Three dimensional network structure
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Solution Overview
Problem
Existing three-dimensional network structures lack durability, acupressure effect, and air permeability, and are inadequate for accommodating various body types, leading to issues such as sagging, unevenness feeling, and poor load distribution.
Innovation Solution
A three-dimensional network structure with continuous filaments having random loops and partially fusion-bonded protrusions, featuring varying bulk densities and surface layers to enhance durability and acupressure effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a basically smooth surface three-dimensional network structure is used, then high hardness and high repulsion are achieved, but sleeping comfort is insufficient for various body types
Solution Approach 1:
The invention applies local quality by creating protrusions with different bulk densities in specific regions of the mattress. The surface layer has higher bulk density (0.03-0.15 g/cm³) than the inner portion (0.01-0.08 g/cm³), providing localized support and acupressure effects while maintaining overall softness for comfort across different body types.
Solution Approach 2:
The invention transitions from a flat two-dimensional surface to a three-dimensional structure with protrusions having varying heights and bulk densities. This dimensional change enables differentiated support zones that adapt to various body contours while maintaining high hardness where needed.
2Ease of operation
If profile processing is applied to create unevenness surface, then body-pressure dispersion effect and ventilation effect are obtained, but durability is reduced due to sagging
Solution Approach 1:
The invention changes the bulk density parameter to resolve the contradiction. The surface layer has higher bulk density (0.03-0.15 g/cm³) compared to the inner portion (0.01-0.08 g/cm³), which provides structural support to prevent sagging while maintaining the pressure dispersion effect of the uneven surface profile.
Solution Approach 2:
The invention creates a composite structure with two distinct regions: a surface layer with higher bulk density and an inner portion with lower bulk density. This composite approach combines the pressure dispersion benefits of profiled surfaces with the durability of high-density structural support.
3Reliability
If higher bulk density is used throughout the structure, then durability is improved, but air permeability and comfort are reduced
Solution Approach 1:
The invention applies local quality by restricting high bulk density (0.03-0.15 g/cm³) to only the surface layer where structural support is needed, while maintaining low bulk density (0.01-0.08 g/cm³) in the inner portion to preserve air permeability and comfort properties.
Solution Approach 2:
The invention segments the mattress structure into two functional zones: a surface layer for durability and support, and an inner portion for breathability and comfort. This segmentation allows each region to optimize its properties without compromising the other.
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 improved acupressure and air permeability with increased durability, allowing for better load dispersibility and comfort for different body types.
Implementation Method 1
the bulk density of the protrusions is 1.05 to 4 times the average bulk density of the main body... the surface layer of the bottom portions is thicker than the surface layer of the top portions of the protrusions
Implementation Method 2
a three-dimensional network structure having a total average bulk density of 0.01 to 1.5 g/cm³... a plurality of protrusions are provided on a surface of the three-dimensional network structure
Data Source
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AI summary
It is an object to provide a three-dimensional network structure in which functionality of protrusions is sustained over a long period of time with high durability. There is provided a three-dimensional network structure used as a cushion, having a total average bulk density of 0.01-1.5 g/cm3, and comprising a plurality of continuous filaments having random loops and being partially fusion bonded. The three-dimensional network structure comprises: a three-dimensional network structure main body; a plurality of protrusions formed on a specific surface of the three-dimensional network structure main body and protruding in a thickness direction thereof, wherein the plurality of protrusions are continuously provided via bottom portions interposed therebetween and having a height lower than that of top portions of the protrusions, and at least one of the plurality of protrusions have an average bulk density that is 1.05 - 6 times the average bulk density of the three-dimensional network structure main body.