Fiber molded article having cushioning property, and product obtained using same
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Solution Overview
Problem
Existing fiber molded bodies for cushioning applications have low durability against repeated compression and poor flexibility, leading to issues with fluff and lint generation, as well as inadequate thermal and sound insulation properties.
Innovation Solution
A fiber molded body is created using a fiber layer formed by opening a bundle of continuous fibers with crimps, which are then folded to create ridges that are thermobonded, resulting in a structure with enhanced durability, flexibility, and cushioning properties, along with improved thermal and sound insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a needle-punched nonwoven fabric is used, then the structure is tight with small gaps, but the cushioning, thermal insulation and sound insulation properties are low
Solution Approach 1:
The fiber web is segmented into multiple layers with different orientations (machine direction and cross direction layers) creating a laminated structure. This segmentation allows each layer to contribute differently to the overall structure, maintaining tightness while creating air pockets for insulation and cushioning properties.
Solution Approach 2:
The invention introduces z-direction loops formed by crimped fibers that extend in the thickness direction, adding a third dimension to the fiber arrangement. This dimensional change creates void spaces and air pockets within the nonwoven fabric, improving cushioning, thermal insulation, and sound insulation without compromising structural integrity.
2Reliability
If short fibers are used to form a nonwoven fabric by card method and folding, then excellent cushioning property is achieved, but durability against repeated compression is low and fluff and lint are generated
Solution Approach 1:
The invention uses inexpensive short fibers that would normally be discarded or have limited life, but through the lamination and bonding process, transforms them into a durable structure. The short fibers are arranged in layered configurations and bonded together, giving them extended functionality and resistance to repeated compression.
Solution Approach 2:
The invention creates a composite nonwoven fabric by laminating multiple fiber layers with different orientations and properties. This composite structure combines the advantages of short fibers (cushioning) with a bonded architecture that provides durability, preventing fluff and lint generation while maintaining compression resistance.
3Duration of action of stationary object
If continuous fibers are opened and folded to form ridges, then durability against repeated compression and cushioning property are improved, but manufacturing complexity increases
Solution Approach 1:
The continuous fibers are pre-crimped before being laid into the web, creating loops and three-dimensional structures in advance. This preliminary action of crimping simplifies the subsequent forming process, as the crimped fibers automatically create the desired ridges and valleys when laid and bonded, reducing the need for complex post-processing equipment.
Solution Approach 2:
The invention changes the physical parameters of the fibers by introducing crimps and controlling their orientation. By adjusting fiber length, crimp density, and layer arrangement parameters, the manufacturing process achieves the desired durability and cushioning properties through parameter optimization rather than complex mechanical processing.
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 resulting fiber molded body exhibits excellent durability against repeated compression, minimal fluff generation, high flexibility, and superior thermal and sound insulation, making it suitable for various applications including medical and automotive uses.
Implementation Method 1
the portions of the fiber layer of the mutually adjacent ridges come into close contact with each other in the thickness direction (4) of the fiber molded body (1) by bonding through thermal bonding of the thermobondable continuous fibers of the fiber layer (3)
Data Source
Figure 1
Figure 2
AI summary
Provided is a fiber molded body which has excellent durability against repeated compression and also has excellent flexibility and a cushioning property. Disclosed is a fiber molded body (1) having a structure in which a fiber layer (3) formed by opening a bundle of continuous fibers having crimps and extending in one direction is folded in the direction in which the continuous fibers extend so that ridges (2) repeatedly appear on a surface of the fiber layer (3); wherein the fiber molded body forms, on a surface of the fiber molded body (1), the ridges (2) having a compressed and flattened shape in the thickness direction (4) of the fiber molded body (1); or wherein the fiber molded body forms a continuous curved surface with the fiber layer (3) which forms the ridges (2) and extends from both sides of the ridges (2) in the thickness direction (4) of the fiber molded body (1), and portions of the fiber layer (3) of mutually adjacent ridges which form ridges and extend in the thickness direction (4) of the fiber molded body (1) come into close contact with each other in the thickness direction (4) of the fiber molded body (1).