Customized Saddle Cushion Modeling from Dynamic Riding Pressure
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Solution Overview
Problem
Existing bicycle saddle solutions fail to provide a custom fit that accounts for both the rider's anatomy and dynamic riding positions, leading to discomfort during long rides.
Innovation Solution
A method involving a deformable molding paste applied to a saddle shell, deformed under the rider's weight and motion, with pressure sensors recording pressures to create a 3-D saddle cushion model for 3-D printing, ensuring a customized fit based on actual riding conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a molding paste is applied to create an anatomically molded saddle, then the saddle fits the rider's buttock shape, but it does not account for dynamic riding positions and pressure distribution
Solution Approach 1:
The patent applies dynamics by using a deformable molding paste that can change shape under the rider's weight and motion during actual riding. The paste transitions from a static anatomical mold to a dynamic form that adapts to multiple riding positions, capturing pressure distribution across different poses rather than just a fixed buttock shape.
Solution Approach 2:
The patent uses preliminary action by having the rider perform multiple riding positions during the molding process itself. The deformable paste records pressure maps from various dynamic positions (leaning forward, upright, etc.) before the final saddle is manufactured, allowing the custom saddle to be pre-configured for these specific riding patterns.
2Measurement precision
If pressure sensors are used to map pressure distribution, then pressure data is obtained, but the data must be integrated into a 3-D model for customization
Solution Approach 1:
The patent applies copying by creating a 3-D digital replica of the deformable molding paste's deformed state. This 3-D model serves as a virtual copy that can be manipulated and analyzed without physically handling the complex deformed paste shape, simplifying the integration of pressure sensor data and the subsequent 3-D printing process.
Solution Approach 2:
The patent uses an intermediary approach by introducing a 3-D modeling step as a mediator between pressure measurement and saddle manufacturing. The 3-D model acts as an intermediate representation that bridges the gap between raw pressure data from sensors and the final customized saddle production, making the overall process more manageable.
3Ease of operation
If multiple layers of paste with different rigidities are used, then comfort is improved by distributing pressure, but manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by using multiple layers of paste with different rigidities positioned at specific locations. Softer layers are placed in areas requiring more cushioning and pressure distribution, while firmer layers are used in areas needing structural support, creating a non-uniform but optimized comfort profile tailored to local anatomical and pressure requirements.
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 method produces a customized saddle cushion that uniformly distributes pressure, enhancing comfort by accounting for anatomical and positional variations, thereby reducing discomfort during extended cycling.
Implementation Method 1
the molding paste being deformable under a weight of the rider; mounting the probe saddle onto a bicycle and letting the molding paste of the probe saddle deform under the weight and motion of a rider
Implementation Method 2
positioning a plurality of pressure sensors onto the probe saddle and recording pressures from the plurality of pressure sensors during another performance by the rider of the riding session
Implementation Method 3
a density of the 3-D saddle cushion pressure mesh being correlated to the 2-D pressure map... 3-D printing the customized saddle cushion
Data Source
Figure 1~2
Figure 3~4
AI summary
A method (10) of manufacturing a customized saddle cushion (30), such as a bicycle saddle cushion, the method comprises applying a molding paste (14) onto a saddle shell (16) to form a probe saddle (18); letting the molding paste of the probe saddle deform under a weight and motion of a rider (12) riding the bicycle during a riding session; obtaining a 2-D pressure map (22) on the geometrically stable deformed molding paste ; obtaining a 3-D saddle cushion model (21) of the geometrically stable deformed molding paste; and associating the 3-D saddle cushion model with the 2-D pressure map to obtain a 3-D saddle cushion pressure mesh (24) to be used as a reference for 3-D printing the customized saddle cushion. A density of the 3-D saddle cushion pressure mesh is correlated to the 2-D pressure map.