Porous structural body and porous structural body manufacturing method
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Solution Overview
Problem
Existing methods for manufacturing cushioning porous structural bodies, such as urethane foam, lack flexibility in adjusting dynamic properties.
Innovation Solution
A porous structural body made of flexible resin or rubber, comprising a skeleton part with bone parts and coupling parts, and partially connected films, manufactured using a 3D printer, allowing for improved adjustability of dynamic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional foaming by chemical reaction is used to manufacture cushioning porous structural bodies, then manufacturing process is established, but degree of freedom in adjusting dynamic properties is limited
Solution Approach 1:
The porous structural body is divided into multiple annular parts, each comprising bone parts and coupling parts. This segmentation allows independent adjustment of dynamic properties for each annular part while maintaining overall structural integrity, thereby increasing the degree of freedom in adjusting dynamic properties without excessive complexity
Solution Approach 2:
The skeleton part is designed with flexible bone parts and coupling parts that can dynamically respond to applied loads. The structure transitions from a static foam material to a dynamic lattice structure where individual components can move and deform, enabling precise adjustment of dynamic properties such as cushioning characteristics and energy absorption
2Ease of manufacture
If 3D printing is used to manufacture porous structural bodies, then ease of manufacture is improved, but degree of freedom in adjusting dynamic properties remains limited
Solution Approach 1:
Different annular parts are designed with locally optimized structures - bone parts with specific cross-sectional areas, coupling parts with varying geometries, and partially connected films at specific locations. This local quality approach allows each region to be optimized for specific dynamic properties while maintaining manufacturability through 3D printing
Solution Approach 2:
The porous structural body combines multiple structural elements (bone parts, coupling parts, partially connected films) into a composite lattice structure. This composite approach enables tuning of dynamic properties by adjusting the composition and arrangement of different structural components, while 3D printing provides the manufacturing flexibility to realize these complex composite structures
3Adaptability or versatility
If annular parts with partially connected films are introduced, then degree of freedom in adjusting dynamic properties is improved, but manufacturing precision requirements increase
Solution Approach 1:
Instead of fully connecting all structural elements, the design employs partially connected films that attach only to specific portions of annular parts. This partial connection approach reduces manufacturing precision requirements compared to full connections, while still providing sufficient control over dynamic properties through the strategically placed partial connections
Data Source
AI summary
A porous structural body 1 made of flexible resin or rubber, the porous structural body includes a skeleton part 2 throughout its entirety. The skeleton part includes a plurality of bone parts 2B and a plurality of coupling parts 2J coupling end parts of the plurality of respective bone parts with each other. The skeleton part has a plurality of annular parts 211 each constituted of the plurality of bone parts and the plurality of coupling parts into an annular shape. Each annular part zones a virtual surface V1 by its inner peripheral side edge part 2111. At least a part of each of one or a plurality of the virtual surfaces is covered with one or a plurality of partially connected films 31. Each of the one or plurality of partially connected films is connected to only a part of the annular part in a peripheral direction.