Ergonomic pillow design and 3D printing manufacturing method based on cervical vertebra physiological structure characteristics

Abstract

The invention discloses an ergonomic pillow design and 3D printing manufacturing method based on cervical vertebra physiological structure characteristics, and belongs to the technical field of pillows. The pillow is designed based on physiological curvature, length and width parameters of the cervical vertebra, is divided into a general style and a customized style, is in a butterfly shape on the whole and is divided into a supine area and a side-lying area with a shoulder support. The radian of the supine area is matched with the physiological curvature of the cervical vertebra, and the height of the side-lying area is matched with the side height of the head and neck. The stress structure of the pillow is made of a hard material with low heat conduction rate and can be hollowed out, and a soft high-elastic material layer can be laid on the outer surface of the pillow. A 3D printing technology is adopted, a three-dimensional model is established according to cervical vertebra parameters and is directly manufactured, accurate forming of complex curved surfaces and individual differences is effectively achieved, and the pillow can provide accurate cervical vertebra support.

Description

Technical Field

[0001] This invention belongs to the field of pillow technology, specifically relating to an ergonomic pillow design and 3D printing manufacturing method based on the physiological structure characteristics of the cervical spine. Background Technology

[0002] With socio-economic development and increased health awareness, people have higher and higher requirements for sleep quality. As a key piece of bedding that supports the head and neck, the scientific design and comfort of a pillow directly affect cervical spine health and sleep experience. However, traditional pillows often use uniform specifications and lack consideration for the unique physiological structure of the cervical spine, making it difficult to effectively maintain the physiological curvature of the cervical spine. This can easily lead to neck discomfort, muscle tension, and other problems for users, and long-term use may even aggravate cervical strain.

[0003] To improve pillow usability, the industry has proposed various improvement solutions. For example, patent CN120078244A discloses a smart pillow with a lifting mechanism and a temperature control system, which adapts to different user needs by adjusting the pillow's height and temperature. However, this design focuses on the mechanical adjustment of external parameters and does not fundamentally design the pillow based on the anatomical characteristics of the cervical spine. Patent CN108433476A proposes a multi-zone pillow that improves support by distinguishing between supine and lateral sleeping areas. However, its zone design is still relatively macroscopic and fails to accurately meet the complex three-dimensional surface requirements determined by individual differences in cervical spine physiological curvature, length, and shoulder width. In addition, patent CN120256717A attempts to match pillows to users through an intelligent recommendation system, reflecting the objective existence of personalized needs. However, this method belongs to the backend matching algorithm and does not solve the source design problem of how the front-end product itself can achieve accurate adaptation.

[0004] In summary, the existing technologies generally have the following limitations: (1) Insufficient design basis, mostly based on experience or macroscopic human body data, lacking in-depth application of the core structural parameters of the cervical spine (such as physiological curvature, neck length, shoulder width) and their correlation; (2) Low degree of personalization, either a "one-size-fits-all" general design or relying on complex adjustable mechanisms, the latter being costly, unstable, and failing to provide initial optimal support based on biomechanical principles; (3) Manufacturing bottleneck, even with scientific design concepts, traditional manufacturing processes are difficult to economically and efficiently realize complex and personalized three-dimensional curved surface shapes.

[0005] Therefore, there is an urgent need in this field for a highly adaptable ergonomic pillow that is based on the fundamental structural characteristics of the human cervical spine, can directly translate personalized parameters into product design, and can be achieved through advanced manufacturing technology. Summary of the Invention

[0006] This invention aims to overcome the shortcomings of existing pillow technology. Existing pillows either have a uniform size that fails to adapt to individual differences, or rely on complex mechanical adjustment mechanisms, resulting in high costs and poor stability. Their fundamental flaw lies in the failure to deeply integrate the anatomical structure of the human cervical spine during the design phase, leading to imprecise support and limited comfort. Therefore, the purpose of this invention is to provide an ergonomic pillow design and 3D printing manufacturing method based on the physiological structure of the cervical spine. This solution uses the core physiological parameters of the cervical spine as the design basis from the outset, and through advanced additive manufacturing technology, achieves a highly adaptable pillow that meets both general needs and allows for personalized customization, thereby providing users with scientific and precise cervical spine support and effectively improving sleep comfort and health.

[0007] To achieve the above objectives, the present invention is implemented through the following technical solution: An ergonomic pillow based on the physiological structure of the cervical spine includes a supine area (1) and a lateral area (2). The core of the pillow is that its support structure is designed based on the physiological structural parameters of the human cervical spine.

[0008] The pillow mainly consists of a rigid support core and a soft covering layer (6).

