Hollow Random Loop Network Structure for Quiet Lightweight Cushioning
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Solution Overview
Problem
Conventional three-dimensional random loop bonded structures produce noise when compressed and recovering shape, disrupting sleep due to sounds from loop interactions, and the process of attaching silicone resin is inefficient and requires separate steps.
Innovation Solution
A three-dimensional random loop bonded structure with a hollow cross-section continuous linear structure, controlled fiber diameter between 0.10 mm and 0.65 mm, and increased bonded points per unit weight between 200/g and 500/g, using thermoplastic resins like polyester thermoplastic elastomers, to reduce noise and improve lightweight properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the three-dimensional random loop bonded structure is compressed and recovers its shape, then the structure provides cushioning function, but it makes sounds like random loops being rubbed together or popped
Solution Approach 1:
The patent changes the physical parameters of the continuous linear structure by controlling fiber diameter within a specific range (0.05 mm to 0.65 mm) and adjusting the degree of hollowness (10%-50%). These parameter changes modify the mechanical properties of the random loops, reducing their rigidity and minimizing the popping sound during compression and recovery, while maintaining the cushioning function.
Solution Approach 2:
The patent applies local quality by creating a hollow cross-section structure within the continuous linear structure. This hollow structure is localized within the fiber itself, providing noise reduction at the local level where the loops interact during compression, while the overall cushioning function is maintained through the network structure.
2Weight of moving object
If the fiber diameter of the continuous linear structure is reduced, then the lightweight property is improved, but the number of bonded points decreases
Solution Approach 1:
The patent optimizes the fiber diameter parameter within a specific range (0.05 mm to 0.65 mm) to achieve the right balance between lightweight properties and structural integrity. By controlling the degree of hollowness (10%-50%), the patent reduces the effective density of the material, improving lightweight properties while maintaining sufficient bonded points through the optimized fiber dimensions.
3Weight of moving object
If the degree of hollowness of the hollow cross section is increased, then the lightweight property is improved, but the rigidity of the random loops increases
Solution Approach 1:
The patent precisely controls the degree of hollowness within the range of 10%-50% to achieve optimal balance. This parameter control ensures that the hollow structure provides sufficient weight reduction while preventing excessive rigidity that would cause popping sounds during compression and recovery cycles.
4Object-generated harmful factors
If the fiber diameter is controlled to reduce noise, then the quietness is improved, but the production complexity increases
Solution Approach 1:
The patent establishes specific parameter ranges for fiber diameter (0.05 mm to 0.65 mm) and degree of hollowness (10%-50%) that can be controlled through standard manufacturing processes. These well-defined parameters enable noise reduction to be achieved through routine production adjustments rather than requiring complex additional manufacturing steps.
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 structure significantly reduces noise and maintains excellent lightweight properties, providing comfortable cushioning and improved quietness while simplifying the production process by integrating noise reduction and lightweight design.
Implementation Method 1
making each loop mutually contact in a molten state to weld the majority of contacted parts
Implementation Method 2
making each loop mutually contact in a molten state to weld the majority of contacted parts
Implementation Method 3
the cross sectional structure of a continuous linear structure is a hollow cross section
Data Source
AI summary
[Problem] An object of the present invention is to provide an elastic network structure that has excellent cushioning properties and makes less sounds when it is compressed and recovers its shape. [Solution] A network structure comprising a three-dimensional random loop bonded structure obtained by forming random loops by curling treatment of a continuous linear structure comprising a thermoplastic resin, and by making each loop mutually contact in a molten state to weld the majority of contacted parts, wherein (a) the continuous linear structure is a hollow cross section, (b) the degree of hollowness of the hollow cross section is not less than 10% and not more than 50%, (c) the fiber diameter of the continuous linear structure is not less than 0.10 mm and not more than 0.65 mm, and (d) the number of bonded points per unit weight of the random loop bonded structure is not less than 200/g and less than 500/g.