Random-Loop Elastomer Net Structure for Weight-Neutral Hardness Zoning
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Solution Overview
Problem
Existing net structures face challenges in varying hardness without impairing texture or increasing weight, as methods to adjust apparent density often result in texture degradation or increased mass, and techniques to create clear boundaries between hard and soft regions are difficult to implement.
Innovation Solution
A net structure with a three-dimensional random loop junction structure composed of thermoplastic elastomer continuous filaments, featuring portions with a 5% or more difference in compressive hardness and a density variation of 0.005 g/cm³ or less, achieved through controlled cooling and manufacturing conditions to vary junction points and fiber diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the apparent density is lowered to reduce the hardness of the net structure, then the hardness is reduced, but the texture of the net structure is impaired
Solution Approach 1:
The patent applies local quality by varying the number of junction points in different zones of the net structure while maintaining uniform apparent density. This allows different regions to have different hardness levels (local mechanical properties) without changing the overall density, thereby resolving the contradiction between hardness reduction and texture preservation. The selective modification of junction density in specific areas enables localized hardness adjustment while maintaining global structural integrity and texture.
Solution Approach 2:
The patent changes the parameter of junction point density rather than apparent density to control hardness. By adjusting the number of junction points per unit volume in different zones, the invention achieves hardness variation without altering the apparent density. This parameter substitution resolves the contradiction by finding an alternative control variable that affects hardness independently of texture-affecting density changes.
2Strength
If the apparent density is increased to increase the hardness of the net structure, then the hardness is increased, but the mass per unit volume and weight of the entire product increase
Solution Approach 1:
The patent implements local quality by creating zonal variations in junction point density rather than uniformly increasing apparent density. This allows specific regions to have higher hardness where needed while other regions maintain lower hardness and lighter weight. The localized modification of structural parameters achieves hardness enhancement without proportional weight increase across the entire product.
Solution Approach 2:
The patent substitutes the parameter of junction point density for apparent density as the control variable for hardness. By changing the frequency and distribution of junction points rather than the overall material density, the invention achieves hardness adjustment without the direct weight penalty that would result from increasing apparent density throughout the entire structure.
3Strength
If the hardness is varied by the apparent density, then the hardness varies, but it is difficult to manufacture a net structure with clear boundaries between sites with different hardnesses
Solution Approach 1:
The patent applies local quality by controlling junction point formation in specific zones during the manufacturing process. The manufacturing method uses localized parameters (such as take-up speed variations in different regions) to create distinct zones with different junction densities, resulting in clear boundaries between hardness regions. This zone-based control approach inherently produces well-defined transitions between different hardness areas.
Solution Approach 2:
The patent employs preliminary action by pre-determining the zonal distribution pattern of junction points during the net formation process. The manufacturing method establishes the spatial distribution of junction densities before the material fully solidifies, allowing clear boundary formation between zones of different hardness. This proactive control of junction formation enables precise boundary definition that would be difficult to achieve through post-processing or density variation methods.
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 allows for varying hardness without altering apparent density, maintaining texture and preventing weight increase, while ensuring clear boundaries between hard and soft regions.
Implementation Method 1
a cooling and forming step of sandwiching ejected filaments in a molten state by a pair of take-off conveyers disposed on cooling water in a water tank, retaining the filaments to form loops, conveying the formed loops into the water tank while the loops come into contact with each other, and cooling the loops with the cooling water to form a random three-dimensional form
Data Source
AI summary
To provide a net structure in which the compressive hardness can be changed without impairing the texture and increasing the product weight, and in which the boundary of the compressive hardness is clear. A net structure having a three-dimensional random loop junction structure composed of thermoplastic elastomer continuous filaments, the net structure including portions differing in terms of compressive hardness by 5% or more zonally, a difference in apparent density between the portions differing in terms of compressive hardness being 0.005 g/cm3 or less.