[0009] Furthermore, the rigid support core, as the main load-bearing structure, is integrally formed by 3D printing technology from a hard material with low thermal conductivity and sufficient structural strength (such as photosensitive resin, nylon, etc.). The core is further divided into a supine support structure (3) corresponding to the supine area (1) and a lateral support structure (4) corresponding to the lateral area (2). Hollow holes (5) can be provided on the supine support structure (3) and the lateral support structure (4). The shape of the hollow holes (5) can be circular, elliptical, or other geometric shapes determined according to the structural stress optimization analysis.

[0010] Furthermore, the soft covering layer (6) covers the entire outer surface of the rigid support core and is made of a soft, high-elastic material (such as memory foam or latex sheet) with a thickness of 0.5-1 cm. It is used to directly contact the skin and improve the tactile comfort.

[0011] Furthermore, the morphology of the supine support structure (3) is determined by the following cervical spine parameters: 1) Curvature of the surface: The curvature of its upper contour line is adapted to the physiological curvature (cervical curve) of the human cervical spine, and the Cobb angle corresponding to this curvature is preferably within the normal range of 20° to 40°.

[0012] 2) Longitudinal length: Its effective support length is adapted to the distance from the occipital protuberance to the spinous process of the seventh cervical vertebra, preferably 10 to 15 cm, to ensure complete support for the entire cervical spine region.

[0013] 3) Support height: The support height in the back of the neck area should be adapted to the differences caused by individual body size and muscle mass. The preferred height is 3 to 6 cm to keep the cervical spine in a natural physiological position when lying on the back.

[0014] 4) Horizontal width: Its width is designed to be 15 to 25 cm to ensure stable support for the neck and provide appropriate freedom of head movement.

[0015] Furthermore, the morphology of the lateral support structure (4) is determined by the following parameters: 1) Support height: Its height is adapted to the height of the human head and neck at the side. Depending on gender and body type, the preferred height is 12 to 18 cm for men and 10 to 16 cm for women to ensure that the cervical spine, thoracic spine and lumbar spine are kept on the same horizontal line when lying on the side.

[0016] 2) Shoulder support: The lateral support structure (4) extends to include a shoulder support area (7) to provide support for the shoulder that is suspended when lying on the side, to avoid pressure on the shoulder and to maintain the straightness of the spine.

[0017] Furthermore, the rigid support core adopts a hollow design for structural optimization. The bottom of the supine support structure (3) and the lateral support structure (4) can be designed as a single-layer curved shell structure with a hollow bottom, and the shell thickness is determined according to the mechanical properties of the selected material and the expected load.

[0018] Furthermore, the pillow has an overall "butterfly" shape, with a concave supine area (1) in the middle and raised lateral areas (2) on both sides. The supine support structure (3) and the lateral support structure (4) are naturally connected by a smooth transition surface, which not only conforms to ergonomics but also facilitates 3D printing manufacturing and enhances the aesthetics and comfort of the product.

[0019] Furthermore, this invention provides both general and customized modes.

[0020] 1) Universal size: Based on statistical data of cervical spine parameters of people of different ages, genders and body types, the design is standardized and several standard sizes are provided.

[0021] 2) Customized version: By obtaining the user's individual cervical spine imaging data (such as X-ray) or 3D scan data, the characteristic parameters such as the curvature and length of the cervical spine are accurately extracted to carry out one-to-one personalized design. Beneficial effects

[0022] Compared with the prior art, the present invention has the following significant advantages: 1. Scientifically designed and precisely supportive: For the first time, core anatomical parameters such as cervical spine physiological curvature (Cobb angle), neck length, and shoulder width are directly quantified into the design basis of the pillow's curvature. This ensures precise support for the cervical spine from a biomechanical perspective, effectively maintaining the normal physiological curvature of the cervical spine and preventing and relieving cervical fatigue from the source.

[0023] 2. High degree of personalization and wide adaptability: By combining "general" and "customized" models, it can meet the needs of large-scale production and provide users with special needs with the ultimate personalized solutions, completely solving the adaptation problem of "one person, one pillow, a thousand people, a thousand faces".

[0024] 3. Optimized Structure, Comfortable and Durable: The use of rigid materials as the main support structure ensures long-lasting and stable support, while the hollow design significantly reduces the product's weight and creates efficient air circulation channels, improving breathability. The outer soft covering layer perfectly solves the problem of the unpleasant feel of rigid materials, achieving the optimal combination of "soft outside and firm inside" for optimal comfort.

