Bead-Based Seat Cushion for Conformable Body Support
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Solution Overview
Problem
Traditional automotive seat cushions, such as those made of thermoset foam, do not conform to different body shapes and sizes, leading to discomfort due to counterforces applied by the seat cushion on the passenger.
Innovation Solution
A seat assembly featuring a bead-based pad with flexible pouches containing movable beads that adjust to the user's shape, optionally enhanced by a vacuum system to fix the beads' position, providing customizable cushioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional thermoset foam padding is used in seat cushions, then the cushion provides structural support and durability, but it does not conform to different body shapes and sizes, causing discomfort due to counterforces
Solution Approach 1:
The cushion is divided into multiple independent bead chambers separated by partitions. Each chamber contains beads that can independently move and conform to different body regions, allowing the cushion to adapt to various body shapes while reducing concentrated counterforces on any single area.
Solution Approach 2:
The cushion transitions from a static foam structure to a dynamic bead-based system where beads can freely move and reposition themselves in response to applied pressure. This dynamic behavior allows the cushion to continuously adapt to different body configurations and distribute forces more evenly.
2Adaptability or versatility
If a fixed and non-moveable padding configuration is used, then the manufacturing process is simple and cost-effective, but the orientation and contour of the seat cushioning remains consistent regardless of user, reducing comfort for different users
Solution Approach 1:
The cushion uses flexible pouches or chambers containing beads, allowing the structure to bend and conform to different body contours. The flexible membrane enclosing the beads enables the cushion to adapt its shape while maintaining a relatively simple internal structure compared to active control systems.
3Object-affected harmful factors
If movable beads are used in flexible pouches, then the cushion can conform to user shape and reduce counterforces, but the cushion structure becomes more complex compared to traditional foam
Solution Approach 1:
The flexible pouch or membrane acts as an intermediary between the beads and the user's body. It allows the beads to move freely while providing a smooth contact surface, and it contains the beads within defined chambers, simplifying the overall structure compared to having loose beads throughout the cushion.
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 bead-based pad system offers enhanced comfort and support by conforming to individual body shapes, reducing counterforces and providing tailored support for various users.
Implementation Method 1
the beads of the first set of beads have a coefficient of friction that is less than 0.15
Implementation Method 2
Responsive to a vacuum source applied to the first compartment, the first pouch resists flexing to fix the first set of beads within the first compartment to maintain a shape of the bead-based pad
Data Source
AI summary
A seat assembly includes a seat bottom having a cushion and a covering. The covering includes a flexible exterior surface configured to receive a user sitting at the seat assembly. The cushion includes a bead-based pad. The bead-based pad includes a flexible first pouch defining a first compartment. A first set of beads are movable within the first compartment. Responsive to the user sitting at the seat assembly, the first pouch flexes according to flexing of the exterior surface and the first set of beads move within the first compartment to at least partially conform the first pouch and the exterior surface of the covering to a shape of the user.