Foam Seat Element With Internal Texture to Prevent Read-Through
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Solution Overview
Problem
Conventional dual density or dual firmness vehicular seat elements are expensive to produce and can result in 'read through' of textured surfaces through the trim cover, compromising both comfort and aesthetic requirements.
Innovation Solution
A foam seat element with internal surfaces of varying textures, where at least one surface is denser near the skin and less dense in the core, creating a contacting interface below the outer surface, allowing for different comfort zones without altering the outer surface's appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If dual density or dual firmness seat elements are used to provide different comfort zones, then occupant comfort is improved, but production cost increases and manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by creating a textured surface layer on the foam seat element that provides different firmness zones only where needed for comfort, while the bulk of the foam remains uniform density. This allows dual-firmness functionality without the complexity of manufacturing entirely dual-density foam components.
Solution Approach 2:
The invention segments the seat element into two functional layers: a uniform density foam substrate and a textured surface layer with varying density patterns. This segmentation allows each layer to be optimized independently, simplifying manufacturing compared to creating entirely dual-density foam structures.
2Ease of operation
If textured surfaces are created on the outer surface of the foam seat element, then comfort is improved, but read through occurs through the trim cover compromising aesthetic appearance
Solution Approach 1:
The patent moves the textured surface from the outer aesthetic surface to an internal surface of the foam element. By placing the comfort-providing texture in the third dimension (internal structure) rather than on the two-dimensional outer surface, the design provides comfort functionality without visual read-through through the trim cover.
Solution Approach 2:
The uniform density foam layer acts as an intermediary between the textured internal surface and the outer trim cover. This intermediate layer masks the texture from view while still allowing the textured surface to provide comfort benefits through the trim material.
3Ease of operation
If multiple types of foam are used to create dual firmness zones, then comfort is improved, but production time increases due to separate production and assembly
Solution Approach 1:
The patent merges multiple foam types into a single uniform density foam substrate, then creates the dual-firmness effect through surface texturing of that single foam piece. This consolidation eliminates the need to produce and assemble multiple separate foam components, significantly reducing production time while maintaining comfort benefits.
4Ease of operation
If insert components are added to create dual firmness zones, then comfort is improved, but device complexity and production cost increase
Solution Approach 1:
The patent extracts the firmness variation function from separate insert components and integrates it directly into the foam substrate through surface texturing. This eliminates the need for additional wire components, flexolators, or other inserts, simplifying the overall structure while maintaining dual-firmness functionality.
Data Source
AI summary
There is described a padded element comprising a foam substrate having disposed therein a first internal surface and a second internal surface opposed to the first internal surface, the first internal surface being interposed between an outer surface of the foam substrate and the second internal surface, at least one of the first internal surface and the second internal surface comprising a textured portion. In a highly preferred embodiment, the pair of internal surfaces disposed within the body of the foam substrate combine to form one or more cavities in the foam substrate (e.g., by the provision of one internal surface have a textured portion and the other internal surface being untextured). The provision of such a textured surface creates a contacting interface (either at rest or when an occupant sits on the seat) between below or remote from the A-surface of the foam element. This interface has different properties than the exposed surface of the seating element. By adopting this internal interface approach to one or more zones of foam element, it is possible to confer different qualities of comfort and feel to the outer surface of the foam element (e.g., A-surface of a vehicular seat element) even though the appearance of that outer surface may be relatively non-textured. In this manner, the occurrence of “read through” described above is obviated or mitigated. A process and mold for produce the padded element are also described.