[0025] 4. Advanced manufacturing and high feasibility: The innovative application of 3D printing technology to pillow manufacturing perfectly solves the technical bottleneck of traditional processes being unable to economically and efficiently produce such complex, personalized three-dimensional curved surface products. This method enables seamless conversion from digital models to physical products, making it particularly suitable for small-batch, multi-variety customized production. Attached Figure Description

[0026] To more clearly illustrate the technical solution of the present invention, the drawings used in the embodiments are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is an axonometric drawing of the soft covering layer of the ergonomic pillow belt based on the physiological structure characteristics of the cervical spine according to the present invention; Figure 2 This is an axonometric drawing of the ergonomic pillow support structure based on the physiological structure of the cervical spine according to the present invention; Figure 3 This is a front view of the ergonomic pillow support structure based on the physiological structure of the cervical spine according to the present invention; Figure 4 This is a side view of the ergonomic pillow support structure based on the physiological structure of the cervical spine according to the present invention. Figure 5 This is a top view of the ergonomic pillow support structure based on the physiological structure of the cervical spine according to the present invention; Figure 6 This is a schematic diagram of the 3D printing manufacturing process for an ergonomic pillow.

[0028] Explanation of reference numerals in the attached figures: 1. Supine area; 2. Lateral area; 3. Supine support structure; 4. Lateral support structure; 5. Hollowed-out openings; 6. Soft covering layer; 7. Shoulder support area. Detailed Implementation

[0029] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0031] The present invention provides an ergonomic pillow based on the physiological structure characteristics of the cervical spine and its manufacturing method. Its core lies in converting the quantitative physiological parameters of the human cervical spine into the specific design dimensions of the pillow support structure, and using 3D printing technology to achieve precise manufacturing from digital model to physical product.

[0032] As attached Figure 1 The ergonomic pillow of this invention features a butterfly-shaped layout, with a supine area 1 in the center and two side-lying areas 2 on either side. The core load-bearing structure of the pillow is a rigid support core, which is integrally formed using 3D printing and clearly divided into a supine support structure 3 and a side-lying support structure 4. To optimize the structure, reduce weight, and enhance breathability, perforations 5 are provided in both the supine support structure 3 and the side-lying support structure 4. Finally, a soft, highly elastic pillowcase 6 is wrapped around the entire rigid support core to provide a skin-friendly feel. Specifically, the side-lying support structure 4 extends outward to form a shoulder support area 7, used to accommodate and support the shoulder when lying on one's side.

[0033] Its manufacturing process specifically includes the following steps: S1: Obtain the cervical spine structural feature parameters of the target user group.

[0034] Parameters are obtained based on production targets.

[0035] General version: Targeted at the target population, statistical data on the structural characteristics of the cervical spine are obtained from publicly available medical anatomy databases or through large-sample measurements, including but not limited to: cervical physiological curvature, neck length, lateral height of the head and neck, and shoulder width.

[0036] Customized version: By acquiring the target user's medical imaging data or 3D body surface scanning technology, the individual's cervical Cobb angle, neck length, and lateral height of the head and neck are accurately measured.

[0037] S2: Create a three-dimensional digital model of the ergonomic pillow.

[0038] Parametric modeling was performed using 3D modeling software based on the parameters obtained in step S1.

[0039] Determine the baseline profile: Use the target neck length as the longitudinal baseline length of the three curved surfaces of the supine support structure.

[0040] Constructing the supine curve: Based on the physiological curvature corresponding to the target Cobb angle, construct a continuous support curve on the upper part of the supine support structure 3. The support height of this curve in the back of the neck area is set according to the user's body shape.

[0041] Set the lateral lying height: Use the height of the target head and neck to the side as the support surface height of the lateral lying support structure 4.

[0042] Integration and Optimization: The curved surfaces of the supine and lateral lying areas are smoothly connected to form a complete butterfly-shaped model. At the same time, the hollow holes 5 are designed in the model, and the bottoms of the supine support structure 3 and the lateral lying support structure 4 are hollowed out to form a single-layer shell structure.

[0043] S3: Model import and printing preparation.

[0044] Export the 3D digital model generated in step S2 in a standard format and import it into the control software of the 3D printing equipment. Set appropriate printing parameters according to the characteristics of the selected hard material.

[0045] S4: 3D printed rigid support core.

[0046] Using a selected rigid material, a complete rigid support core is manufactured by printing layer by layer using 3D printing equipment. Necessary post-processing is then performed after printing.

[0047] S5: Configure a soft covering layer 6.

[0048] A soft, highly elastic material of appropriate thickness is used to create a soft covering layer 6 that is completely fitted to the final shape of the rigid support core, and this layer is then wrapped around the core. Example

[0049] This embodiment details the process of customizing a personalized ergonomic pillow for a 35-year-old male user who is 175 cm tall and weighs 70 kg.

[0050] Parameter acquisition: The user's cervical spine Cobb angle was accurately measured to be 28 degrees using a lateral cervical spine X-ray.

