Foam Upholstery Core With Interlocking Layers for Suspension Comfort
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Solution Overview
Problem
Existing foam inner cores for upholstery in seating and reclining furniture do not adequately enhance suspension comfort beyond current levels of springiness.
Innovation Solution
A foam inner core design featuring two layers of interlocking longitudinal and transverse webs with opposing crests that can be glued together, optionally with an intermediate layer, allowing for varying degrees of hardness and improved adaptation to the body through varying cross-sections of the webs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single layer of foam with longitudinal and transverse webs is used, then the structure provides basic suspension properties, but the spring comfort and suspension comfort are insufficient
Solution Approach 1:
The foam inner core is divided into multiple layers (at least two layers) with longitudinal and transverse webs, where each layer contributes to the overall suspension properties. This segmentation allows each layer to be optimized independently while collectively providing enhanced spring comfort and suspension comfort compared to a single-layer structure.
Solution Approach 2:
The patent combines multiple foam layers with different web configurations into a composite structure. The longitudinal and transverse webs are integrated in a composite arrangement where they interlock and support each other, creating a multi-functional structure that simultaneously provides structural integrity, suspension, and comfort properties that cannot be achieved with a single material or layer.
2Adaptability or versatility
If the cross-sections of longitudinal and transverse webs are made uniform, then manufacturing is simplified, but adaptation to the body shape is reduced
Solution Approach 1:
The patent implements local quality by varying the cross-sections of longitudinal and transverse webs at different positions within the foam structure. Specifically, the cross-sections are adapted to match the expected pressure distribution and body contours, with different web thicknesses and spacing in different zones. This allows the foam to provide optimized support and comfort for different body regions while maintaining a systematic manufacturing approach.
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 significantly improves spring comfort and dimensional stability of the foam padding, enabling the creation of medium-firm to firm mattresses with enhanced suspension properties.
Implementation Method 1
the crests of the corrugations of the layers lying opposite one another to touch one another and be glued to one another
Data Source
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AI summary
An existing foam inner core of an upholstery for seating and / or reclining furniture consists of wave-shaped longitudinal (31, 32) and transverse webs (41, 42, 51, 52), wherein the waves of the longitudinal (31, 32) and transverse webs (41, 42, 51, 52) are interlinked. There are two layers (1, 2) with each toothed shafts of the longitudinal (31, 32) and transverse webs (41, 42, 51, 52) connected to each other one above the other, wherein the wave crests of the layers (1, 2) lie opposite one another . and Characterized the Federungskarnfort is improved.