Resin Foam Bubble Structure for Soft Touch and Long-Stroke Support
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Solution Overview
Problem
Existing resin foams struggle to achieve both a good sense of touch at the initial stage of load application and a good sense of support when the load reaches the bottom, often compromising on one sensation to improve the other.
Innovation Solution
A resin foam structure is designed with two distinct bubble groups, a first group of small bubbles and a second group of large bubbles, characterized by a specific radius distribution and volume rates, forming a multimodal histogram with two approximate straight lines, enhancing the sense of touch and support through a network of small bubble walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the resin type or composition is changed to obtain a resin foam with a lower elasticity modulus, then the sense of touch is improved, but the stroke until the load reaches the bottom is short, failing to provide a good sense of support
Solution Approach 1:
The invention segments the bubble structure into two distinct groups: small bubbles (radius < predetermined value) that provide soft touch sensation through their numerous thin walls, and large bubbles (radius ≥ predetermined value) that provide long stroke for support. This segmentation allows each bubble group to specialize in one function, resolving the contradiction between soft touch and long stroke.
Solution Approach 2:
The invention applies local quality by assigning different functional roles to different bubble size regions within the same foam structure. Small bubbles located throughout the foam provide localized softness and touch sensation, while large bubbles provide localized support and stroke. This spatial differentiation of functional qualities enables both soft touch and long stroke simultaneously.
2Length of moving object
If the presence ratio of large bubbles is increased to lengthen the stroke, then the stroke is lengthened, but thin bubble walls formed between the bubbles result in a decrease in function of the walls as columns supporting a load, failing to provide a good sense of support
Solution Approach 1:
The invention segments the bubble population into two groups with distinct functional roles. Small bubbles form a dense network of thin walls that act as load-bearing columns, while large bubbles provide the stroke necessary for support. This segmentation prevents the degradation of wall strength that would occur if only large bubbles were present.
Solution Approach 2:
The foam structure functions as a composite material system where two different bubble size 'phases' work together. The small bubbles form a reinforcing network that maintains wall strength, while the large bubbles provide the deformable volume for stroke. This composite bubble structure achieves both long stroke and strong support function.
3Strength
If the porosity is reduced to improve the sense of support, then the sense of support is improved, but the weight increases
Solution Approach 1:
The invention uses local quality by concentrating the load-bearing function in specific regions (small bubble walls) while maintaining low overall density. The small bubbles create localized strong support structures without requiring the entire foam to be dense, thus improving support sensation without significantly increasing weight.
4Strength
If Patent Document 1 technique is applied to increase the warpage of the flexible polyurethane foam in a high load area, then the sense of support is improved, but the sense of touch is not improved
Solution Approach 1:
The invention segments the bubble structure into two functional groups: small bubbles that provide soft touch sensation through their numerous thin walls deforming at low load, and large bubbles that provide support through their volume and stroke at high load. This segmentation allows both sense of touch and sense of support to be improved simultaneously, unlike Patent Document 1 which only addressed support.
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 resin foam achieves both a good sense of touch and a good sense of support by distributing bubble volumes and radii in a way that maximizes the absorption of load through small bubble walls while maintaining sufficient support.
Implementation Method 1
a resin foam including: a first bubble group of bubbles having a radius r less than a predetermined value; and a second bubble group of bubbles having a radius r of the predetermined value or more
Data Source
AI summary
A range of radii from a bubble radius of 0 mm to a maximum bubble radius is divided into 20 radius sections r1 to r20. Bubble volume rates are calculated by dividing a product of the number of bubbles having a radius r and a volume of the bubbles having the radius r by a volume of all the bubbles, and the bubble volume rates are integrated for each radius section rn. Integrated values thus obtained are plotted on the respective radius sections rn, thereby obtaining a scatter diagram. A first approximate straight line obtained from plots of a first bubble group in the scatter diagram and a second approximate straight line obtained from plots of a second bubble group have different slopes. A sum of bubble volume rates of the bubbles forming the second bubble group ranges from 10% to 80% of a whole bubble volume rate.