Foam Upholstery Core Web Structure for Pressure Distribution
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Solution Overview
Problem
Existing foam padding for seating and reclining furniture lacks optimal pressure distribution and dimensional stability, which affects suspension comfort and lying comfort.
Innovation Solution
The foam inner core features longitudinal and transverse webs with varying cross-sections, where outer webs have larger cross-sections for increased stability and smaller cross-sections in specific areas like the shoulder for better body adaptation, along with stiffening strips for enhanced dimensional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the inner core uses uniform cross-section webs throughout, then the manufacturing process is simple, but the pressure distribution and body adaptation are suboptimal
Solution Approach 1:
The patent applies local quality by varying the cross-section of longitudinal and transverse webs at different positions within the inner core. Specifically, webs in the shoulder area have smaller cross-sections to provide better adaptation and comfort, while webs in other areas maintain larger cross-sections for structural support. This localized variation in web geometry enables the mattress to adapt to different body regions with different pressure requirements.
2Stability of the object's composition
If outer webs have larger cross-sections for dimensional stability, then the structural stability improves, but the material consumption increases
Solution Approach 1:
The patent implements local quality by assigning larger cross-sections to outer longitudinal and transverse webs specifically where dimensional stability is needed at the edges of the mattress. The inner webs, particularly in the shoulder area, have smaller cross-sections optimized for body adaptation. This localized differentiation achieves the required structural stability without uniformly increasing material consumption throughout the entire inner core.
3Stability of the object's composition
If stiffening strips are added to edges, then the dimensional stability increases, but the device complexity and manufacturing steps increase
Solution Approach 1:
The patent applies segmentation by adding stiffening strips as separate components attached to the edges of the inner core. These strips are distinct from the main foam structure and can be independently manufactured and then assembled. This segmentation allows the stiffening function to be added without fundamentally changing the manufacturing process of the main inner core, thereby limiting the increase in overall device complexity.
4Ease of operation
If smaller cross-sections are used in the shoulder area, then the lying comfort improves, but the structural strength decreases
Solution Approach 1:
The patent applies local quality by creating a differentiated web structure where longitudinal and transverse webs in the shoulder area have smaller cross-sections optimized for comfort and body adaptation. Meanwhile, outer webs and webs in other areas maintain larger cross-sections to provide the necessary structural strength. This localized variation resolves the contradiction by providing small cross-sections only where comfort is prioritized while maintaining structural integrity elsewhere.
Solution Approach 2:
The patent implements preliminary action by pre-positioning the varying cross-section webs during manufacturing to anticipate and prevent potential structural weaknesses. The smaller cross-section webs in the shoulder area are strategically placed before use, and the overall structure is designed in advance to ensure that the reduced local strength does not compromise the global structural integrity of the mattress.
Data Source
AI summary
The inner core has foamed material, longitudinal bars and transverse bars. Longitudinal bars (1, 2, 2 ') or transverse bars (3, 3 ', 4, 4 ') have different cross sections in different areas of inner core. Both the longitudinal bars and transverse bars have a larger cross sectional area than the bars lying in between.