Additively Manufactured Trim Article With Graded Lattice Elastic Modulus
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Solution Overview
Problem
Current trim articles, such as headrest assemblies, lack the ability to customize elastic modulus effectively, resulting in inadequate structural configuration tuning and cushioning performance.
Innovation Solution
A lattice matrix is created using additive manufacturing techniques, with multiple sections having varying elastic moduli, including a first section with a lower elastic modulus, a second section with a higher elastic modulus, and a third section with an even higher elastic modulus, surrounding a hollow core, to provide customized cushioning and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional foam padding is used for trim articles, then cushioning performance is achieved, but structural configuration tuning capability is insufficient
Solution Approach 1:
The lattice matrix is divided into multiple sections (first, second, and third sections) with different elastic moduli. The first section has a lower elastic modulus for softer cushioning, while the second and third sections have higher elastic moduli for structural support. This local differentiation of material properties enables both customized structural configuration and reliable cushioning performance within a single integrated component.
2Ease of manufacture
If uniform elastic modulus is used throughout the trim article, then manufacturing is simplified, but customized cushioning performance is lost
Solution Approach 1:
The elastic modulus parameter is varied across different sections of the lattice matrix. By changing the density and structural parameters of the lattice in each section during additive manufacturing, the patent achieves customized cushioning performance with multiple elastic moduli (first, second, and third sections) while maintaining the manufacturing simplicity of a single additive process.
3Adaptability or versatility
If multiple separate components are used to achieve varying elastic moduli, then customized cushioning is achieved, but device complexity increases
Solution Approach 1:
Multiple lattice sections with different elastic moduli are merged into a single integrated lattice matrix structure. The first, second, and third sections with varying cushioning characteristics are combined in one additive manufacturing process, eliminating the need for multiple separate components while achieving customized cushioning performance and reducing assembly complexity.
Data Source
AI summary
A headrest assembly includes a lattice matrix having a plurality of three-dimensional (3D) cells. Each 3D cell of includes a node and a plurality of links outwardly extending from the node. The lattice matrix includes a plurality of sections including a first section having a first overall elastic modulus, a second section positioned adjacent to the first section and having a second overall elastic modulus that is higher than the first overall elastic modulus of the first section, and a third section positioned adjacent to the second section and having a third overall elastic modulus that is higher than the second overall elastic modulus of the second section. The lattice matrix is integrally constructed using an additive manufacturing technique, wherein the 3D cells of each section are provided in various patterns and cured to varying degrees to provide the varying overall elastic moduli of each section of the lattice matrix.