Lordosis pad and method of manufacturing lordosis pad
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Solution Overview
Problem
The existing methods for producing lumbar cushions are labor-intensive, prone to leaks, and limit ergonomic design due to the need for multiple weld seams and flat initial construction, which increases manufacturing costs and assembly effort.
Innovation Solution
A lumbar cushion composed of welded cushioning and carrier films with integrated fluid lines, featuring a foldable web that connects multiple inflatable chambers, allowing for pre-shaped three-dimensional construction and reduced assembly complexity, with the option of three-dimensionally structured surfaces for enhanced comfort and massage functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple weld seams are used to assemble lumbar support cushions from film sections, then the cushion can be manufactured with standardized components, but the risk of leaks increases and manufacturing reliability decreases
Solution Approach 1:
The patent merges multiple film sections into a single co-molded thermoplastic elastomer component, eliminating the need for multiple weld seams. The integrated construction combines what would traditionally be separate pieces into one monolithic structure, thereby removing leak risks at seam locations while maintaining ease of manufacture through single-step molding processes.
Solution Approach 2:
The patent applies preliminary action by pre-forming the three-dimensional shape and integrating all structural features during the molding process itself, rather than assembling flat sections and shaping them later. The concave and convex portions are created directly in the mold, eliminating subsequent assembly steps and potential leak points.
2Ease of operation
If lumbar support cushions are manufactured as flat constructions that are inflated at the installation location, then storage and transport are simplified, but the assembly effort increases and manufacturing costs rise
Solution Approach 1:
The patent performs preliminary action by pre-shaping the thermoplastic elastomer component into its final three-dimensional form during manufacturing. The concave and convex portions are created in advance through co-molding, so that when the component is installed and inflated, it already has the correct ergonomic shape without requiring complex assembly operations.
Solution Approach 2:
The patent combines multiple assembly operations into a single molding process. What would traditionally require separate steps for cutting, welding, and shaping multiple film sections is consolidated into one co-molding operation that produces the complete three-dimensional structure in a single step, thereby reducing assembly effort and complexity.
3Adaptability or versatility
If the lumbar support cushion is designed with a single large cushioning chamber, then the structure is simple and manufacturing is easier, but the ergonomic contouring capability is limited
Solution Approach 1:
The patent applies segmentation by dividing the cushioning function into multiple concave and convex portions within the single thermoplastic elastomer component. Each portion can be independently shaped to provide specific ergonomic support zones, allowing complex contouring while maintaining a unified monolithic structure that avoids the complexity of multiple separate chambers.
Solution Approach 2:
The patent implements local quality by creating different geometric features (concave and convex portions) at specific locations within the cushion component. Each local region is shaped to provide tailored ergonomic support for different body areas, enabling versatile ergonomic design through localized geometric variations rather than requiring multiple separate chambers.
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
This solution reduces manufacturing costs and assembly effort, enhances ergonomic design, and increases comfort by allowing the lumbar cushion to be pre-shaped for optimal support and massage functionality, while maintaining the same orientation in both unfolded and folded states.
Implementation Method 1
a cushioning film (10) and a carrier film (11), which are welded together to form at least one first inflatable cushioning chamber (12)
Data Source
Figure 1
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AI summary
The invention relates to a lumbar support cushion 1 comprising a cushioning film 10 and a carrier film 11, which are welded together to form at least one first inflatable cushioning chamber 12 and one second inflatable cushioning chamber 14 and at least one web 16 separating the cushioning chambers 12 and 14, wherein the first cushioning chamber 12 and the second cushioning chamber 14 are each connected to a fluid line 13 opening into them. The web 16 has at least one fold 18 extending in a transverse direction Y, wherein the lumbar support cushion 1 is foldable along the fold 18.