Crosslinked Foam Saddle Layer for Water-Resistant Toughness
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Solution Overview
Problem
Bicycle saddles made of polyurethane foam exhibit low toughness, poor water resistance, and susceptibility to decay when the skin layer is punctured, leading to exposure and decay of the foam.
Innovation Solution
A crosslinked foam composition comprising ethylene/α-olefin multi-block copolymer, ethylene/propylene/diene terpolymer, and optional additives, adhered to a substrate with an adhesive layer, providing improved toughness, heat resistance, and water resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional PU foam is used for bicycle saddle, then softness is provided, but toughness and water resistance are poor
Solution Approach 1:
The patent uses a composite foam structure consisting of a closed-cell foam core layer surrounded by a foam skin layer. The closed-cell structure provides toughness and water resistance, while the foam skin layer maintains softness and comfort. This composite approach resolves the contradiction between toughness and water resistance.
2Reliability
If skin layer is added to protect PU foam, then protection is provided, but puncture resistance is low leading to decay
Solution Approach 1:
The patent employs a composite foam structure with a closed-cell foam core layer that inherently provides puncture resistance and protection against decay. The foam skin layer forms a protective barrier that maintains reliability while the closed-cell structure ensures toughness.
3Strength
If foam is adhered to rigid substrate, then structural support is provided, but delamination occurs
Solution Approach 1:
The patent utilizes heat-activated adhesive properties of the foam composition. The adhesive layer is activated at elevated temperatures during molding to bond the foam to the substrate, then remains stable at lower service temperatures, preventing delamination while maintaining strong adhesion.
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 enhances the saddle's durability and resistance to water, preventing decay and maintaining structural integrity.
Implementation Method 1
an adhesive layer, and a substrate composed of an olefin-based polymer
Implementation Method 2
The crosslinked foam composition has a balance of toughness, heat resistance and water resistance
Implementation Method 3
The crosslinked foam composition includes an ethylene/α-olefin multi-block copolymer, an ethylene/propylene/diene terpolymer (EPDM)
Data Source
AI summary
The present disclosure provides an article. The article includes a crosslinked foam composition, an adhesive layer, and a substrate composed of an olefin-based polymer. The crosslinked foam composition includes an ethylene/α-olefin multi-block copolymer, an ethylene/propylene/diene terpolymer (EPDM), optional silicone rubber, optional blend component selected from ethylene/α-olefin random copolymer, ethylene-vinyl acetate copolymer (EVA), styrene-butadiene block copolymer, hydrogenated styrene-butadiene block copolymer, and combinations thereof, optional plasticizer, optional filler, and optional additive.