Internally supported cushion for seating system
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Solution Overview
Problem
Conventional seating cushions are not well-suited for wireframe lounge chairs as they lack sufficient support and can slip through gaps in the seatback or armrest, failing to provide ergonomic support for extended use by various users.
Innovation Solution
An internally supported cushion with a rigid core element sandwiched between foam layers, featuring standoffs and a bracket assembly for secure attachment to the seat support, along with batting layers for comfort, to provide ergonomic support and prevent slipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional foam cushion is used, then the cushion is soft and comfortable, but it lacks sufficient support and slips through gaps in wireframe lounge chairs
Solution Approach 1:
The cushion combines foam layers with a rigid core element (wood, metal, or plastic) to create a composite structure that provides both comfort and support stability. The rigid core prevents the cushion from slipping through gaps while the foam layers maintain softness and comfort.
Solution Approach 2:
The rigid core element is nested within the foam layers, creating a layered composite structure. This nested configuration allows the soft outer foam to provide comfort while the inner rigid core provides structural support and prevents slippage.
2Reliability
If a rigid support structure is added to the cushion, then support stability is improved, but the manufacturing complexity increases
Solution Approach 1:
The cushion is segmented into distinct functional layers: foam layers for comfort and a separate rigid core element for support. This segmentation allows each component to be manufactured independently using different processes, then assembled together, managing complexity through modular construction.
Solution Approach 2:
The rigid core element serves multiple functions: it provides structural support, prevents slippage through gaps, and acts as an attachment point for mounting hardware. This multi-functionality reduces the need for additional separate components, managing overall structural complexity.
3Reliability
If the cushion is made with multiple layers and internal structure, then ergonomic support is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The multi-layer cushion structure is divided into separable components (foam layers, rigid core, batting, cover) that can be manufactured independently and then assembled. This segmentation enables specialized manufacturing processes for each material type while simplifying the overall production workflow through modular assembly.
Solution Approach 2:
The rigid core element is prepared in advance with pre-attached mounting hardware (bracket assembly and standoffs) before the foam layers are added. This preliminary preparation of the support structure allows for efficient assembly of the complete cushion unit and simplifies the manufacturing sequence.
4Reliability
If standoffs and bracket assembly are added for secure attachment, then the cushion remains stable on wireframe chairs, but the device complexity increases
Solution Approach 1:
The mounting hardware (bracket assembly and standoffs) is integrated with the rigid core element, either attached to it or formed as part of it. This merging eliminates the need for separate attachment components and simplifies the overall structure while maintaining stable cushion positioning on wireframe chairs.
Solution Approach 2:
The attachment mechanism combines the rigid core material with metal or wood mounting components to create a composite assembly that provides both structural integrity and secure attachment capability, managing complexity through material composite construction.
Data Source
AI summary
An internally supported cushion for a seating unit is provided. The internally supported cushion includes an internal structure that provides rigidity when used adjacent a back upright or a side upright of a seating unit. The internal structure generally includes a rigid core element that is sandwiched between foam layers. The rigid core element is approximately upright and extends in the lengthwise and widthwise directions of the internally supported cushion. A batting layer is positioned immediately beneath an upholstery covering to prevent the covering from contacting the internal foam layers, which encapsulate the rigid core element.