Textured Exercise Resistance Bands Without Dusting Residue
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Solution Overview
Problem
Commercially available elastic exercise bands have smooth surfaces that lack adequate grip, making them difficult to use during exercises and physical therapy.
Innovation Solution
A process involving calendaring rubber sheets with a low-shrinkage thermoplastic textile separator to create textured surfaces on both sides, which is then vulcanized to form textured rubber sheets for exercise bands, eliminating the need for dusting agents and ensuring a secure grip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dusting agents are used to prevent sticking during calendaring, then the rubber sheets can be processed without粘连, but the dusting agents leave residues that reduce grip quality
Solution Approach 1:
A release paper is introduced as an intermediary substance between rubber sheet layers during calendaring. The release paper prevents direct contact and sticking between rubber surfaces while leaving no residues on the rubber, thereby maintaining both ease of manufacture and grip quality. The release paper is removed after processing, taking any potential contaminants with it.
Solution Approach 2:
The harmful element (dusting agents) is completely removed from the process. Instead of using dusting agents that leave residues, the patent extracts this substance entirely and replaces it with a release paper system that achieves the same non-sticking function without contaminating the rubber surface, thus preserving grip quality.
2Ease of manufacture
If smooth surfaces are used on rubber sheets, then the manufacturing process is simple, but the grip during exercise is inadequate
Solution Approach 1:
The textured pattern is applied to the rubber sheet surface during the calendaring process itself, before the rubber is cut into bands. This preliminary texturing is integrated into the manufacturing flow and does not require additional post-processing steps, maintaining manufacturing simplicity while providing the grip enhancement needed for exercise use.
Solution Approach 2:
The rubber sheet surface is modified locally by adding a textured pattern only where contact with the user's hand will occur. The texturing is applied to the outer surfaces of the rubber sheets during calendaring, creating localized grip-enhancing features while leaving the bulk material properties unchanged, thus maintaining ease of manufacture.
3Ease of operation
If textured patterns are added to improve grip, then user safety and comfort improve, but the manufacturing process becomes more complex
Solution Approach 1:
The texturing function is merged with the existing calendaring process. The release paper used for preventing sticking during calendaring also serves as the source of the textured pattern. As the rubber passes through the calendering rolls with the release paper, the pattern from the release paper is transferred to the rubber surface, combining two functions into one process step without adding complexity.
4Ease of operation
If release paper is used instead of dusting agents, then grip quality is maintained, but the process requires additional materials and steps
Solution Approach 1:
The release paper serves multiple functions simultaneously: it prevents sticking between rubber layers during calendaring, provides the textured pattern for grip enhancement, and acts as a carrier that can be removed without leaving residues. This multi-functionality eliminates the need for separate dusting agents and post-texturing operations, reducing overall process complexity despite the addition of release paper.
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 textured rubber sheets provide enhanced grip and usability during exercises and physical therapy, improving user experience and safety.
Implementation Method 1
the separator is a low shrinkage, thermoplastic textile with a thread count configured to impart an impression on the rubber sheet
Implementation Method 2
heating the roll of combined rubber sheet and separator so as to vulcanize the rubber sheet
Data Source
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AI summary
A rubber sheet product with both sides having a textured surface is produced in accordance with the present invention. A low-shrinkage thermoplastic textile fiber separator sheet separates layers of rubber sheeting that would otherwise stick together during the production of the rubber sheet. The separator is used in place of talc or dust that is commonly used to separate layers of rubber sheeting during or after the calendaring process and prior to the vulcanization process (after vulcanization, the rubber is no longer naturally tacky). In certain embodiments, the separator is constructed using a weave of not more than 90 x 70 threads/square inch so that it creates an impression on the material to be separated, thereby affording the material a textured surface.