Net-like structure
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Solution Overview
Problem
Existing net-like structures for cushion materials lack differentiation in cushioning performance between faces, leading to varying compression durability when used from different sides, and often have high production costs and adverse changes in cushioning feel due to adhesive use.
Innovation Solution
A net-like structure with a three-dimensional random loop bonded structure composed of thermoplastic elastomer continuous linear bodies, featuring a solid-section fiber main region, a hollow-section fiber main region, and a mixed region, where the fibers have specific cross-sectional shapes and sizes, ensuring minimal difference in compression durability regardless of the applied face, achieved through a manufacturing process involving thermoplastic elastomers like polyester-based or polyolefin-based materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a net-like structure uses the same design on both faces, then manufacturing is simple, but cushioning performance cannot be differentiated between faces
Solution Approach 1:
The patent applies local quality by creating different fiber compositions in different regions of the net-like structure. The first face has a higher proportion of first fibers (e.g., hollow fibers) while the second face has a higher proportion of second fibers (e.g., solid fibers), allowing each face to provide different cushioning characteristics without requiring entirely different structural designs
2Adaptability or versatility
If different net-like structures are bonded together to achieve different cushioning performance, then cushioning differentiation is possible, but production cost increases and compression durability varies between faces
Solution Approach 1:
The patent merges multiple fiber types (first fibers and second fibers) into a single integrated net-like structure formed by one continuous linear body. This combining approach achieves face differentiation without requiring separate bonding of different structures, thereby reducing production cost and eliminating adhesive-related issues while maintaining compression durability balance
3Adaptability or versatility
If adhesive is used to bond net-like structures, then different cushioning performance can be achieved, but cushioning feel changes and production cost increases
Solution Approach 1:
The patent extracts the adhesive bonding function entirely from the structure by creating face differentiation through fiber composition variation within a single integrated net-like structure. This eliminates the harmful effects of adhesives on cushioning feel and removes the associated production costs while maintaining the ability to provide different cushioning performance on each face
4Reliability
If compression durability is optimized for one face, then that face has high durability, but the other face has low durability
Solution Approach 1:
The patent applies parameter changes by carefully controlling the proportion of first fibers and second fibers in different regions of the net-like structure. By adjusting fiber composition, diameter, and distribution parameters, the structure achieves balanced compression durability on both faces while maintaining different cushioning performance characteristics, enabling reversible use
Data Source
Figure 1A~1C
AI summary
A net-like structure has a three-dimensional random loop bonded structure constituted of a thermoplastic elastomer continuous linear body having a fiber size of greater than or equal to 0.1 mm and less than or equal to 3.0 mm. The net-like structure has, in the thickness direction, a solid-section fiber main region mainly including solid-section fibers, a hollow-section fiber main region mainly including hollow-section fibers, and a mixed region including solid-section fibers and hollow-section fibers in a mixed state, located between the solid-section fiber main region and the hollow-section fiber main region. Both solid-section fiber main region-side residual strain of the net-like structure and hollow-section fiber main region-side residual strain of the net-like structure are less than or equal to 20%, and the difference between the solid-section fiber main region-side residual strain and the hollow-section fiber main region-side residual strain is less than or equal to 10 points.