Elastic network structure with excellent quietness and lightweight properties
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Solution Overview
Problem
Conventional three-dimensional random loop bonded structures produce noise when compressed and recovering, disrupting sleep due to sounds from loop interactions, and the process of attaching silicone resin is separate and inefficient.
Innovation Solution
A three-dimensional random loop bonded structure with a hollow cross-section continuous linear structure, controlled fiber diameter, and increased bonded points per unit weight, utilizing thermoplastic resins like polyester thermoplastic elastomers, to reduce noise and enhance lightweight properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional three-dimensional random loop bonded structure is used, then lightweight properties are achieved, but noise is generated when compressed and recovering
Solution Approach 1:
The patent applies parameter changes by controlling the fiber diameter within a specific range (0.05 mm to 0.65 mm) and adjusting the degree of hollowness (10% to 50%) of the hollow cross-section structure. These parameter optimizations reduce the rigidity of individual fibers while maintaining the overall lightweight structure, thereby suppressing the popping noise generated during compression and recovery cycles.
2Object-generated harmful factors
If fiber diameter is reduced to decrease rigidity and reduce popping sound, then quietness is improved, but production efficiency may be affected
Solution Approach 1:
The patent specifies an optimized fiber diameter range (0.05 mm to 0.65 mm) that balances noise reduction with manufacturability. This parameter range ensures that fibers are thin enough to reduce rigidity and popping sounds, while remaining within practical limits for continuous production processes, thereby maintaining production efficiency.
3Object-generated harmful factors
If number of bonded points is increased to fix random loops and reduce popping frequency, then quietness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent controls the number of bonded points within a specific range (200/g to 500/g) to optimize quietness while maintaining manufacturing simplicity. This parameter range ensures sufficient bonding to reduce popping frequency without requiring excessive bonding operations or complex manufacturing processes.
4Weight of moving object
If hollow cross section is used to improve lightweight properties, then weight is reduced, but structure rigidity decreases
Solution Approach 1:
The patent optimizes the degree of hollowness within the range of 10% to 50% to balance lightweight properties with structural rigidity. This controlled hollowness reduces weight while maintaining sufficient rigidity to prevent excessive fiber movement and noise generation during compression and recovery.
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 and maintains excellent lightweight properties, providing quiet and comfortable cushioning while improving heat resistance and durability.
Implementation Method 1
making each loop mutually contact in a molten state to weld the majority of contacted parts
Implementation Method 2
making each loop mutually contact in a molten state to weld the majority of contacted parts
Data Source
AI summary
The present invention provides an elastic network structure that has excellent cushioning properties and makes less sound when it is compressed and recovers its shape. A network structure including a three-dimensional random loop bonded structure obtained by forming random loops by curling treatment of a continuous linear structure comprising a thermoplastic resin, and by making each loop mutually contact in a molten state to weld the majority of contacted parts, wherein (a) the continuous linear structure is a hollow cross section, (b) the degree of hollowness of the hollow cross section is not less than 10% and not more than 50%, (c) the fiber diameter of the continuous linear structure is not less than 0.10 mm and not more than 0.65 mm, and (d) the number of bonded points per unit weight of the random loop bonded structure is not less than 200/g and less than 500/g.