3D Knitted Ironing Table Padding for Heat-Resilient Cushioning
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Solution Overview
Problem
Existing ironing boards face issues with foam padding compression under heat and pressure, leading to reduced cushioning properties, moisture accumulation, and high costs due to complex multi-layered structures.
Innovation Solution
A three-dimensional knitted fabric with vapor and air-permeable layers and arcuate spacer threads that connect the top and base layers, providing cushioning, spring-back properties, and temperature resistance, while maintaining a simple and cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a foam padding layer is used, then cushioning properties are provided, but the foam compresses under heat and pressure leading to reduced cushioning properties and moisture accumulation
Solution Approach 1:
The patent uses a three-dimensional knitted fabric with inherent porosity and channel structures that allow steam and air to pass through. This porous structure prevents moisture accumulation while maintaining cushioning properties under heat and pressure, unlike solid foam materials that compress and trap moisture.
Solution Approach 2:
The invention combines multiple materials with different properties: a three-dimensional knitted fabric (providing structure and porosity), spacer threads (providing mechanical resilience and spring-back), and temperature-resistant materials (withstanding ironing temperatures). This composite approach achieves both cushioning and durability.
2Manufacturing precision
If a multi-layered structure with silicone mat and plastic fabric is used, then protection from button marks and shiny spots is improved, but the structure becomes complex and expensive
Solution Approach 1:
The patent merges multiple functions into a single integrated three-dimensional knitted fabric layer that combines cushioning, moisture management, and protection functions. The spacer threads integrated within the knitted structure provide mechanical support while the fabric itself provides the protective surface, eliminating the need for separate silicone mats and plastic fabrics.
Solution Approach 2:
The three-dimensional knitted fabric provides different properties at different locations: the top surface provides smooth contact for preventing shiny spots, the internal structure provides cushioning through porosity, and the spacer threads provide localized mechanical support. This local differentiation achieves high ironing quality without complex multi-layer structures.
3Temperature
If the padding layer is made temperature-resistant, then direct contact with iron is tolerated, but the material becomes less resilient and more expensive
Solution Approach 1:
The patent uses composite materials where temperature-resistant fibers (such as polyester or aramid) are combined with elastic spacer threads. The temperature-resistant material withstands the ironing temperature while the elastic spacer threads maintain mechanical resilience and spring-back properties, achieving both temperature resistance and resilience.
Solution Approach 2:
Different regions of the padding layer have different material properties: the top cover layer is made highly temperature-resistant for direct iron contact, while the internal spacer threads and knitted structure use materials optimized for elasticity and resilience. This local differentiation achieves temperature resistance without sacrificing overall resilience.
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 ensures effective cushioning and prevents shiny spots and button imprints during ironing, with the knitted fabric relaxing after use and maintaining resilience, while being resistant to heat and moisture, thus addressing the limitations of previous designs.
Implementation Method 1
the spacer threads being arcuate, bent both into the top layer and protruding into the base layer and being designed as bending stressed springs
Implementation Method 2
the knitted fabric relaxing after use and maintaining resilience
Implementation Method 3
vapor and air-permeable layers
Data Source
Figure 1
Figure 2~3
AI summary
The present invention relates to an ironing table having a base plate, a padding layer, and a cover. An ironing table is provided having an improved padding, of simple construction, that can be produced economically. To this end, the padding layer comprises a three-dimensional knitted fabric having a knitted cover layer permeable to steam and air, a knitted base layer permeable to steam and air, and spacing fibers connecting the cover and base layers to each other, wherein the spacing fibers are curved and extend bent into the cover layer and the base layer.