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 products like weighted blankets.
Innovation Solution
The application of an elastomeric polymer to a fabric substrate in a controlled printing process, where the elastomeric element extends across the substrate but covers 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 fabric layer to increase weight, then the weight distribution is improved, but the flexibility and stretchability of the fabric is reduced
Solution Approach 1:
The elastomeric polymer is applied in targeted regions rather than uniformly across the entire fabric layer. The printing process deposits polymer material in specific patterns that provide weight in certain areas while leaving other areas lighter, creating local variations in weight distribution that maintain overall fabric flexibility and stretchability.
Solution Approach 2:
The elastomeric polymer application is divided into multiple discrete printed regions or patterns rather than a continuous layer. This segmentation allows different areas of the fabric to have different weight characteristics, enabling the fabric to maintain flexibility in some regions while providing weighted sensation in others.
2Weight of moving object
If elastomeric polymer is applied in high density to increase weight, then the weight distribution is improved, but the breathability and comfort of the fabric is reduced
Solution Approach 1:
The printing process creates localized regions of elastomeric polymer with varying densities and distributions. These localized applications provide the desired weight effect while maintaining open spaces and fabric porosity in other areas, allowing air circulation and breathability to be preserved throughout the weighted blanket.
3Weight of moving object
If elastomeric polymer is applied to cover the entire fabric layer to maximize weight effect, then the weight distribution is improved, but the delamination risk increases
Solution Approach 1:
The elastomeric polymer is applied as discrete printed regions rather than a continuous covering layer. This segmented approach reduces the total surface area of polymer-fabric interface, thereby reducing the overall risk of delamination while still achieving effective weight distribution through strategic placement of polymer regions.
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 articles such as weighted blankets with optimized weight distribution and flexibility, ensuring comfort and effectiveness while preventing delamination of the elastomeric element from the substrate.
Implementation Method 1
The application of an elastomeric polymer to a fabric substrate in a controlled printing process
Implementation Method 2
an elastomeric element that comprises a weighted member adhered to the fabric layer
Data Source
AI summary
A method for manufacturing an article includes providing a fabric layer; extruding, via at least one nozzle, a first cushion material on a surface of the fabric layer to form a first strip; moving the at least one nozzle along a first axis perpendicular or substantially perpendicular to an orientation of the first strip; and extruding, via the at least one nozzle, the first cushion material on the surface of the fabric layer to form a second strip.