Fiber-Rubber Composite Cushioning Pad for Heat Press Uniformity
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Solution Overview
Problem
Conventional hot press cushioning pads face challenges in maintaining excellent cushioning, in-plane uniformity, and heat transfer properties while being durable and dimensionally stable after repeated use, due to issues with fiber orientation, resin impregnation, and thickness limitations.
Innovation Solution
A hot press cushioning pad composed of a fiber-rubber composite material layer using texturized glass fibers and a rubber impregnated woven fabric, with a void ratio of 5-50%, providing excellent cushioning, uniformity, and heat transfer, and maintaining these properties through the use of a woven fabric structure and specific rubber impregnation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If needle-punched nonwoven fabric is used to create a hot press cushioning pad, then the cushioning property is improved, but the in-plane uniformity deteriorates
Solution Approach 1:
The patent uses a woven fabric structure with intentionally created voids (porosity of 20-80%) to provide cushioning properties. The voids are formed by the woven fabric's inherent structure and are maintained during rubber impregnation, allowing the material to compress and recover while maintaining dimensional stability and in-plane uniformity.
Solution Approach 2:
The patent creates a composite material by impregnating woven fabric with rubber. The woven fabric provides the structural framework for in-plane uniformity, while the rubber filling the voids provides the cushioning property. This composite structure allows both requirements to be satisfied simultaneously.
2Temperature
If the thickness of the hot press cushioning pad is reduced to improve heat transfer property, then the heat transfer property is improved, but the cushioning property deteriorates
Solution Approach 1:
The patent applies local quality by creating voids specifically within the woven fabric structure where rubber impregnation occurs. The voids are distributed throughout the material at appropriate locations to provide cushioning, while the overall thickness is kept small (1-5 mm) to ensure good heat transfer. The rubber-filled voids provide localized cushioning without requiring the entire material to be thick.
3Manufacturing precision
If conventional paper cushioning pad is used, then the in-plane uniformity and heat transfer property are improved, but the reliability deteriorates due to fiber degradation and inability to restore voids
Solution Approach 1:
The patent moves away from disposable paper cushions that degrade after use. Instead, it creates a durable woven fabric-rubber composite that can be repeatedly used. The rubber impregnation into the woven fabric creates a stable structure that maintains its void ratio and cushioning properties through multiple press cycles, eliminating the need for frequent replacement.
Solution Approach 2:
The composite of woven fabric and rubber creates a material that combines the dimensional stability and in-plane uniformity of woven structures with the elasticity and void-restoring capability of rubber. This composite structure maintains its cushioning properties through repeated use, solving the reliability issue of conventional paper cushions.
4Reliability
If rubber impregnation is increased to improve durability, then the durability is improved, but the void ratio decreases and cushioning property deteriorates
Solution Approach 1:
The patent optimizes the rubber impregnation parameters to achieve the right balance. The void ratio is controlled to be within 20-80%, and the rubber content is adjusted to provide sufficient durability while maintaining adequate cushioning. By carefully controlling these parameters, the material achieves both durability for repeated use and sufficient cushioning property.
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 achieves excellent cushioning, in-plane uniformity, and heat transfer properties, along with dimensional stability and durability, allowing for repeated use without degradation, by utilizing a fiber-rubber composite material with a balanced void ratio and suitable rubber impregnation.
Implementation Method 1
a cushioning property for absorbing concaves and convexes
Implementation Method 2
the paper contains an appropriate amount of voids, and this contributes to the cushioning property
Implementation Method 3
a heat transfer property for efficiently transferring heat from the hot platens 13 to the laminated plate material 12
Implementation Method 4
the needle-punched nonwoven fabric is heated and pressed after impregnated with a heat-resistant resin. Therefore, the void ratio becomes small and the cushioning property is not so good
Data Source
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Figure 9~10
AI summary
A hot press cushioning pad 1 has a fiber-rubber composite material layer formed by a woven fabric and a rubber impregnated in the woven fabric. The warp of the woven fabric is a doubled and twisted yarn, and the weft thereof is a texturized yarn made of glass fibers. The fiber-rubber composite material layer has voids inside.