Interlocking Cushioning Structure for Directional Load Distribution
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Solution Overview
Problem
Current cushioning systems, such as mattresses and shoe soles, primarily deflect force vertically and lack effective load distribution, resulting in limited cushioning efficacy.
Innovation Solution
A system comprising two complementary surfaces with inclined protuberances of different densities, which interlock to deflect force applied, achieving directable cushioning by splitting vertical and horizontal forces, thereby allowing transverse movement and improved load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional vertical cushioning structures are used, then the structure is simple, but the cushioning effect is limited and load distribution is poor
Solution Approach 1:
The cushioning body is divided into multiple layers with different densities (first cushioning layer, second cushioning layer, third cushioning layer), each layer providing different cushioning characteristics. This segmentation allows optimization of load distribution and cushioning effect while maintaining manageable structural complexity
Solution Approach 2:
The patent uses composite cushioning structures with layers of different densities and material properties. The first cushioning layer has lower density than the second cushioning layer, creating a composite structure that optimizes both comfort and support, resolving the contradiction between simple structure and effective cushioning
2Reliability
If force is only deflected vertically, then the cushioning system is simple, but load distribution is insufficient
Solution Approach 1:
Different layers of the cushioning body have different local properties (density, elasticity) optimized for specific functions. The first cushioning layer provides initial comfort with lower density, while the second layer provides structural support with higher density, achieving improved load distribution through localized material properties
Solution Approach 2:
The patent introduces inclined surfaces and angled deflection paths within the cushioning layers, transforming purely vertical force deflection into multi-directional force distribution. This dimensional change in force deflection paths improves load distribution across the cushioning body
3Reliability
If uniform density is used throughout the cushioning body, then manufacturing is simple, but pressure distribution on the body is uneven
Solution Approach 1:
The cushioning body employs layers with different density characteristics - the first cushioning layer has lower density for pressure relief, while the second cushioning layer has higher density for structural support. This local differentiation of material properties optimizes pressure distribution across different body zones
Solution Approach 2:
The patent varies the density parameter across different layers of the cushioning body. By changing the density parameter from the first layer to the second layer, the system achieves improved pressure distribution while maintaining manufacturability through standardized layering 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 system provides enhanced cushioning and load distribution, improving comfort and reducing pressure on the body, particularly effective in mattresses for spinal health and sleep quality, while also being applicable to various impact cushioning applications.
Implementation Method 1
The two surfaces will be made of a significantly elastic material, and each part will be of a different density
Data Source
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AI summary
The system is based on the combination of two parts (1 and 1') of differing densities with complementary tilted protuberances (2 and 2'), coupled to form a single unit. These protuberances vary in shape, length and thickness so that systems of differing rigidity can be obtained, thus achieving cushioning in virtue of the said protuberances (2 and 2'), enabling the path of the force applied to be defined, thus achieving optimum cushioning force. The system is applicable to both pressure cushioning systems (mattresses, pillows, seats. etc.) and impact cushioning systems (footwear, wheels, helmets, etc.).