Angled Unit-Cell Cushioning Structure for Directional Force Absorption
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Solution Overview
Problem
Existing cushioning structures are not optimized for force absorption in different directions and are inefficient for 3-D printing, leading to excess energy consumption and higher build failure rates in additive manufacturing.
Innovation Solution
A cushioning structure comprising a plurality of unit cells with angled walls, arranged in a 2D or 3D array, allowing for improved force absorption based on the direction of applied force and optimized scanning patterns for efficient 3D printing, reducing errors and power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If generic cushioning structures (honeycomb, bar, lattice, 3D lattice, trigonal, tetragonal, and cubic structures) are used, then different mechanical properties can be provided in different zones, but the structures are not optimized for force absorption in different directions and have complex scanning patterns leading to excess energy consumption and higher build failure rates in 3-D printing
Solution Approach 1:
The cushioning structure is divided into multiple unit cells arranged in an array, where each unit cell contains angled walls that can be independently optimized. This segmentation allows the overall structure to provide different mechanical properties in different zones while maintaining manufacturing efficiency through standardized unit cell designs that are optimized for 3-D printing scanning patterns
Solution Approach 2:
The patent applies local quality by configuring specific zones with different unit cell arrangements or angled wall orientations to provide direction-specific force absorption. The angled walls within each unit cell are specifically designed to absorb forces in particular directions, allowing the structure to have optimized mechanical properties tailored to local requirements without compromising overall manufacturability
2Adaptability or versatility
If generic cushioning structures are used, then different mechanical properties can be provided in different zones, but the scanning patterns needed to generate these structures are inefficient or complex, leading to excess energy consumption and higher build failure rates
Solution Approach 1:
The unit cells incorporate angled walls with specific asymmetries that are optimized for efficient scanning patterns during 3-D printing. The angled walls are designed at specific angles relative to the build direction, allowing the printing head to follow more efficient continuous paths rather than requiring frequent direction changes or complex scanning patterns, thereby reducing energy consumption while maintaining directional force absorption capabilities
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 cushioning structure provides enhanced force absorption capabilities and efficient manufacturing through optimized unit cell design and scanning patterns, reducing errors and energy consumption in additive manufacturing processes.
Implementation Method 1
configured to bend or deform and absorb force and thereby provide a cushioning effect from the force
Data Source
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AI summary
Disclosed herein are cushioning structures and methods for their manufacture. Certain aspects provide a cushioning structure comprising a plurality of unit cells formed in an array, each unit cell of the plurality of unit cells comprising one or more first walls parallel to a central plane and a first protruding structure that protrudes from the central plane, the first protruding structure forming a concave structure on a first side of the central plane and a convex structure on a second side of the central plane, the first protruding structure comprising one or more walls at a non-perpendicular angle to the central plane.