Composite body support member and methods for the manufacture and recycling thereof
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Solution Overview
Problem
Existing body support structures, such as suspended membranes and molded polymer structures, face challenges in providing a combination of adaptivity, aeration, and contouring while minimizing material usage and ensuring safety from pinching hazards.
Innovation Solution
A composite body support structure featuring a molded polymeric grid with three-dimensional contour and a bonded fabric layer, where the fabric covers through openings and lands, allowing for increased adaptivity and aeration without an integral frame, and enabling recycling by melting the composite materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a suspended membrane structure is used, then adaptivity and aeration are improved, but structural rigidity and contour definition deteriorate
Solution Approach 1:
The patent combines a suspended membrane with a three-dimensional molded contour structure to create a composite body support. The membrane provides adaptivity and aeration, while the molded structure provides structural rigidity and contour definition, resolving the contradiction between flexibility and structural integrity
Solution Approach 2:
The body support is divided into multiple zones with different membrane tensions and opening sizes, allowing different regions to provide different levels of support and flexibility while maintaining overall structural integrity
2Stability of the object's composition
If a molded polymer structure is used, then structural integrity and contour definition are improved, but adaptivity and aeration deteriorate
Solution Approach 1:
The molded polymer structure incorporates through openings that provide aeration while maintaining structural integrity. The porous design allows the structure to breathe and reduce heat buildup while retaining sufficient rigidity for body support
Solution Approach 2:
The molded structure is designed with varying thickness and density in different regions, allowing it to dynamically adapt to applied loads. Thinner regions provide more flexibility while thicker regions provide structural support
3Adaptability or versatility
If fabric is secured around peripheral portion only, then flexibility is improved, but safety and coverage deteriorate
Solution Approach 1:
The fabric is pre-bonded to the molded structure at multiple locations including around the periphery and at strategic internal points. This preliminary bonding prevents fabric from becoming loose or creating pinching hazards while maintaining flexibility in non-bonded regions
4Quantity of substance
If larger openings are used, then material usage is reduced, but safety and structural integrity deteriorate
Solution Approach 1:
The molded structure features lands of varying sizes and distributions in different regions. Larger lands are positioned strategically to provide structural reinforcement and prevent pinching hazards in high-stress areas, while smaller lands allow for larger openings in regions where structural demands are lower
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 composite structure offers enhanced user adaptivity, reduced material volume by up to 40%, and safety from pinching hazards while maintaining aesthetic and tactile qualities, with the ability to recycle the materials for further use.
Implementation Method 1
The surface layer is melted using an infrared emitter
Implementation Method 2
melting only a surface layer of the support grid while maintaining a solid substrate adjacent the molten surface layer
Implementation Method 3
the adhesive is heated, for example by way of an infrared emitter or by conducting heat through the fabric as it is pressed against the adhesive
Implementation Method 4
conducting heat through the fabric as it is pressed against the adhesive
Implementation Method 5
melting the bonded fabric and the support grid and thereby forming a melted material
Data Source
Figure 1~2
Figure 3~4B
Figure 5~7
AI summary
A body support structure includes a molded polymeric support grid having a three-dimensional molded contour. The support grid includes a body support region having a plurality of through openings separated by a plurality of lands. In one embodiment, an area of the openings is greater than an area of the lands. In another embodiment, the ratio of a surface area of the lands relative to an area defined by an outer peripheral edge is less than or equal to 0.74. A fabric layer is bonded to the plurality of lands and covers the plurality of openings. Methods of manufacturing and recycling the body structure are also provided.