Curved Void-Cell Cushioning Structure for Buckling Resistance
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Solution Overview
Problem
Conventional cushioning systems face challenges in providing maximum comfort and impact protection due to issues like buckling and rapid displacement during high-impact events, which can lead to stress concentrations and degradation over time.
Innovation Solution
A cushioning structure comprising mutated void cells with multiple outwardly curved surfaces of varying radius measurements, which resist deflection and prevent buckling by absorbing energy, allowing for effective compression and shock absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional cushioning systems use simple cell structures, then manufacturing is easier, but they experience buckling and rapid displacement during high-impact events
Solution Approach 1:
The void cells incorporate outwardly curved surfaces with specific radius measurements (e.g., first radius R1, second radius R2) on their sidewalls. These curved surfaces prevent buckling by distributing compressive forces more evenly across the cell structure during high-impact events, eliminating the need for complex internal support structures while maintaining reliability.
2Reliability
If void cells have larger surface area for impact distribution, then comfort is improved, but material usage and complexity increase
Solution Approach 1:
The cushioning structure applies curvature selectively to specific regions of the void cells rather than making the entire structure complex. The outwardly curved surfaces are positioned at critical locations where buckling occurs, with specific radius measurements tailored to local stress distributions. This localized approach provides effective impact protection while maintaining overall structural simplicity.
3Duration of action of stationary object
If cushioning structure uses more material for durability, then performance over time is improved, but weight and cost increase
Solution Approach 1:
The patent optimizes the radius measurements of the outwardly curved surfaces (e.g., R1, R2, and their relationships) to achieve the minimum effective geometry for preventing buckling. By carefully selecting these geometric parameters, the structure achieves maximum durability with minimum material, reducing weight while ensuring the cushioning structure maintains performance over multiple compression cycles.
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 comfort and impact protection by maintaining performance over multiple compressions without significant degradation, supporting high-impact loads and ensuring a smooth compression profile.
Implementation Method 1
The outwardly curved surfaces dominate the overall design of the void cell and prevent buckling and provide support for high impact by absorbing energy
Implementation Method 2
a first array of spaced apart elastically deformable void cells that resist deflection due to compressive forces
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A cushioning structure (100) comprises a first array (106) of spaced apart elastically deformable void cells (102, 104, 200), wherein each of the void cells include four sidewalls forming a rectangular outline (204); at least two of the sidewalls each include one outwardly curved surface (110, 210) and at least two inwardly curved surfaces (126, 226). The outwardly curved surfaces have concave curvatures that face away from the interior of a void cell, and the inwardly curved surfaces have concave curvatures that face toward the interior of the void cell. The outwardly curved surfaces constitute at least 20% of the overall exterior surface area of each void cell. The cushioning structure (100) may further comprise a second array (108) of elastically deformable void cells, wherein peak surfaces of peak portions of void cells in the second array (108) of void cells are attached to peak surfaces of peak portions of void cells in the first array (106).