Equine Protective Covering Perforation Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing equine protective coverings face issues with ventilation and moisture circulation due to dirt accumulation in perforations and delays in manufacturing caused by bonding processes, and they often result in reduced durability and comfort.
Innovation Solution
A method involving a cushion assembly with a first synthetic fabric layer and a perforated neoprene layer, where the neoprene layer is perforated before bonding, and a heated stamp is used to permanently bond the layers while maintaining open perforations, enhancing ventilation and moisture circulation and reducing dirt accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the neoprene layer is perforated before bonding, then ventilation and moisture circulation are improved, but the bonding process becomes more complex as glue or binder must be applied carefully to avoid closing perforations
Solution Approach 1:
The neoprene layer is perforated before bonding to the fabric layer, allowing the perforations to be created while the material is still in its original state. This preliminary action ensures that ventilation channels are established before the bonding process, avoiding the complexity of applying glue around existing holes and ensuring consistent airflow paths are maintained throughout the bonded structure.
Solution Approach 2:
A foam layer is introduced as an intermediary between the perforated neoprene layer and the fabric layer. This foam intermediary allows for bonding while maintaining the perforations' openness, as the foam can be bonded to both layers without requiring direct glue application that would close the holes. The foam acts as a mediator that preserves ventilation functionality while enabling secure bonding.
2Ease of operation
If a knit fabric is secured only at edges to shield perforations, then the fabric can be easily applied, but detached areas are prone to damage and wear during mounting and dismounting
Solution Approach 1:
The knit fabric is bonded to the neoprene layer across the entire surface area, merging these two protective layers into a unified structure. This comprehensive bonding eliminates detached areas that would otherwise be prone to damage during mounting and dismounting, while maintaining ease of application through the use of heat-activated bonding that secures the layers together uniformly.
3Strength
If glue or binder is applied to bond fabric to neoprene, then bonding strength is achieved, but setting time delays manufacturing efficiency
Solution Approach 1:
The bonding process utilizes heat as a parameter change to activate the adhesive properties of the materials. By applying heat through a heated press or similar device, the bonding occurs rapidly without requiring extended setting times associated with traditional glue application. This thermal activation method maintains strong bonding while significantly reducing manufacturing cycle time.
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
This method results in a more qualitative, durable, and comfortable equine protective covering with improved ventilation and moisture circulation, and a more efficient manufacturing process, while minimizing weight and maximizing air and moisture exchange.
Implementation Method 1
applying a stamp comprising a profiled shape with a predetermined temperature and pressure to the interior side of the cushion assembly such that concurrently: the first synthetic fabric layer and the second neoprene layer are permanently bonded
Implementation Method 2
the second neoprene layer is plastically deformed such that the profiled shape of the stamp is permanently transferred to the second neoprene layer
Data Source
AI summary
An improved method of manufacturing an equine protective covering includes applying a stamp comprising a profiled shape with a predetermined temperature and pressure to the interior side of the cushion assembly such that concurrently: the first synthetic fabric layer and the second neoprene layer are permanently bonded; the second neoprene layer is plastically deformed such that the profiled shape of the stamp is permanently transferred to the second neoprene layer; and the plastic deformation of the second neoprene layer is such that the perforations remain open.