Elastic Network Structure for Quiet Cushioning
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Solution Overview
Problem
Conventional three-dimensional random loop bonded structures used in cushioning applications produce noise when compressed and recovered, disrupting sleep and requiring additional processing steps for improved quietness.
Innovation Solution
A network structure with a controlled number of bonded points per unit weight, ranging from 500 to 1200/gram, utilizing thermoplastic resins like soft polyolefin or polyester thermoplastic elastomers, and specific manufacturing processes to enhance quietness and cushioning properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the number of bonded points in the random loop bonded structure is increased to fix the random loops and reduce popping sounds, then the quietness of the network structure is improved, but the production process becomes more complex and less efficient
Solution Approach 1:
The patent merges the bonding process with the manufacturing process by controlling the number of bonded points during the formation of the random loop bonded structure. This integration eliminates the need for separate bonding steps, thereby improving quietness through increased bonded points while maintaining production efficiency.
Solution Approach 2:
The patent applies parameter changes by precisely controlling the number of bonded points per unit weight (500-1200/gram) and apparent density (0.005-0.200 g/cm³) of the random loop bonded structure. These parameter optimizations achieve the desired quietness without requiring additional complex production steps.
2Object-generated harmful factors
If silicone resin is attached to the surfaces of the random loops to reduce rubbing sounds, then the quietness is improved, but an additional separate processing step is required
Solution Approach 1:
The patent combines the bonding process with the manufacturing process, eliminating the need for separate silicone resin attachment steps. By controlling bonded points during formation, the patent achieves quietness improvement without sacrificing production efficiency.
3Object-generated harmful factors
If the random loop bonded structure is made denser to reduce noise, then the quietness is improved, but the cushioning properties deteriorate
Solution Approach 1:
The patent optimizes the apparent density parameter within the range of 0.005-0.200 g/cm³ to achieve the right balance between quietness and cushioning properties. This parameter control allows the structure to reduce popping sounds while maintaining excellent cushioning 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 structure significantly reduces noise while maintaining elasticity, providing excellent cushioning properties and improved production efficiency by integrating the bonding process within the manufacturing steps.
Implementation Method 1
making each loop mutually contact in a molten state to weld the majority of contacted parts
Implementation Method 2
when the random loop bonded structure is compressed and recovers its shape
Data Source
AI summary
[Problem] The objective of the present invention is to provide an elastic mesh structure having exceptional cushioning and reducing noise during compression or recovery.[Solution] A mesh structure comprising a three-dimensional, random-loop, joining structure formed by winding a continuous line of thermoplastic resin to form random loops, bringing the loops into contact with one another in a molten state, and fusing the majority of the contact area, wherein (a) the apparent density of the random-loop contact structure is 0.005-0.200 g/cm3, and (b) the number of contact points per unit weight of the random-loop contact structure is 500-1200/g.