Coated Elastomeric Cushion for Roll-Packing Without Wall Adhesion
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Solution Overview
Problem
Cushions, such as mattresses, are bulky and costly to transport due to their traditional flat packaging, which makes them difficult to handle and ship efficiently.
Innovation Solution
A cushioning element with elastomeric material forming intersecting buckling walls and a coating comprising stearic acid, metal stearate, propylene glycol, and triethanolamine, allowing the cushion to be compressed and roll-packed for easier handling and shipping, with the coating facilitating the return to the expanded form without manual manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If cushions are packaged in traditional flat configuration, then they maintain their structural integrity and cushioning properties, but they become bulky and costly to transport
Solution Approach 1:
The cushion is rolled into a cylindrical configuration and placed inside a packaging bag, with the buckling walls nested within each other in a compact arrangement. This nesting approach reduces the shipping volume from a flat bulky configuration to a tight cylindrical roll that fits efficiently within the packaging.
Solution Approach 2:
The cushion transitions from a static flat configuration to a dynamic rolled configuration during shipping, and then automatically returns to its original flat configuration after unpacking. The coating enables this dynamic transformation by preventing the buckling walls from sticking together during compression and roll-packing.
2Loss of time
If cushions are compressed for shipping, then transportation costs are reduced, but the buckling walls stick together and require manual manipulation to separate
Solution Approach 1:
A coating is applied to the buckling walls before compression and roll-packing to prevent sticking. This preliminary protective action ensures that when the cushion is compressed for shipping, the walls remain separated and do not adhere to each other, eliminating the need for manual manipulation after unpacking.
Solution Approach 2:
A coating material acts as an intermediary substance between the buckling walls during compression and roll-packing. This coating layer prevents direct contact and adhesion between the walls, allowing them to be compressed tightly together while maintaining the ability to separate easily after unpacking.
3Productivity
If a coating is applied to prevent sticking, then the cushion returns to expanded form automatically, but additional materials and processing steps are required
Solution Approach 1:
The coating material changes the surface properties of the buckling walls by providing a non-stick coating. This parameter change in surface characteristics prevents adhesion during compression and enables automatic expansion after unpacking, significantly improving productivity without requiring complex application equipment.
Solution Approach 2:
A simple coating material is applied to the buckling walls to provide the necessary non-stick property. This relatively simple and inexpensive coating approach achieves the desired functionality of automatic expansion without requiring complex or expensive application systems.
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
Enables the cushion to be efficiently compressed for shipping and returns to its original form quickly after unpacking, improving handling and reducing transportation costs by allowing immediate use without manual separation of buckling walls.
Implementation Method 1
The coating material comprises stearic acid, a metal stearate, propylene glycol, and triethanolamine
Implementation Method 2
Cushioning materials may be formed of materials that deflect or deform under load, such as polyethylene or polyurethane foams
Implementation Method 3
The elastomeric material comprises an elastomeric polymer and a plasticizer
Implementation Method 4
A first wall buckles when a threshold force is applied. Buckling of the first wall may cause buckling of a second wall
Data Source
AI summary
A cushion includes a cushioning element and a coating material provided on a surface of the cushioning element. The cushioning element includes an elastomeric material forming a plurality of intersecting buckling walls defining a plurality of hollow columns in an expanded form. The coating material includes stearic acid, a metal stearate, propylene glycol, and triethanolamine. The cushioning element is configured to be compressed, such as by a roll-packing machine, into the compressed form and subsequently released from the compressed form to transform to the expanded form. Methods of forming the cushion include forming the cushioning element comprising an elastomeric material, coating a surface of the cushioning element with the coating material, and compressing the cushioning element into a compressed form.