Vertically Lapped Nonwoven Padding for Breathable Cushioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Foam materials used in padding applications, such as sporting equipment, are poor in moisture transport, not environmentally friendly, and emit volatile organic compounds, leading to discomfort and health concerns.
Innovation Solution
Vertically lapped nonwovens are used instead of foam materials, offering high elastic recovery, breathability, and recyclability, with a backing material and acquisition layer for superior cooling and sweat management, and can be secured to substrates using hook and loop fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If foam materials are used for padding, then cushioning and resiliency are improved, but moisture transport capability deteriorates
Solution Approach 1:
The patent uses vertically lapped nonwoven fabric with a porous structure that allows moisture to pass through while maintaining cushioning properties. The vertical lapping creates channels and voids that facilitate moisture transport unlike dense foam materials.
Solution Approach 2:
The invention combines nonwoven fabric with foam or other materials to create a composite structure that integrates the cushioning properties of foam with the moisture transport capability of nonwoven fabric.
2Adaptability or versatility
If foam materials are used, then elasticity and adaptability are improved, but environmental friendliness deteriorates due to VOC emissions
Solution Approach 1:
The patent promotes using nonwoven fabric as a replaceable, removable component that can be disposed of or replaced rather than permanently attached, reducing long-term environmental impact and VOC exposure.
Solution Approach 2:
The invention changes the material parameter from foam (which emits VOCs) to nonwoven fabric (which does not emit VOCs), maintaining the necessary adaptability through the fabric's structural properties.
3Quantity of substance
If vertically lapped nonwoven is used, then moisture transport and breathability are improved, but structural density deteriorates
Solution Approach 1:
The vertically lapped nonwoven structure creates porous channels that enhance moisture transport while the overall structure maintains sufficient density for cushioning when combined with foam or other supporting layers.
Data Source
AI summary
A fibrous nonwoven material which is vertically lapped in its entirety or which includes one or more lapped regions which include vertically lapped fibers provides for padding to be applied to a substrate (e.g., an article of interest such as a handle for sporting equipment or tool, or on the inside of a motorcycle or bicycle helmet, etc.). The skin contacting surface of the nonwoven has regions which are relatively thicker than other regions, and air, sweat, and the like are allowed to easily pass through these regions for cooling, wicking of fluid and enhanced breathability. The lapped nonwoven includes a backing material which helps define the pad shape and which permits securing to a substrate. A hook and loop fastener may be affixed to the lapped nonwoven at the backing material so as to allow retrieval and replacement of the nonwoven on the substrate. An acquisition layer on the surface can be used on the surface of the nonwoven, and a carded consolidated web may be positioned within the nonwoven. The nonwoven may take a variety of shapes including the shape of a strip and the shape of a koozie.