Textured Resistance Bands Using Textile Separators for Better Grip
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Solution Overview
Problem
Commercially available elastic exercise bands have smooth surfaces that lack adequate grip, making them difficult to handle during exercise and physical therapy activities.
Innovation Solution
A process involving calendaring rubber sheets with a low-shrinkage thermoplastic textile separator to create a textured surface on both sides, which is then vulcanized to form exercise resistance bands with enhanced grip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a smooth rubber sheet is used for exercise bands, then the manufacturing process is simple, but the grip for users is inadequate
Solution Approach 1:
The patent applies a textured separator material with a porous or patterned structure between rubber sheets during calendaring. This separator imparts a textured surface pattern on the rubber bands that enhances grip while maintaining manufacturing simplicity through the calendaring process.
Solution Approach 2:
The patent introduces a textured separator as an intermediary material between the rubber sheets during the calendaring process. This separator temporarily holds the sheets apart and simultaneously imprints the desired textured surface pattern, solving both the grip enhancement and manufacturing efficiency requirements.
2Ease of operation
If dusting agents are used during calendaring to prevent sticking, then the sheets can be handled easily, but the surface becomes contaminated and grip is reduced
Solution Approach 1:
The patent uses a textured separator as an intermediary barrier between rubber sheets during calendaring, replacing traditional dusting agents. This separator prevents sheets from sticking together without contaminating the surface, thereby maintaining both ease of handling and optimal grip characteristics.
Solution Approach 2:
The separator used in the process is a disposable element that serves its function during calendaring and is then discarded. It provides the necessary non-stick property and surface texturing without requiring cleaning or reuse, eliminating surface contamination issues associated with reusable dusting agents.
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 surface provides improved grip and handling of exercise bands, enhancing user experience and safety during use.
Implementation Method 1
combining the rubber sheet on a drum with a separator... heating the combined rubber sheet and separator so as to vulcanize the rubber sheet
Implementation Method 2
heating the combined rubber sheet and separator so as to vulcanize the rubber sheet
Data Source
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 90×70 threads/square inch so that it creates an impression on the material to be separated, thereby affording the material a textured surface.