reduced shrinkage and wrinkle formation, enhanced elastic properties fitting human body needs, and suitable for diverse applications such as medical care and furniture, ensuring comfort and ease of use.
Implementation Method 1
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
Implementation Method 2
a hysteresis loss of not higher than 34% and not lower than 13%
Implementation Method 3
bonding continuous filaments partly at random in loops
Data Source
AI summary
A three-dimensional striped structure is provided which is formed by bonding continuous filaments in random in loops, has a longitudinal direction corresponding to an extruding direction, a lateral direction and a thickness direction perpendicular to the extruding direction, and 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 striped 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, and does not shrink during high-temperature sterilization.