Flexible Polymer Stall Dividers for Dairy Cows

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Solution Overview

Problem

Conventional stall dividers, typically made of metal, do not flex and can cause injuries to dairy cows when they run into them, as they do not yield upon impact, which is a concern for cow comfort and milk production in both free and tie stall systems.

Innovation Solution

The development of hollow flexible polymer tubing stall dividers that can laterally flex upon impact, minimizing injury and guiding cows into proper positions between dividers, using varying densities and materials like polypropylene, polyurethane, and polyethylene to balance durability and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional metal stall dividers are used, then structural strength and durability are improved, but cow injury risk increases due to lack of flexibility

Engineering Contradiction:

Improvestructural strengthVSAvoidcow injury risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent applies this principle by replacing rigid metal stall dividers with flexible polymer tubing that can bend and yield when cows impact against them, eliminating the harmful rigid structure while maintaining the divider function through the flexible polymer shell

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the material parameter from rigid metal to flexible polymer, fundamentally altering the mechanical properties of the stall divider to enable flexibility and injury prevention while maintaining structural adequacy for the application

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If flexible polymer tubing is used, then cow safety and comfort are improved, but manufacturing complexity increases due to multi-density material requirements

Engineering Contradiction:

Improvecow safetyVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent applies segmentation by dividing the stall divider into multiple sections with different polymer densities, allowing each section to be optimized for its specific function (impact absorption, structural support, flexibility) while simplifying the overall manufacturing process through modular assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses composite materials by combining different densities of polymer materials within the same stall divider structure, creating a multi-density composite that balances flexibility and durability while remaining manufacturable through extrusion and assembly processes

Inventive Principle:

Principle #40Composite materials

3Reliability

If varying polymer densities are used throughout the stall divider, then durability and flexibility are optimized, but manufacturing precision requirements increase

Engineering Contradiction:

ImprovedurabilityVSAvoiddensity distribution precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by assigning different polymer densities to specific locations within the stall divider - higher density in sections requiring durability and lower density in sections requiring flexibility - allowing each local region to have the optimal material properties for its function

Inventive Principle:

Principle #3Local quality

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 flexible polymer stall dividers effectively reduce the risk of injury to cows by allowing lateral flexing and returning to their original shape, ensuring cow comfort and safety while maintaining structural integrity and ease of manufacturing.

Implementation Method 1

The curved end member in this Earle patent application is significantly more flexible than the polymer horizontally-extending members to minimize injury to the cows entering the stall, and perhaps impacting the stall dividers

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

the polymer stall divider will return to its original position after the cow has moved into a proper position between the adjacent stall dividers

Methodology Applied

Scientific EffectElastic recovery: Elastic Recovery

Data Source

PatentUS10645900B2Integrally manufactured stall dividers for barns

Publication Date: 2020.05.12 ZARTMAN THOMAS L

AI summary

A hollow polymer stall divider for use in a barn permits lateral flexing when a cow presses against the stall divider while the stall divider asserts a lateral force against the cow to urge the cow to move into a proper position between adjacent stall dividers without causing injury to the cow. The polymer stall divider can be formed of a single polymer material having a unitary density throughout. Alternatively, the polymer stall divider can be formed of multiple sections of different densities of polymer material, and different types of polymer material. The different sections of polymer material can be plastic welded together or connected by plug members inserted into the adjoining ends of the sections and secured with adhesives or other bonding material to form line blanks that can be heated until softened sufficiently to be bent into a proper shape within a pre-formed mold.