Three-dimensional net-like structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing three-dimensional net-like structures used in mattresses and cushions face challenges with heat resistance and chemical resistance, and the mixing of propylene homopolymer with propylene polymer is difficult, leading to variations in hardness and manufacturing complexity, including the need for expensive twin-screw extruders.
Innovation Solution
A three-dimensional net-like structure made from a mixture of polypropylene copolymers with different flexural moduli, specifically a propylene-(α-olefin) copolymer and a propylene-(α-olefin) copolymer, which are easily mixed and processed using a single-screw extruder, providing uniformity and stability in hardness while maintaining heat resistance and chemical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If propylene homopolymer (b) is mixed with propylene polymer (a) to improve heat resistance, then heat resistance is improved, but mixing uniformity deteriorates causing variations in hardness
Solution Approach 1:
The invention changes the polymer composition parameters by using propylene polymer (a) with 5-49 mol% α-olefin content and propylene homopolymer (b), specifically controlling the flexural modulus ratio between the two components. This parameter optimization enables uniform mixing while maintaining heat resistance and consistent hardness throughout the product.
Solution Approach 2:
The invention creates a composite material system combining propylene polymer (a) and propylene homopolymer (b) in specific weight ratios (30-70% and 70-30% respectively). This composite approach allows the synergistic combination of heat resistance from homopolymer (b) and mixability from copolymer (a), achieving both improved heat resistance and uniform hardness.
2Manufacturing precision
If a twin-screw extruder is used to improve mixing uniformity, then mixing uniformity is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The invention changes the material parameters by selecting propylene polymer (a) with specific α-olefin content (5-49 mol%) and flexural modulus (100-1600 MPa), which inherently improves mixability. This allows the use of simpler single-screw extruders while still achieving uniform mixing, thereby reducing device complexity and manufacturing cost.
Solution Approach 2:
The invention replaces expensive twin-screw extruders with cheaper single-screw extruders by optimizing the polymer composition. The cost savings from using simpler equipment and lower operating costs compensate for the material composition control requirements, achieving an overall more economical manufacturing process.
3Ease of manufacture
If a single-screw extruder is used to reduce manufacturing cost, then manufacturing cost is reduced, but mixing uniformity deteriorates causing variations in hardness
Solution Approach 1:
The invention optimizes the material parameters by controlling the α-olefin content (5-49 mol%) and flexural modulus (100-1600 MPa) of propylene polymer (a), and the weight ratio (30-70% (a) and 70-30% (b)). These parameter changes inherently improve mixability, allowing single-screw extruders to achieve uniform mixing without sacrificing manufacturing precision.
Solution Approach 2:
The invention designs a composite material system where propylene copolymer (a) acts as a mixing aid due to its lower flexural modulus and higher elasticity, while propylene homopolymer (b) provides heat resistance. This composite structure enables effective mixing in single-screw extruders while maintaining product uniformity and reducing manufacturing cost.
4Temperature
If propylene homopolymer (b) content is increased to improve heat resistance, then heat resistance is improved, but product hardness increases reducing cushioning property
Solution Approach 1:
The invention optimizes the weight ratio parameters of propylene polymer (a) and propylene homopolymer (b) within 30-70% and 70-30% ranges respectively. This parameter optimization balances the heat resistance contribution from homopolymer (b) with the cushioning property contribution from copolymer (a), achieving both high heat resistance and appropriate hardness.
Solution Approach 2:
The invention creates a composite material system where propylene homopolymer (b) (70-30% by weight) provides heat resistance and propylene copolymer (a) (30-70% by weight) provides cushioning properties. The synergistic combination in this specific ratio range achieves both high heat resistance (withstanding disinfection temperatures) and soft cushioning characteristics suitable for medical and nursing applications.
Data Source
AI summary
A three-dimensional net-like structure is provided that has a soft cushioning property and less variations of hardness and is less expensive.The three-dimensional net-like structure is made from a thermoplastic resin including a mixture of a polypropylene copolymer (a) and a polypropylene copolymer (b) and has a spring structure formed by bonding continuous filaments partly in random in loops. The polypropylene copolymer (a) has a flexural modulus that is different from a flexural modulus of the polypropylene copolymer (b).