3D Printed Headrest Lattice With Tunable Stiffness Gradient
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Solution Overview
Problem
Existing trim articles lack the ability to provide customized elastic moduli through structural configuration tuning, resulting in inadequate cushioning and support properties.
Innovation Solution
A method of forming a trim article using additive manufacturing to create a lattice matrix with varying elastic moduli by layer-by-layer deposition and controlled energy source exposure, allowing for voxel-level tuning of 3D cells to achieve specific stiffness gradients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a uniform lattice matrix structure is used throughout the trim article, then the manufacturing process is simple, but the cushioning and support properties are inadequate due to lack of customized elastic moduli
Solution Approach 1:
The patent applies local quality by varying the elastic modulus at different locations within the lattice matrix. Specifically, the outer layers are configured with lower elastic moduli to provide cushioning, while inner layers have higher elastic moduli for structural support. This is achieved by adjusting structural parameters (such as cell size, wall thickness, or material density) at specific spatial locations within the lattice matrix, allowing each region to have optimized properties tailored to its functional requirements.
Solution Approach 2:
The lattice matrix is segmented into multiple layers or regions, each with distinct elastic modulus values. The trim article is divided into outer layers and inner layers, with each layer independently configured to have specific mechanical properties. This segmentation enables the structure to provide different functions (cushioning vs. support) in different zones, resolving the contradiction between simplicity and customized performance.
2Adaptability or versatility
If the entire lattice matrix is cured with the same energy exposure, then the manufacturing process is efficient, but the elastic modulus cannot be tuned to provide both cushioning and support
Solution Approach 1:
The curing process applies local quality by delivering different energy exposures to different regions of the lattice matrix. The outer layers receive lower energy exposure or shorter curing times to achieve lower elastic moduli for cushioning, while inner layers receive higher energy exposure or longer curing times to achieve higher elastic moduli for support. This spatially varying curing approach enables stiffness gradient formation without requiring separate manufacturing steps for each region.
Solution Approach 2:
The curing process uses periodic action by applying energy in controlled intervals or sequences. Different regions of the lattice matrix are cured at different times or with different energy intensities during the manufacturing process, allowing the formation of distinct elastic modulus zones. This time-based differentiation enables the creation of stiffness gradients while maintaining overall process efficiency.
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 method enables the production of trim articles with tailored cushioning and support properties, enhancing comfort and structural integrity by providing a stiffness gradient from outer to inner layers.
Implementation Method 1
printing a photocurable composition with a three-dimensional (3D) printer in a layer-by-layer deposition process (2) irradiating the first section of the lattice matrix with an energy source to cure the first section of the lattice matrix (4) irradiating the first group of 3D cells of the second section of the lattice matrix with the energy source to cure the first group of 3D cells
Implementation Method 2
printing a photocurable composition with a three-dimensional (3D) printer in a layer-by-layer deposition process (3) printing the photocurable composition with the 3D printer in a layer-by-layer deposition process to form a first group of 3D cells and a second group of 3D cells
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.