Flocked Fiber Surface Coating to Enhance Impact Force Absorption
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Solution Overview
Problem
Flocked Energy Absorbing Material (FEAM) structures currently have limited Impact Force Absorbing (IFA) properties compared to comparable thicknesses of foam materials like Vinyl Nitrile and Polyurethane, and there is a need for improved manufacturing efficiency.
Innovation Solution
Enhanced energy absorbing structures are created by attaching monofilament flock fibers to a substrate with surface coatings and using divider fabrics and cover fabrics, including resinous coatings and micro-suede coverings, to increase friction and inter-fiber entanglement, thereby enhancing IFA properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If FEAM structures are used as impact force absorbing material, then the structure is flexible and manageable, but the IFA properties are lower compared to foam materials of comparable thickness
Solution Approach 1:
The patent applies parameter changes by coating the flock fibers with resin to modify their physical and mechanical properties. The resin coating increases fiber stiffness, inter-fiber friction, and entanglement characteristics, thereby enhancing the IFA properties of the FEAM structure while preserving its flexibility
Solution Approach 2:
The patent creates a composite material system by combining flock fibers with resin coating. This composite structure integrates the flexibility of the fibrous network with the enhanced mechanical properties of the resin-coated fibers, achieving both ease of operation and improved impact force absorption
2Strength
If resin coating is applied to flock fibers to enhance IFA properties, then friction and inter-fiber entanglement increase, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex mechanical bonding systems with a chemical coating approach. By applying resin coating to the flock fibers, the process simplifies the manufacturing steps while achieving enhanced IFA properties through increased friction and entanglement, rather than relying on complex mechanical interlocking structures
3Stability of the object's composition
If divider fabric and cover fabric are added to enhance IFA properties, then structural integrity improves, but device complexity increases
Solution Approach 1:
The patent applies multi-functionality to the divider and cover fabrics, which serve multiple purposes: providing structural integrity, containing the resin-coated fibers, distributing impact forces, and maintaining the overall stability of the FEAM structure. This reduces the need for additional separate components, thereby limiting the increase in device complexity
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 enhanced structures demonstrate improved impact force absorption capabilities, as evidenced by higher Force Loss % values in impact testing, with the use of resin coatings and divider fabrics showing significant improvements over control panels.
Implementation Method 1
surface coating applied to a surface of the plurality of monofilament flock fibers adjacent to the first end
Implementation Method 2
surface coating includes a silicone based water repellent resin spray-on coating, a flat finish polyurethane based varnish spray, a gloss finish varnish spray, a semi-gloss finish varnish spray, a water based acrylic varnish spray coating or a pigmented spray paint with nano-silica or alumina particles
Data Source
AI summary
Embodiments of fiber surface finish enhanced flocked surface impact force absorbing structure include a plurality of flock fibers disposed on a substrate, a surface coating applied to the plurality of flock fibers, and in another embodiment, a divider fabric bonded to the tops of flock fibers.