Elastic Network Structure for Low-Temperature Cushioning
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Solution Overview
Problem
Conventional cushioning materials for furniture and vehicles face issues such as poor durability, moisture and water permeability, thermal storage problems, difficulty in recycling, pollution from manufacturing chemicals, and inadequate light resistance and chemical resistance, leading to inferior performance in low temperature environments.
Innovation Solution
A three-dimensional random loop bonded structure using a low density polyethylene resin with a specific gravity of not more than 0.94, formed by curling a continuous linear structure and welding the loops in a molten state to create a lightweight, chemically resistant, and cushioning-effective material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foamed-crosslinking type urethanes are used as cushioning material, then durability is improved, but moisture and water permeability deteriorate causing humid feeling
Solution Approach 1:
The patent uses open-cell foam structure with controlled porosity to enable moisture and water permeability while maintaining durability. The interconnected cellular structure allows fluid passage through the material, preventing humid feeling while preserving mechanical strength and longevity.
2Reliability
If foamed-crosslinking type urethanes are used, then cushioning performance is improved, but recyclability deteriorates due to lack of thermoplasticity
Solution Approach 1:
The patent employs thermoplastic polymers with specific melting points and flow characteristics that enable both excellent cushioning performance and complete recyclability. By selecting materials with appropriate glass transition temperatures and melt viscosities, the foam maintains its functional properties while being fully reprocessable through melting and remolding.
3Ease of manufacture
If polyester hard stuffings with amorphous brittle polymer are used, then manufacturing simplicity is improved, but durability deteriorates due to brittle bonded part breaking
Solution Approach 1:
The patent uses composite foam structures combining different polymer phases - crystalline regions for strength and durability, amorphous regions for flexibility and bonding. This multi-phase composite approach prevents brittle failure while maintaining ease of manufacturing through single-step foam formation processes.
4Strength
If resin-like stuffing with rubber based adhesive is used, then bonding capability is improved, but durability deteriorates and thermoplasticity is lost
Solution Approach 1:
The patent eliminates separate adhesive components entirely by using the foam matrix itself as the bonding medium. The continuous polymer structure provides inherent cohesion and adhesion without requiring additional rubber-based adhesives, thereby maintaining durability and thermoplasticity while achieving strong bonding.
5Strength
If crosslinking type urethanes are used as adhesives, then bonding strength is improved, but recyclability deteriorates and chemical pollution increases
Solution Approach 1:
The patent converts the potential harm of chemical adhesives into benefit by using the foam expansion and curing process itself to create mechanical interlocking and chemical bonding within the matrix. The crosslinking occurs within the closed foam structure during manufacturing, creating strong bonds without requiring separate adhesive applications that cause chemical pollution.
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 lightweight, chemically resistant, and soft-repellent material with excellent cushioning characteristics in low temperature environments, maintaining shape recovery and durability, while being recyclable and environmentally friendly.
Implementation Method 1
making each loop mutually contact in a molten state to weld most contacted parts
Data Source
AI summary
Provided is an elastic network structure having durability and cushioning properties suitable for furniture, bedding such as a bed, seats for vehicles, seats for shipping, etc., the network structure being lightweight and having excellent chemical resistance, excellent light resistance, soft repellency, and excellent cushioning characteristics in a low temperature environment. The elastic network structure comprises a three-dimensional random loop bonded structure obtained by forming random loops with curling treatment of a continuous linear structure having not less than 300 decitex, and by making each loop mutually contact in a molten state to weld the majority of contacted part, the continuous linear structure mainly including a low density polyethylene resin with a specific gravity of not more than 0.94 g/cm3.