Elastomeric Yarn Pad Structure for High Compressibility and Recovery
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Solution Overview
Problem
Existing composites and cushioning materials in applications like athletic shoes and flooring lack sufficient elastic behavior under load and high through-thickness recovery, limiting their shock-absorbing capabilities and durability.
Innovation Solution
A compressible and resilient structure utilizing a woven or nonwoven fabric with elastomeric yarns in a cross-direction, allowing the structure to collapse and rebound, combined with a binder yarn for bonding, which enhances elastic behavior and recovery characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid resin or viscoelastomeric materials are used for cushioning, then structural strength is improved, but elastic behavior and through-thickness recovery deteriorate
Solution Approach 1:
The invention uses a composite structure combining rigid resin matrix with flexible foam core and elastomeric yarns. This composite approach allows the outer resin layers to provide structural strength while the internal foam and elastomeric components deliver elastic behavior and through-thickness recovery, resolving the contradiction between strength and elasticity.
Solution Approach 2:
The pad is segmented into multiple functional layers: rigid resin outer layers for structural support, flexible foam core for compression and recovery, and elastomeric yarns for elastic behavior. This segmentation allows each layer to specialize in its function, achieving both strength and elastic recovery simultaneously.
2Reliability
If molded solid materials with air channels are used, then cushioning capability is improved, but rigidity increases and through-thickness recovery deteriorates
Solution Approach 1:
Different regions of the pad have different properties: the outer resin layers provide rigidity and structural integrity, while the internal foam core and elastomeric yarns provide cushioning and elastic recovery. This local differentiation allows the pad to be rigid where needed for structure and soft where needed for cushioning, resolving the contradiction between cushioning capability and rigidity.
3Stability of the object's composition
If resin-impregnated structures are used, then structural integrity is improved, but compressibility and through-thickness recovery deteriorate
Solution Approach 1:
The invention introduces elastomeric yarns in the cross-direction (lateral dimension) rather than only in the longitudinal direction. This dimensional approach allows the structure to maintain integrity in the plane while gaining compressibility and recovery in the through-thickness direction, resolving the contradiction between structural integrity and compressibility.
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 improved elastic behavior, extended lifespan, moisture resistance, and breathability, offering superior cushioning and dampening capabilities with a lightweight and durable structure.
Implementation Method 1
The elastic media used in the cross-direction may be polyurethane, rubber or Lycra or any deformable material that has sufficient elasticity as well as strength to allow the structure to compress and rebound, or 'spring back'.
Data Source
AI summary
A structure for use in a compressible resilient pad. The structure contains both axially elastomeric yarns and relatively inelastic yarns in various patterns. The structure has a high degree of both compressibility under an applied normal load and excellent recovery (resiliency or spring back) upon removal of that load.