Dual-Resolution Void Cell Cushioning for Even Pressure Distribution
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Solution Overview
Problem
Conventional cushioning systems often fail to provide even pressure distribution and optimal comfort due to direct coupling of cells or springs, leading to uneven force distribution and potential pressure points when a contoured object, such as a human body, is placed on them.
Innovation Solution
A cellular cushioning system comprising two matrices of void cells with different resolutions, where the peaks of the higher cell resolution cells in the top matrix are attached to the peaks of the lower cell resolution cells in the bottom matrix, allowing for more even pressure distribution and improved comfort by varying the wall thickness and geometry of the cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If cells or springs are directly coupled together to tie the cushioning system together, then structural integrity is improved, but pressure distribution becomes uneven and comfort deteriorates
Solution Approach 1:
The cushioning system is divided into multiple independent cells or springs that are not directly coupled. Each cell/spring acts as an independent element, allowing localized deformation and more even pressure distribution across the contact surface, thereby maintaining structural integrity while improving comfort.
Solution Approach 2:
Different regions of the cushioning system have varying cell/spring densities and configurations. Areas experiencing higher pressure have different structural properties compared to low-pressure areas, enabling optimized local response to pressure while maintaining overall system stability.
2Ease of manufacture
If uniform cell structure is used throughout the cushioning system, then manufacturing simplicity is improved, but pressure distribution becomes uneven and comfort deteriorates
Solution Approach 1:
The cushioning system employs non-uniform cell structures with varying sizes, shapes, and densities in different regions. This local variation allows the structure to adapt to different pressure zones, providing superior comfort and pressure distribution while the overall manufacturing process remains relatively simple through modular construction.
Solution Approach 2:
The patent introduces variability in the third dimension (depth/height of cells) in addition to planar variations. Cells at different depths provide progressive cushioning response, allowing the system to accommodate contoured objects like the human body more effectively while maintaining manufacturability through layered construction.
3Ease of operation
If higher cell resolution is used throughout the cushioning system, then pressure distribution improves, but material usage increases and manufacturing complexity worsens
Solution Approach 1:
High cell resolution is applied only in regions where it is most needed for pressure distribution, such as areas corresponding to high-pressure contact zones of the human body. Lower resolution cells are used in regions requiring less support, thereby reducing overall material consumption while maintaining effective pressure distribution where required.
Solution Approach 2:
Instead of uniformly applying high cell resolution throughout the entire cushioning system, the patent implements high resolution partially in critical areas. This partial application achieves the necessary pressure distribution benefits without the excessive material usage and manufacturing complexity that would result from universal high-resolution construction.
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 system achieves a softer, more supportive surface with even pressure distribution and reduced mechanical noise, enhancing user comfort and mitigating impact through the unique arrangement and attachment of void cells, which resist deflection with a relatively constant resistive force.
Implementation Method 1
the void cells resist deflection with a relatively constant resistive force
Data Source
AI summary
Implementations described and claimed herein include a cellular cushioning system comprising a first matrix of void cells, and a second matrix of void cells opposing the first matrix of void cells, wherein one or more peaks of each void cell in the second matrix is attached to one or more peaks of each void cell in the first matrix, and wherein the void cells of the first matrix have a higher cell resolution than the void cells of the second matrix. In another implementation, a method of manufacturing a cushioning system includes molding a first matrix of void cells, molding a second matrix of void cells, the void cells of the first matrix having a higher cell resolution than the void cells in the second matrix, and attaching peak surfaces of the void cells of the first matrix and peak surfaces of the void cells of the second matrix together.