Cushioning member systems and assemblies

Solution Overview

Problem

Traditional cushioning members often provide limited cushioning, are difficult to manufacture, expensive, and offer insufficient support, especially when dynamic forces are applied, such as lateral forces.

Innovation Solution

Cushioning members with a plurality of elastomeric walls forming cavities, featuring variable compression regions and controlled stiffness profiles, which can be interlocked to form a cushioning grid for enhanced support and stability, using materials like styrenic block copolymer and oil, and manufactured through injection molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional cushioning members are used, then manufacturing simplicity is maintained, but cushioning performance and support stability are limited

Engineering Contradiction:

Improvesupport stabilityVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cushioning member is divided into multiple walls forming a plurality of cavities, where each wall can be independently configured with different compression regions. This segmentation allows each wall to provide targeted support while collectively achieving enhanced overall stability without requiring a completely complex structural design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different walls or regions of walls are assigned different compression characteristics through varying wall thicknesses, materials, or geometric configurations. This local quality approach enables specific areas to provide different levels of cushioning and support, optimizing performance while maintaining manufacturing feasibility through standardized modular components.

Inventive Principle:

Principle #3Local quality

2Reliability

If traditional cushioning materials and configurations are used, then material and manufacturing costs are controlled, but cushioning effectiveness and support capability are insufficient

Engineering Contradiction:

Improvecushioning effectivenessVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The cushioning member is divided into multiple walls forming a plurality of cavities, where each wall can be independently configured with different compression regions. This segmentation allows each wall to provide targeted support while collectively achieving enhanced overall stability without requiring a completely complex structural design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent varies parameters such as wall thickness, material composition, and geometric configuration across different walls to optimize cushioning performance. These parameter changes are implemented within manufacturing capabilities by using standardized production processes with adjustable parameters rather than requiring entirely new manufacturing methods.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If uniform wall thickness is used throughout the cushioning member, then manufacturing simplicity is maintained, but dynamic force distribution and stability are insufficient

Engineering Contradiction:

Improvedynamic force resistanceVSAvoidwall configuration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Different walls or regions of walls are assigned different compression characteristics through varying wall thicknesses, materials, or geometric configurations. This local quality approach enables specific areas to provide different levels of cushioning and support, optimizing performance while maintaining manufacturing feasibility through standardized modular components.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The wall configurations are designed to dynamically respond to applied forces, with varying thicknesses and materials allowing different regions to deform and recover in response to dynamic loading conditions. This dynamic behavior enhances stability under varying force conditions while the modular wall design keeps manufacturing complexity manageable.

Inventive Principle:

Principle #15Dynamics

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 improved cushioning and support, especially under dynamic forces, while being cost-effective and modular, allowing for customizable stiffness distribution and reduced manufacturing complexity.

Implementation Method 1

a plurality of walls extending from the top end to the bottom end and defining a plurality of cavities, wherein the plurality of walls comprise an elastomeric material

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

each wall comprises at least a first compression region and a second compression region

Methodology Applied

Scientific EffectHysteresis: Hysteresis

Data Source

PatentUS20240285088A1Cushioning member systems and assemblies

Publication Date: 2024.08.29 SEALY TECHNOLOGY LLC

AI summary

A cushioning system may include a plurality of cushioning members comprising an elastomeric material. Each cushioning member may comprise a top end, bottom end, and a plurality of walls extending from the top end to the bottom end and defining a plurality of cavities. Each cushioning member may be substantially planar with a mating profile configured to engage with a complimentary mating profile of a second cushioning member. A mattress assembly may include a cushioning system as a support layer.