Polymeric Mesh Cushion Assembly Without Foam for Recyclable Seating
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Solution Overview
Problem
Existing seat cushions in vehicles and furniture often rely on foam materials that are heavy, difficult to recycle, and may compromise comfort and support.
Innovation Solution
A mesh member assembly made of randomly looped, bonded polymeric filaments, which are bonded together without foam, and adhered using a heat-activated adhesive in a mold assembly to form a lightweight, air-permeable cushion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If foam materials are used for seat cushions, then comfort and support are provided, but weight increases and recyclability decreases
Solution Approach 1:
The patent extracts and eliminates foam material from the cushion construction, replacing it with a mesh member assembly made of polymeric filaments. This removal of harmful foam material directly addresses the recyclability issue while maintaining cushion functionality through the mesh structure.
Solution Approach 2:
The patent uses composite construction by combining multiple mesh members with different orientations (first mesh member with first orientation, second mesh member with second orientation) and bonding them together with adhesive. This composite approach provides structural integrity and comfort without relying on foam materials.
2Object-affected harmful factors
If foam materials are used for seat cushions, then comfort and support are provided, but environmental friendliness deteriorates
Solution Approach 1:
The patent removes foam material from the cushion assembly, eliminating the harmful environmental factor associated with foam production and disposal. The mesh member assembly provides equivalent comfort support without the environmental burden of foam.
Solution Approach 2:
The patent enables recovery and recycling of polymeric materials by eliminating foam that is difficult to recycle. The mesh members can be separated and the polymeric filaments recovered for reuse, improving the overall recyclability and environmental sustainability of the cushion.
3Strength
If mesh members are bonded using adhesive, then structural integrity is maintained, but manufacturing complexity increases
Solution Approach 1:
The patent introduces adhesive as an intermediary substance to bond the mesh members together. The adhesive acts as a mediator that creates strong bonds between the first and second mesh members, maintaining structural integrity while allowing for relatively simple manufacturing processes.
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 reduces weight, improves support and comfort, and facilitates recycling by eliminating foam material while maintaining structural integrity and breathability.
Implementation Method 1
an adhesive that is adhered to the first mesh member and the second mesh member
Data Source
Figure 1~2
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AI summary
An assembly and method of manufacture. The assembly comprises a first mesh member, a second mesh member, and an adhesive. The first and second mesh members comprise first and second sets of filaments of polymeric material, respectively. The adhesive is adhered to the first mesh member and the second mesh member.