Polyester 3D Mesh Structure for Smooth Bending in Medical Mattresses
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Solution Overview
Problem
Three-dimensional net-like structures made from high surface density materials like polyethylene are difficult to bend smoothly due to unnatural deformation and wrinkles, posing challenges in medical and nursing care settings where a lightweight and durable mattress is required.
Innovation Solution
A three-dimensional net-like structure made from polyester with a specific swelling ratio and density, featuring a curled spring structure and three-dimensional striped sparse-dense configuration, allowing for enhanced flexibility and smooth bending without noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high surface density material like polyethylene is used, then durability is improved, but bendability deteriorates causing wrinkles and folds
Solution Approach 1:
The patent changes the material parameter from high-density polyethylene to polyester with controlled swelling ratio (1.03-1.20), filament diameter (0.1-1.0 mm), and bulk density (0.01-0.2 g/cm³). This parameter optimization enables the material to bend smoothly without wrinkles while maintaining durability through the curled spring structure and three-dimensional net-like configuration.
2Stability of the object's composition
If high surface density material is used, then structural stability is improved, but flexibility deteriorates making smooth bending difficult
Solution Approach 1:
The patent employs a composite structure combining polyester filaments with specific physical properties (swelling ratio, diameter, bulk density) arranged in a three-dimensional net-like structure with curled spring elements. This composite approach achieves both structural stability through the interconnected network and flexibility through the optimized filament characteristics and spatial arrangement.
3Force
If material with high density is used, then load-bearing capacity is improved, but weight increases burdening caregivers
Solution Approach 1:
The patent utilizes a porous three-dimensional net-like structure with controlled bulk density (0.01-0.2 g/cm³) created by the winding and tangling of polyester filaments. This porous configuration reduces material density and overall weight while maintaining load-bearing capacity through the structural framework of interconnected filaments forming voids and spaces.
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 is adequately flexible and bendable, providing a soft texture with enhanced heat-resistant temperature, suitable for mattresses, and can be easily washed and dried, while reducing the load on caregivers.
Implementation Method 1
the swelling ratio is shown as D2/D1 against shear rate when the polyester in molten state is extruded to the filaments from a capillary having a tube inner diameter D1 of 1.0 mm and a length of 10 mm at a temperature of 210°C
Data Source
AI summary
By taking into account the difficulty in smoothly bending along the shape of, for example, a care bed, there is provided a three-dimensional net-like structure made from polyester having a swelling ratio dependent on a shear rate such as to be 1.10 to 1.38 at a shear rate of 60.8 sec-1 and 1.17 to 1.43 at a shear rate of 608 sec-1 and having an MFR of 3 to 35 g/ 10 min and a density of 1.01 to 1.60 g/cm3 and configured to have a spring structure of filaments randomly brought into contact with and tangled with one another, have a three-dimensional striped sparse-dense configuration in a lateral direction relative to an extrusion direction. The swelling ratio is shown as D2/D1 against shear rate when a molten thermoplastic resin is extruded to filaments from a capillary having a tube inner diameter D1 of 1.0 mmφ and a length of 10 mm and D2 denotes a diameter of cross section of the filaments extruded and cooled down.