Bulked-Yarn Woven Surface Layer for Hot-Press Cushioning Followability
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Solution Overview
Problem
Cushioning materials with hard surface layers have insufficient unevenness followability, leading to defects in hot-pressed products due to trapped foreign matter, and exhibit low flexibility, causing wrinkles and cracks during handling and high-temperature processing.
Innovation Solution
A cushioning-material surface layer comprising a resin layer, a rubber layer, and a woven fabric layer with bulked yarns, where the woven fabric layer has a high residual interstice ratio, providing excellent unevenness followability and flexibility while reducing fuzz formation and improving releasability and adhesive properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hard surface layer is used to improve heat resistance and releasability, then heat resistance and releasability are improved, but unevenness followability deteriorates, causing defects due to trapped foreign matter
Solution Approach 1:
The surface layer is divided into multiple functional layers: a hard heat-resistant layer (fluororubber) for heat resistance and releasability, and a soft cushioning layer (silicone rubber) for unevenness followability. This segmentation allows each layer to perform its specific function without compromising the other.
Solution Approach 2:
The surface layer uses a composite structure combining fluororubber (for heat resistance and releasability) and silicone rubber (for softness and unevenness followability). This composite material approach enables simultaneous achievement of contradictory properties: hardness for heat resistance and softness for conformability.
2Reliability
If a hard surface layer is used to improve heat resistance, then heat resistance is improved, but flexibility deteriorates, causing wrinkles and cracks during handling and processing
Solution Approach 1:
The surface layer is segmented into a hard outer layer (fluororubber) for heat resistance and a soft inner layer (silicone rubber) for flexibility. The soft layer acts as a buffer that prevents the hard layer from developing wrinkles and cracks during handling.
Solution Approach 2:
The composite structure of fluororubber and silicone rubber allows the hard component to provide heat resistance while the soft component maintains flexibility and prevents structural failures like wrinkles and cracks during processing.
3Manufacturing precision
If the surface layer is made softer to improve unevenness followability, then unevenness followability is improved, but heat resistance and releasability deteriorate
Solution Approach 1:
The surface layer is segmented with the soft silicone rubber layer contacting the cushioning material to provide unevenness followability, while the hard fluororubber layer faces the hot platen to provide heat resistance and releasability. Each layer is positioned to optimize its specific function.
Solution Approach 2:
The composite material system combines the softness of silicone rubber for conformability with the heat resistance and non-stick properties of fluororubber, allowing the surface layer to simultaneously achieve unevenness followability and thermal performance.
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 surface layer effectively absorbs minute unevenness caused by foreign matter, reduces the occurrence of crazings, wrinkles, and cracks, and enhances the handleability and durability of hot-press cushioning materials, ensuring high-quality product manufacturing.
Implementation Method 1
a rubber layer that is disposed on the other side of the surface layer to cover the side of the surface layer... The surface layer effectively absorbs minute unevenness caused by foreign matter
Implementation Method 2
a resin layer that is disposed on one side of the surface layer to cover the side of the surface layer... in terms of releasability improvement, recent cushioning materials sometimes include cushioning-material surface layers
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The cushioning-material surface layer 11a includes a resin layer 12 disposed on one side of the surface layer 11a to cover the side thereof, a rubber layer 13 disposed on the other side of the surface layer 11a to cover the side thereof, and a woven fabric layer 14 disposed between the resin layer 12 and rubber layer 13 and including bulked yarns for at least one of warp and weft. The woven fabric layer 14 includes a woven fabric-resin composite layer 17 disposed on the resin layer 12 side and formed by impregnating part of the woven fabric with resin that forms the resin layer 12, and a woven fabric-rubber composite layer 18 disposed on the rubber layer 13 side and formed by impregnating part of the woven fabric with rubber that forms the rubber layer 13. The woven fabric layer 14 includes interstices 20 therein.