Cushioning structures including interconnected cells
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cushioning mats and pads are heavy and lack the necessary properties for light weight, high coefficient of friction, and effective elastic recovery, making them unsuitable for various applications such as matting, fall protection, and vibration dampening.
Innovation Solution
A cushioning article comprising a cell layer with interconnected cells, each having at least three shared cell walls and a land region at the second major surface, attached to a base layer, formed through an extrusion replication process that creates a patterned surface with modulated cell walls and a continuous structure for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional foam or molded rubber materials are used for cushioning mats, then cushioning performance is achieved, but the mats become heavy (>4000 grams/m2)
Solution Approach 1:
The cushioning mat is divided into an array of discrete cells (e.g., hexagonal, triangular, or rectangular) that are interconnected through shared walls. This segmentation allows the structure to maintain cushioning performance through the collective behavior of multiple small cells while using less material overall, reducing weight from >4000 grams/m2 to <2000 grams/m2 in some embodiments.
Solution Approach 2:
The mat employs a porous cellular structure with interconnected void spaces within each cell and between cells. This porous architecture provides cushioning through compression of the cell walls and air pockets while significantly reducing material density and weight compared to solid foam or rubber materials.
2Weight of moving object
If lightweight materials are used to reduce mat weight, then weight is reduced, but coefficient of friction and elastic recovery properties deteriorate
Solution Approach 1:
The mat incorporates a land region (solid material area) at the second major surface that connects adjacent cell walls. This local concentration of material provides high coefficient of friction for traction while the rest of the structure remains lightweight and porous for cushioning. The land region acts as a localized feature that delivers specific surface properties without compromising overall lightness.
3Weight of moving object
If lightweight materials are used to reduce mat weight, then weight is reduced, but elastic recovery capability deteriorates
Solution Approach 1:
The cellular structure is designed to be dynamically responsive to applied loads. The cell walls are configured to flex, bend, and rebound in response to compression forces, providing elastic recovery. The interconnected cells can deform independently and return to their original configuration, enabling the lightweight structure to exhibit excellent elastic recovery properties comparable to or better than traditional heavy materials.
Solution Approach 2:
The cell walls are designed with curved or modulated surfaces rather than flat planes, creating arch-like structures that naturally resist compression and promote elastic recovery. The curved geometry distributes stresses more effectively and enables the thin-walled cells to rebound efficiently after deformation, enhancing elastic recovery in the lightweight structure.
4Reliability
If complex cellular structures are created to improve cushioning properties, then cushioning performance is enhanced, but manufacturing complexity increases
Solution Approach 1:
The extrusion die is designed to simultaneously perform multiple functions: it forms the cell walls, creates the land region, establishes the cellular pattern, and provides structural support all in a single extrusion process. This multi-functionality eliminates the need for separate steps to create cells, add surface features, or attach reinforcement layers, simplifying manufacturing despite the complex final structure.
Solution Approach 2:
The patent combines the formation of cell walls and land regions into a single continuous extrusion process rather than manufacturing them separately and assembling them. The interconnected cellular structure with integrated land regions is created in one step, merging multiple structural elements into a unified manufacturing operation that reduces complexity.
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 solution provides lightweight, soft, and resilient cushioning articles with high friction and good elastic recovery, suitable for diverse applications including matting, fall protection, and vibration dampening, while maintaining low cost and versatility.
Implementation Method 1
cooling the molten extrudate to provide a cell layer
Implementation Method 2
good elastic recovery
Data Source
AI summary
Cushioning articles or structures are provided including a cell layer with an array of cells interconnected with each other. Each of the cells includes at least three cell walls extending between the first and second major surfaces thereof. The cell walls are shared by the adjacent cells, and the cell layer further includes a land region located at the second major surface and connecting the at least three cell walls. A base layer is attached to the second major surface of the cell layer to form a sheet.