3D Lattice Body-Supporting Component to Replace Foam and Trim Parts
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Solution Overview
Problem
Existing body-supporting components, such as seat backrests and seating surfaces, often require multiple parts and materials, leading to increased weight, complexity, and difficulty in maintaining cleanliness and waterproofing.
Innovation Solution
A body-supporting component with a 3D lattice structure made from flexible polyurethane or thermoplastic materials, produced through 3D printing, which integrates deflection properties and eliminates the need for separate foam and trim parts, offering a monolithic, lightweight, and waterproof solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional foam parts and trim parts are used in seat construction, then comfort and support are provided, but weight increases and heat transfer is reduced
Solution Approach 1:
The patent employs a 3D lattice structure with inherent porosity and void spaces that enable superior heat transfer while maintaining structural integrity. The porous lattice architecture allows thermal energy to dissipate through multiple pathways, solving the heat transfer problem while the lightweight material composition addresses the weight reduction goal simultaneously.
Solution Approach 2:
The patent utilizes composite material construction combining lightweight structural materials with thermally conductive elements within the lattice framework. This composite approach enables the seat component to achieve both reduced weight and enhanced heat transfer performance by integrating materials with complementary properties into a unified structure.
2Device complexity
If multiple separate parts (foam, trim, attachments) are used in seat construction, then functional requirements are met, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent integrates multiple previously separate seat components (foam padding, trim elements, structural attachments) into a single monolithic 3D lattice structure. This merging eliminates the need for assembly operations, reduces part count, and simplifies manufacturing while maintaining all necessary functional properties through the integrated design.
Solution Approach 2:
The 3D lattice structure is designed to perform multiple functions simultaneously: providing structural support, offering comfort through controlled deflection, enabling heat transfer via its porous architecture, and facilitating easy cleaning due to its seamless surface. This multi-functionality in a single component directly reduces device complexity and manufacturing burden.
3Ease of operation
If traditional foam and trim parts are used, then seat functionality is provided, but ease of cleaning and waterproofing becomes difficult
Solution Approach 1:
By merging all seat components into a single seamless 3D lattice structure, the patent eliminates joints, seams, and attachment points where water and dirt would traditionally penetrate or accumulate. The unified structure can be made fully waterproof as a single unit and can be cleaned without disassembly, simultaneously improving ease of cleaning and ensuring waterproofing integrity.
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 3D lattice structure provides improved load-compression characteristics, reduced weight, enhanced heat transfer, and simplified maintenance, while allowing for customizable elasticity and replacing traditional foam elements with a single, robust component.
Implementation Method 1
a body-supporting component which comprises a main body having a 3D lattice structure wherein the 3D lattice structure of the main body define deflection properties portions of the main body and the main body is formed by a flexible material according to the 3D lattice structure combined with the deflection properties portions
Implementation Method 2
the 3D lattice structure is produced e.g. in a 3D printing process, e.g. in a selective laser sintering process (shortly named SLS) or in a fused deposition modeling (shortly named FDM), of the flexible material
Implementation Method 3
the 3D lattice structure is produced e.g. in a 3D printing process, e.g. in a selective laser sintering process (shortly named SLS) or in a fused deposition modeling (shortly named FDM), of the flexible material
Implementation Method 4
Such a body-supporting component has a reduced weight and a better heat transfer due to larger surface areas
Data Source
AI summary
A body-supporting component may have a main body. A 3D lattice structure of the main body may have deflection properties portions of the main body. The main body may be formed by a flexible material according to the 3D lattice structure combined with the deflection properties portions.