Composite Foam Seat Structure for Thin Vibration-Damping Support

Solution Overview

Problem

Existing polyurethane foam seat designs face challenges in providing adequate comfort and support while minimizing thickness and weight, particularly in vehicular applications, as they struggle to effectively dampen vibrations and accommodate passengers of varying sizes and weights.

Innovation Solution

A composite foam article comprising a high-resiliency polyurethane foam surface layer and a viscoelastic polyurethane foam base layer, with a thickness ratio of 17:3 to 2:3, which provides improved comfort and support properties by combining the resilience of HR foam with the damping properties of VE foam.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high-resiliency polyurethane foam is used to provide comfort and support, then passenger comfort is improved, but the thickness must be increased to accommodate passengers of various sizes and weights

Engineering Contradiction:

Improvecomfort and supportVSAvoidthickness

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The foam article is segmented into multiple layers with different foam types (HR and VE foam) arranged in specific configurations. This segmentation allows each layer to contribute different properties - HR foam provides resiliency and support while VE foam provides comfort and vibration damping - enabling reduced overall thickness while maintaining performance for passengers of various sizes and weights

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite foam structures combining different polyurethane foam types (high-resiliency and viscoelastic foam) in multi-layer configurations. This composite approach allows the article to achieve both comfort and support functions in a thinner profile than single-layer HR foam would require

Inventive Principle:

Principle #40Composite materials

2Reliability

If high-resiliency polyurethane foam is used to provide comfort and support, then passenger comfort is improved, but the weight of the seat is increased

Engineering Contradiction:

Improvecomfort and supportVSAvoidweight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The foam article is segmented into multiple layers with different foam types (HR and VE foam) arranged in specific configurations. This segmentation allows each layer to contribute different properties - HR foam provides resiliency and support while VE foam provides comfort and vibration damping - enabling reduced overall thickness while maintaining performance for passengers of various sizes and weights

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the physical parameters of the foam structure by using different foam densities, resilience values, and layer thicknesses. The HR foam layer has higher resilience (greater than 40% ball rebound) while the VE foam layer has lower resilience (less than 40% ball rebound), creating an optimized weight-to-performance ratio

Inventive Principle:

Principle #35Parameter changes

3Reliability

If thick polyurethane foam is used to accommodate passengers of various sizes and weights, then comfort and support are improved, but the thickness increases reducing storage space

Engineering Contradiction:

Improvecomfort and supportVSAvoidthickness

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The foam article is segmented into multiple layers with different foam types (HR and VE foam) arranged in specific configurations. This segmentation allows each layer to contribute different properties - HR foam provides resiliency and support while VE foam provides comfort and vibration damping - enabling reduced overall thickness while maintaining performance for passengers of various sizes and weights

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite foam structures combining different polyurethane foam types (high-resiliency and viscoelastic foam) in multi-layer configurations. This composite approach allows the article to achieve both comfort and support functions in a thinner profile than single-layer HR foam would require

Inventive Principle:

Principle #40Composite materials

4Ease of manufacture

If single-layer polyurethane foam is used, then manufacturing is simple, but it cannot effectively dampen vibrations in the frequency range that makes riders feel uncomfortable

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidvibration damping

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The foam article is segmented into multiple layers with different foam types (HR and VE foam) arranged in specific configurations. This segmentation allows each layer to contribute different properties - HR foam provides resiliency and support while VE foam provides comfort and vibration damping - enabling reduced overall thickness while maintaining performance for passengers of various sizes and weights

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite foam structures combining different polyurethane foam types (high-resiliency and viscoelastic foam) in multi-layer configurations. This composite approach allows the article to achieve both comfort and support functions in a thinner profile than single-layer HR foam would require

Inventive Principle:

Principle #40Composite materials

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 foam article achieves enhanced comfort and support at reduced thickness and weight, offering superior damping performance and accommodating a wide range of passengers, while allowing for increased storage options and reduced mass in vehicular seating applications.

Implementation Method 1

the base layer comprises a viscoelastic polyurethane foam having an impact resilience of less than about 50%

Methodology Applied

Scientific EffectViscoelasticity: Viscoelasticity

Implementation Method 2

to obtain a comfortable feeling, it is effective to remarkably dampen the vibration in a frequency range that makes riders feel uncomfortable

Methodology Applied

Scientific EffectVibration damping: Damping

Implementation Method 3

the surface layer comprises a high-resiliency polyurethane foam having an impact resilience of greater than about 50%

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11926136B2Composite foam article

Publication Date: 2024.03.12 PROPRIETECT LP

AI summary

A composite foam article is disclosed herein. The composite foam article comprises a surface layer and a base layer with an interface therebetween. The surface layer comprises a high-resiliency polyurethane foam having an impact resilience of greater than about 50% when tested in accordance with ASTM D3574-17, and presents a seating surface. The base layer comprises a viscoelastic polyurethane foam having an impact resilience of less than about 50% when tested in accordance with ASTM D3574-17, and presents a mounting surface opposite the seating surface. The surface layer and the base layer are present in a thickness ratio of from about 17:3 to about 2:3.