Foam Cell Wall Structure for Controlled Compressibility

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Solution Overview

Problem

Existing foams have limited compressibility due to structural deficiencies such as uneven cell distribution, variable wall thickness, and intersecting cells, which affect durability and manufacturing processes.

Innovation Solution

A method for creating foams with constant wall width between cells, using a process that involves generating a two-dimensional surface with defined boundaries, populating it with points to represent cell locations, and generating cell regions with uniform thickness, which can be applied to various shapes and sizes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If cells are removed from bulk foam to increase compressibility, then compressibility is improved, but structural deficiencies such as uneven wall thickness and reduced durability are introduced

Engineering Contradiction:

ImprovecompressibilityVSAvoiddurability

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The patent applies local quality by creating uniform cell wall thickness throughout the foam structure. Instead of having variable thickness that results from random cell removal, the invention ensures consistent wall thickness (e.g., 0.5-2 mm) across all regions, including areas where cells intersect with boundaries. This localized uniformity maintains structural integrity and durability while achieving the desired compressibility through controlled cell distribution.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention changes the geometric parameters of the foam structure by controlling cell size, cell distribution density, and wall thickness as design parameters. By adjusting these parameters during the foam creation process (using molds or 3D printing), the patent achieves optimal compressibility without compromising durability. Specifically, the cell wall thickness parameter is maintained within a controlled range to prevent structural weakness while allowing sufficient compression.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If variable wall thickness is present in foam cells, then manufacturing flexibility is improved, but uneven compressibility and reduced durability result

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidcompressibility uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies homogeneity by ensuring uniform cell wall thickness throughout the entire foam structure. The invention creates a homogeneous distribution of cells with consistent wall dimensions (e.g., 0.5-2 mm thickness) across all regions. This uniformity eliminates the compressibility variations that occur with variable thickness and ensures predictable, even compression across the foam surface, directly addressing the manufacturing precision requirement.

Inventive Principle:

Principle #33Homogeneity

3Quantity of substance

If cells intersect with foam boundaries, then foam density is improved, but durability at boundary areas is reduced

Engineering Contradiction:

Improvefoam densityVSAvoidboundary durability

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent applies local quality by providing enhanced structural reinforcement at foam boundaries where cells intersect with external surfaces. The invention ensures that boundary regions have sufficient material thickness and structural support to maintain durability, while the interior regions can have optimal cell density for compressibility. This localized differentiation allows the foam to achieve high overall density without compromising boundary strength.

Inventive Principle:

Principle #3Local quality

4Productivity

If conventional foam manufacturing is used, then production speed is improved, but control over cell distribution and wall thickness is limited

Engineering Contradiction:

Improveproduction speedVSAvoidcell structure control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by preparing precise foam molds or 3D printing templates before the foam creation process. These pre-designed tools incorporate the desired cell distribution patterns, wall thickness specifications, and boundary conditions into the manufacturing setup. By establishing the geometric framework in advance, the invention enables conventional foam manufacturing processes to produce foams with controlled and uniform cell structures, achieving both production speed and manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250196269A1Controlled Foam Compressibility Using Constant Wall Thickness Between Cells

Publication Date: 2025.06.19 SAMSUNG ELECTRONICS CO LTD

AI summary

In one embodiment, a method of manufacturing a foam material includes generating a two-dimensional surface enclosed by one or more boundaries and populating the two-dimensional surface with a number of points. The method further includes generating, for each of the number of points, a corresponding cell region on the two-dimensional surface, where each cell region has a cell surface area bounded by a cell wall, and where each cell wall has the same thickness. The method further includes generating, for each of the one or more surface boundaries, a boundary wall having a particular boundary-wall thickness; applying the two-dimensional surface to a foam material; and creating, in the foam material, cells in accordance with the cell regions within the two-dimensional surface.