Random Loop Net Structure for Soft Touch and Compression Durability
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Solution Overview
Problem
Existing net-like structures for cushion materials face challenges in achieving a balance between reduced bottom touch feeling and excellent compression durability, with previous solutions either being too heavy or lacking in softness when using solid-section fibers, and too hard or having poor durability when using hollow-section fibers.
Innovation Solution
A net-like structure with a three-dimensional random loop bonded structure composed of thermoplastic elastomer continuous linear bodies, featuring a thin fiber main region, a thick fiber main region, and a mixed region with a high percentage of thin and thick fibers in a mixed state, where the thin fibers are solid-section fibers and the thick fibers are hollow-section fibers, optimized for reduced residual strain and hysteresis loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid-section fibers are used to reduce weight and improve compression durability, then compression durability is improved, but the net-like structure develops a bottom touch feeling and loses softness
Solution Approach 1:
The patent applies local quality by creating distinct regions within the net-like structure: a surface layer with predominantly thin fibers (≥90% by number) for soft touch, and a base layer with predominantly thick fibers for compression durability. This spatial differentiation of fiber characteristics allows each region to fulfill its specific functional requirement without compromising the other.
Solution Approach 2:
The patent uses composite materials by combining thin solid-section fibers and thick hollow-section fibers in a single net-like structure. The surface layer primarily contains thin solid-section fibers for softness, while the base layer primarily contains thick hollow-section fibers for durability and weight reduction, creating a composite structure that integrates multiple functional benefits.
2Weight of stationary object
If hollow-section fibers are used to reduce weight and increase hardness, then weight is reduced and hardness is improved, but soft touch is less likely to be imparted
Solution Approach 1:
The patent applies local quality by concentrating thin solid-section fibers in the surface layer to provide soft touch, while placing thick hollow-section fibers in the base layer for weight reduction and structural support. This localized distribution ensures that the softness function is fulfilled at the contact surface while the weight reduction function is fulfilled in the base structure.
3Ease of manufacture
If multiple net-like structures are laminated without melt-adhesion to maintain simplicity, then manufacturing simplicity is preserved, but residual strain increases and compression durability deteriorates
Solution Approach 1:
The patent merges the surface layer and base layer into a single integrated net-like structure through melt-adhesion of continuous linear bodies. This combining approach allows the thin fibers and thick fibers to be thermally bonded together, creating a unified structure that reduces residual strain and improves compression durability compared to laminated structures without adhesion.
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 provides a net-like material with a reduced bottom touch feeling and excellent compression durability, suitable for various applications including office chairs, furniture, and vehicle seats, while maintaining softness and durability.
Implementation Method 1
a net-like structure having a three-dimensional random loop bonded structure constituted of a thermoplastic elastomer continuous linear body
Implementation Method 2
the net-like structure in which a base layer formed of continuous linear bodies having a thicker fiber size is not melt-adhered to a surface layer formed of continuous linear bodies having a thinner fiber size
Implementation Method 3
the residual strain after 750 N constant load repeated compression at pressurization from the side of the thin fiber main region of the net-like structure is less than or equal to 15%
Implementation Method 4
optimized for reduced residual strain and hysteresis loss
Data Source
Figure 1A~1C
AI summary
A net-like structure of the present invention is one having a three-dimensional random loop bonded structure constituted of a thermoplastic elastomer continuous linear body, wherein the net-like structure has, in a thickness direction thereof, a thin fiber main region that mainly includes thin fibers having a fiber size of greater than or equal to 0.1 mm and less than or equal to 1.5 mm, a thick fiber main region that mainly includes thick fibers having a fiber size of greater than or equal to 0.4 mm and less than or equal to 3.0 mm and a mixed region that is located between the thin fiber main region and the thick fiber main region and includes the thin fibers and the thick fibers in a mixed state, the fiber size of the thick fibers is greater than that of the thin fibers by greater than or equal to 0.07 mm, and the residual strain after 750 N constant load repeated compression at pressurization from the side of the thin fiber main region of the net-like structure is less than or equal to 15%. Thus, a net-like structure is provided, which has a reduced bottom touch feeling and excellent compression durability while keeping soft touch upon use.