[0051] Measured physical characteristics, the neck length, i.e. the distance from the occipital bone to the seventh cervical vertebra, was found to be 12.5 cm.

[0052] The lateral height of its head and neck was measured to be 15 centimeters.

[0053] 3D modeling: Using 3D CAD software, a supine support curve was constructed with a length of 12.5 cm, conforming to the 28-degree cervical spine curve. The support height in the posterior neck region was set to 4.5 cm, and the width of the supine area was set to 18 cm.

[0054] A lateral support structure 4 is constructed with a height of 15 centimeters, and a shoulder support area 7 is integrated.

[0055] The supine and lateral recumbent areas are smoothly merged to form a butterfly-shaped basic model. Then, an array of five circular perforations with a diameter of 2 cm are added to the model, and the bottom is hollowed out to form a single-layer shell structure with a thickness of 10 mm. This ultimately generates a three-dimensional digital model.

[0056] Printing and manufacturing: The model was imported into a selective laser sintering 3D printer, and nylon PA12 powder was selected as the printing material.

[0057] The printing layer thickness was set to 0.1 mm for printing. After printing, the part was removed and sandblasted to obtain the final rigid support core.

[0058] assembly: The pillow is made of 0.8 cm thick slow-rebound memory foam material, which is precisely cut and sewn into a soft covering layer 6 according to the shape of the inner core. It is then wrapped around the inner core with a hidden zipper to obtain the final customized pillow.

[0059] The pillow manufactured using this embodiment has parameters that are highly matched to the user's cervical spine physiological characteristics. When lying on the back, the pressure on the cervical spine is significantly reduced, and when lying on the side, the spine can maintain a good straight line, greatly improving comfort.

[0060] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made to the technical solutions of the present invention by those skilled in the art without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. An ergonomic pillow based on the physiological structure of the cervical spine, characterized in that, include: The rigid support core is integrally formed by 3D printing technology and includes a supine support structure (3) and a lateral support structure (4) located on both sides of it. The supine support structure (3) and the lateral support structure (4) are smoothly connected to form a butterfly-shaped layout of the pillow. A soft covering layer (6) covers the outer surface of the rigid support core; The upper contour of the supine support structure (3) is configured as a continuous curve that adapts to the physiological curvature of the human cervical spine; the height of the lateral support structure (4) is configured to adapt to the lateral height of the human head and neck.

2. The ergonomic pillow according to claim 1, characterized in that, The curvature of the upper contour curve of the supine support structure (3) is adapted to the physiological curvature of the cervical spine with the Cobb angle in the range of 20° to 40°.

3. The ergonomic pillow according to claim 1 or 2, characterized in that, The effective support length of the supine support structure (3) is 10 to 15 cm, the neck support height is 3 to 6 cm, and the width is 15 to 25 cm.

4. The ergonomic pillow according to claim 1, characterized in that, The height of the lateral support structure (4) is configured as follows: 12 to 18 cm for men or 10 to 16 cm for women.

5. The ergonomic pillow according to claim 1, characterized in that, The lateral support structure (4) also includes a shoulder support area (7) extending outward.

6. The ergonomic pillow according to claim 1, characterized in that, The rigid support core is made of a hard material with low thermal conductivity, and the supine support structure (3) and / or the lateral support structure (4) are provided with hollow holes (5).

7. The ergonomic pillow according to claim 6, characterized in that, The hollowed-out hole (5) is circular, elliptical, or a geometric shape determined by structural stress optimization analysis.

8. The ergonomic pillow according to claim 6, characterized in that, The supine support structure (3) and the lateral support structure (4) are single-layer curved shell structures with hollow bottoms.

9. The ergonomic pillow according to claim 1, characterized in that, The soft covering layer (6) is made of memory foam or latex and has a thickness of 0.5 to 1 cm.

10. A 3D printing manufacturing method for producing the ergonomic pillow according to any one of claims 1-9, characterized in that, Includes the following steps: S1: Obtain cervical spine structural characteristic parameters of the target user group. These parameters include at least the cervical spine physiological curvature, neck length, and lateral head and neck height. For general-purpose pillows, these cervical spine structural characteristic parameters are obtained from statistical data of specific age groups and body types. For customized pillows, these parameters are obtained by acquiring individual user medical imaging data or 3D scan data. For individuals with deformed physiological curvature, the physiological curvature is designed to be within the normal range. S2: Based on the cervical spine structural feature parameters, establish a three-dimensional digital model of an ergonomic pillow with a butterfly-shaped layout, supine support curve, and lateral support height. S3: Import the three-dimensional digital model into the 3D printing equipment; S4: The rigid support core of the ergonomic pillow is manufactured in one piece using rigid materials and 3D printing process.

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