Alternating Pattern Gel Cushioning Elements
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Solution Overview
Problem
Conventional gel cushions lack effective three-dimensional patterning for optimal cushioning and pressure relief, and existing manufacturing methods do not efficiently produce alternating patterned gels with desired structural and performance characteristics.
Innovation Solution
Development of three-dimensionally patterned or alternating patterned gel cushions made from elastomers, such as SEBS or SEPS, with the addition of hollow microspheres for reduced weight and cost, and manufacturing methods involving compression molding, extrusion, and heat-fusing techniques to create unique patterns and configurations for enhanced cushioning properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional compressible materials are used for cushioning, then ease of manufacture is improved, but pressure distribution uniformity deteriorates
Solution Approach 1:
The cushion is divided into multiple cells or compartments with alternating high and low density regions. This segmentation allows each region to function independently in pressure distribution, creating uniform overall pressure distribution while maintaining manufacturability through modular construction
Solution Approach 2:
Different regions of the cushion have different material densities - high density regions provide structural support while low density regions provide comfort and pressure relief. This local variation in material properties enables uniform pressure distribution across the cushion surface
2Stress or pressure
If alternating pattern gel is used for superior pressure relief, then pressure distribution uniformity is improved, but device complexity increases
Solution Approach 1:
The cushion combines gel material with alternating high and low density regions in a single integrated structure. This composite approach achieves uniform pressure distribution through material heterogeneity while simplifying manufacturing by forming the pattern in one piece rather than assembling multiple components
3Weight of moving object
If hollow microspheres are added to gel, then weight is reduced, but material strength deteriorates
Solution Approach 1:
Hollow microspheres are selectively incorporated into low density regions of the alternating pattern while high density regions maintain solid gel structure. This local differentiation reduces overall weight in comfort zones while preserving structural strength in support zones
Solution Approach 2:
The cushion uses a composite structure combining solid gel in high density regions with gel containing hollow microspheres in low density regions. This composite material approach optimizes the weight-strength tradeoff by placing lightweight material where strength is less critical and dense material where structural support is needed
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 resulting alternating patterned gel cushions provide superior pressure relief and support, allowing for customizable designs and applications in various products, including mattresses, footwear, and medical equipment, with improved manufacturing efficiency and cost-effectiveness.
Implementation Method 1
The gel may contain hollow microspheres which not only lightens the gel
Implementation Method 2
By gel, we mean an elastomeric gel such as a solid elastomer extended by at least 20 parts plasticizer per 100 parts solid elastomer by weight
Implementation Method 3
alternating patterned gels made from elastomers, such as SEBS or SEPS, with hollow microspheres, which are molded into specific patterns to create a cushioning element with aligned protrusions and recesses on opposite sides
Data Source
AI summary
An alternating pattern gel cushioning device and methods for making the same. The gel pattern may be two- or three-dimensional. The devices may be zoned or stacked. The device may be made by a variety of methods including roller molding, open-face molding, injection molding, casting, extrusion, compression molding and other methods.