Composite object comprising a body and a foam and method for producing same
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Solution Overview
Problem
Existing methods for producing mattresses and pillows lack cost-efficiency and individualization, often relying on traditional materials like flexible polyurethane foams and not fully utilizing additive manufacturing for customizable mechanical properties.
Innovation Solution
A composite object comprising a body and a solid foam, where the body is manufactured using additive sintering with a spatial network of nodes connected by struts, and the foam is formed to fill the space between the struts, providing synergistic mechanical properties and customizable damping characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional flexible polyurethane foams are used for mattresses and pillows, then production is simple and cost-effective, but mechanical properties and damping characteristics cannot be customized
Solution Approach 1:
The patent applies local quality by creating spatially varying strut densities and configurations within the lattice body. Different regions of the mattress have different numbers of struts per unit volume, allowing customization of mechanical properties and damping characteristics in specific zones while maintaining a consistent manufacturing process.
Solution Approach 2:
The patent utilizes parameter changes by varying geometric parameters of the lattice structure, including strut diameter, strut length, node configuration, and spatial density. These parameter variations enable customization of mechanical properties without changing the fundamental manufacturing approach or material system.
2Adaptability or versatility
If additive manufacturing is used to create customized mechanical properties, then individualization is achieved, but production cost and process complexity increase
Solution Approach 1:
The patent segments the mattress into a lattice framework and foam filling components. The lattice body serves as a cost-effective scaffold produced by additive manufacturing, while the foam material provides the primary cushioning function. This segmentation allows customization where needed while maintaining cost-effectiveness through standardized material usage.
Solution Approach 2:
The patent creates a composite structure combining additively manufactured lattice material (thermoplastic or metal) with traditional foam materials. This composite approach leverages the cost-effectiveness and simplicity of foam production while incorporating the customization capabilities of additive manufacturing for the structural lattice framework.
3Adaptability or versatility
If cavities are incorporated locally into mattress layers using oscillating knives, then zoning with different elastic properties is achieved, but manufacturing precision and structural integrity are compromised
Solution Approach 1:
The patent applies preliminary action by pre-defining the precise cavity locations, shapes, and sizes during the additive manufacturing process. The cavities are built-in as integral parts of the lattice structure with exact geometric precision, eliminating the need for subsequent mechanical cutting operations that would compromise structural integrity.
Solution Approach 2:
The patent replaces the mechanical oscillating knife cutting system with an additive manufacturing system. Instead of cutting cavities into pre-formed foam layers, the cavities are directly fabricated with precise geometries during the layer-by-layer construction process, achieving both zoning capability and manufacturing precision.
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 composite object achieves enhanced mechanical properties and cost-effectiveness by allowing for individualized production with adjustable damping properties, suitable for use as supporting or storage elements like mattresses and pillows.
Implementation Method 1
The body (10, 20) was manufactured using an additive sintering manufacturing process
Implementation Method 2
contacting the body with a reaction mixture that reacts to form a polyurethane foam
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A composite object (1, 2) comprises a body (10, 20) and a solid foam (301). The body (10, 20) was produced by means of an additive production method and is at least interlockingly connected to the foam (301). The material of the body (10, 20) differs from that of the foam (301). The body (10, 20) preferably comprises a spatial network of node points (200) connected to each other by struts (100) and a space (300) between the struts (100). At least partially a foam (301) is present in the space between the struts (100). The composite object is suitable for use as a supporting element and/or bearing element. A method to produce a composite object (1, 2) of this kind comprises the following steps: I) producing a body (10, 20) by means of an additive production method; II) bringing the body (10, 20) into contact with a foam-forming composition, wherein the composition penetrates at least partially into the interior of the body (10, 20); III) forming a foam to obtain the composite object (1, 2).