Fatigue-resistant layered elastomeric structure
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Solution Overview
Problem
Existing layered elastomers fail to achieve optimal durability and hardness retention under repeated compression, with existing methods limiting the proportion of continuously bonded points, resulting in inadequate fatigue resistance for applications like cushions and mattresses.
Innovation Solution
The development of a fatigue-resistant layered elastomer with a proportion of continuously bonded points greater than 20%, achieved by controlling the melt index and melting point of thermoplastic polyester elastomer raw materials, which enhances the durability and reduces hardness loss rate during repeated compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the proportion of continuously bonded points is increased to improve repeated compression durability, then the service life and hardness retention are improved, but the manufacturing complexity and process control difficulty increase
Solution Approach 1:
The patent applies parameter changes by optimizing the melt index of thermoplastic polyester elastomer to a specific range (15-25 g/10min) and controlling the melting point below 180°C. These parameter adjustments directly influence the bonding behavior during the curling process, enabling the formation of continuously bonded points with proportion exceeding 20% without requiring complex additional processing equipment or procedures.
Solution Approach 2:
The patent implements preliminary action by pre-controlling the material properties (melt index and melting point) before the curling and bonding process. By selecting thermoplastic polyester elastomer with specific characteristics, the material is pre-conditioned to facilitate spontaneous formation of continuously bonded points during curling, eliminating the need for post-processing interventions or complex bonding control mechanisms.
2Strength
If the melt index and melting point of raw materials are controlled to increase continuously bonded points, then the bonding strength and fatigue resistance are improved, but the material selection constraints and manufacturing precision requirements increase
Solution Approach 1:
The patent defines specific parameter ranges for melt index (15-25 g/10min) and melting point (below 180°C) that balance bonding performance with manufacturing feasibility. These parameter specifications ensure sufficient bonding strength through continuous bonded points while avoiding overly restrictive material selection criteria, making the process controllable with standard manufacturing precision.
3Reliability
If the proportion of continuously bonded points is increased beyond existing methods, then the hardness loss rate during repeated compression is reduced, but the process deviation risk and quality consistency challenges increase
Solution Approach 1:
The patent establishes a balanced parameter range for melt index (15-25 g/10min) that ensures consistent formation of continuously bonded points during curling. This parameter optimization prevents process deviation by avoiding both insufficient bonding (lower melt index) and excessive material flow (higher melt index), thereby maintaining quality consistency and process stability while achieving hardness retention below 25% loss after 80,000 compression cycles.
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 significantly improves the repeated compression durability and service life of the elastomer, maintaining a hardness loss rate less than 25% after 80,000 cycles of 750 N compression, outperforming existing methods by maintaining excellent fatigue resistance and hardness retention.
Implementation Method 1
the polyester elastomer at molten state is extruded through spinning die
Implementation Method 2
the polyester elastomer at molten state is extruded through spinning die
Implementation Method 3
after being extruded, the elastomer is put into water for cooling
Implementation Method 4
the polyester elastomer at molten state is extruded... after being extruded, the elastomer is put into water for cooling
Implementation Method 5
the contact parts are welded together to make both sides flat
Implementation Method 6
the contact parts are welded together
Data Source
AI summary
A fatigue-resistant layered elastomeric structure is obtained by first extruding raw material of thermoplastic polyester elastomer into long linear structures. The long linear structures are further curled and bonded to form a volume of layered elastomeric structure with a certain thickness. Intermittently bonded points and continuously bonded points with fused sections equal to longer than 5 mm are formed during this process. Among all bonded points, the continuously bonded points have a proportion of at least 20%. Hardness loss rate after repeated compression is less than 23%. Relevant parameters are adjusted to obtain even larger percentages of continuously bonded points with better repeated compression durability.