Printed elastomeric elements
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Solution Overview
Problem
Existing technologies face challenges in creating articles of manufacture with elastomeric elements that are effectively printed onto substrates, particularly in achieving a balanced distribution of weight and flexibility in weighted blankets and similar products.
Innovation Solution
The application of an elastomeric polymer to a fabric substrate in a controlled printing process, where the elastomeric element extends substantially across the substrate while covering only a portion of it, allowing for overlapping configurations and varying densities to achieve desired weight and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If elastomeric polymer is applied extensively across the substrate to increase weight distribution, then weight distribution is improved, but flexibility and breathability deteriorate
Solution Approach 1:
The elastomeric polymer is segmented into discrete elongated elements with winding configurations rather than applying a continuous layer. This segmentation allows weight distribution through multiple elements while preserving flexibility and breathability by leaving gaps between elements.
Solution Approach 2:
Different regions of the substrate receive different elastomeric polymer configurations - some areas have denser element distributions for weight, while other areas maintain lower density for flexibility and breathability. This local variation optimizes both weight distribution and flexibility simultaneously.
2Weight of moving object
If elastomeric polymer is applied in dense configurations to increase weight, then weight distribution is improved, but breathability deteriorates
Solution Approach 1:
The polymer is divided into separate elongated elements with winding paths rather than forming a solid continuous layer. This segmentation creates inherent breathability channels between elements while maintaining weight distribution through the collective mass of elements.
Solution Approach 2:
The elastomeric element structure inherently creates a porous configuration with gaps and winding paths that allow air circulation. This porous structure maintains breathability while the cumulative mass of elements provides weight distribution.
3Weight of moving object
If elastomeric polymer is applied to cover the entire substrate to maximize weight, then weight distribution is improved, but manufacturing complexity increases
Solution Approach 1:
The elastomeric polymer is extruded in a self-forming manner where the material creates its own winding elongated elements through controlled extrusion processes. This self-service approach reduces manufacturing complexity by eliminating the need for complex molding or assembly operations.
Solution Approach 2:
Manufacturing parameters such as extrusion temperature, extrusion rate, and substrate movement speed are optimized to enable the elastomeric polymer to naturally form winding elongated elements during the application process. These parameter changes simplify manufacturing while achieving the desired weight distribution.
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
This approach enables the creation of weighted blankets and other articles with optimized weight distribution and flexibility, ensuring comfort and effectiveness while preventing delamination of the elastomeric element from the substrate.
Implementation Method 1
The printed elastomeric element 30 may be applied to the substrate 20 in such a way that the elastomeric polymer extends substantially across the substrate while covering only a portion of the substrate
Implementation Method 2
ensuring comfort and effectiveness while preventing delamination of the elastomeric element from the substrate
Data Source
AI summary
An article of manufacture, such as a weighted blanket, a cushioning element, or the like, includes an elastomeric element that includes elongated elements that follow nonlinear, partially overlapping paths and voids between adjacent portions of the elongated elements. Such an elastomeric element may define a weighted layer of a weighted blanket, a cushioning layer of a cushioning element of the like. The elastomeric element may be secured directly to a substrate, such as a fabric layer. Alternatively, an adhesion layer may secure the elastomeric element to the substrate. An adhesion layer may cover only a portion of the substrate. A cover may be provided over the elastomeric element. Together, the cover and the substrate may contain the elastomeric element.