Lattice Structure Body Support with Segmented Stiffness Zones
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Solution Overview
Problem
Conventional seating structures, such as chairs, often have rigid frames or shells that limit flexibility and comfort, leading to hard contact points and restricted ergonomic responsiveness, and require complex assembly processes with multiple parts and costly tooling.
Innovation Solution
A body support structure featuring a lattice structure with interconnected support and base members, including a structural lattice for rigidity and a compressive lattice for flexibility, manufactured through additive processes like 3-D printing, allowing for a compliant and ergonomic design with integrated kinematic features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid frame or shell structure is used to provide structural support, then structural strength and stability are improved, but flexibility and ergonomic responsiveness deteriorate
Solution Approach 1:
The body support member is segmented into a lattice structure composed of multiple interconnected struts or beams arranged in a three-dimensional pattern. This segmentation allows the structure to maintain overall strength while enabling localized flexibility and deformation, resolving the contradiction between structural integrity and adaptive comfort
Solution Approach 2:
The lattice structure parameters (such as strut thickness, spacing, and geometric configuration) are optimized to achieve the desired balance between strength and flexibility. By adjusting these parameters, the structure can provide both structural support and ergonomic responsiveness simultaneously
2Adaptability or versatility
If multiple assemblies and parts are used to create conventional chairs, then functional requirements are met, but device complexity and manufacturing cost increase
Solution Approach 1:
Multiple conventional chair components (backrest, seat, armrests, and support structures) are merged into a single integrated body support member manufactured as one piece using additive manufacturing. This consolidation eliminates the need for multiple separate parts and complex assembly processes while maintaining all necessary functions
Solution Approach 2:
The body support member is designed to perform multiple functions simultaneously: providing structural support, enabling reclining motion, offering ergonomic comfort, and serving as the primary frame structure. This multi-functionality replaces what would traditionally require multiple specialized components
3Ease of manufacture
If traditional manufacturing processes with stamping or casting are used, then structural components are produced, but manufacturing complexity and tooling cost increase
Solution Approach 1:
Traditional mechanical manufacturing processes (stamping, casting, welding) are replaced with additive manufacturing technology. This substitution enables direct digital fabrication of complex lattice structures without requiring expensive tooling, molds, or multiple assembly steps, significantly simplifying the manufacturing process
Data Source
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AI summary
A body support structure includes a structural lattice structure having a first stiffness, and a compressive lattice structure supported by the structural lattice structure and having a second stiffness less than the first stiffness. A skin lattice structure is supported by the compressive lattice structure, wherein the skin lattice structure is resistant to shear deformation in response to a normal force and is expandable in a direction transverse to the normal force.