3D Lattice Headrest Structure for Tuned Cushioning and Support
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Solution Overview
Problem
Existing trim articles lack the ability to provide customized elastic moduli and structural support, leading to suboptimal cushioning and rigidity characteristics.
Innovation Solution
An additively manufactured lattice matrix with varying elastic moduli is created using voxel-level tuning, comprising different groups of 3D cells with specific exposure times to an energy source, coupled with a support armature for enhanced structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a uniform lattice matrix is used throughout the trim article, then manufacturing is simpler, but the article cannot provide customized elastic moduli for different regions
Solution Approach 1:
The patent applies local quality by varying the lattice cell characteristics (size, shape, density, or material composition) in different regions of the lattice matrix to achieve customized elastic moduli. Specifically, the lattice matrix includes first plurality of lattice cells with first characteristics and second plurality of lattice cells with second characteristics, where the characteristics differ to provide region-specific mechanical properties. This allows different portions of the trim article to have tailored cushioning and support characteristics.
Solution Approach 2:
The patent segments the lattice matrix into multiple groups of lattice cells, where each group contains lattice cells with specific characteristics. The lattice matrix is divided into first plurality of lattice cells and second plurality of lattice cells, with each plurality having distinct characteristics that determine their elastic modulus. This segmentation enables independent optimization of different regions while maintaining overall structural integrity.
2Strength
If the lattice matrix provides sufficient structural support, then rigidity is improved, but cushioning comfort deteriorates
Solution Approach 1:
The patent resolves this contradiction by assigning different lattice cell characteristics to different regions: lattice cells closer to the support armature have characteristics that provide higher rigidity and structural support, while lattice cells farther from the support armature have characteristics that provide softer cushioning. This spatial variation in lattice cell properties allows the same structure to simultaneously provide both structural support and comfort.
Solution Approach 2:
The patent segments the lattice matrix into multiple groups with different characteristics, where each group is positioned to fulfill specific functional requirements. The first plurality of lattice cells provides structural support near the armature, while the second plurality provides cushioning in outer regions. This functional segmentation allows the structure to deliver both support and comfort without compromise.
3Adaptability or versatility
If additively manufactured 3D cells with varying elastic moduli are used, then customized cushioning and rigidity are achieved, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by systematically varying lattice cell parameters (such as cell size, wall thickness, or material density) across different regions of the lattice matrix. The additive manufacturing process enables precise control of these parameters, allowing the first plurality of lattice cells to have first parameters and the second plurality to have second parameters. This parametric variation achieves customized mechanical properties while leveraging the capabilities of additive manufacturing.
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 solution provides a trim article with tailored cushioning and rigidity, offering improved comfort and support by integrating a lattice matrix with varying elastic moduli and a support armature.
Implementation Method 1
the first elastic modulus of the first group of additively manufactured 3D cells and the second elastic modulus of the second group of additively manufactured 3D cells are produced by the exposure of the first and second groups of additively manufactured 3D cells to an energy source
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.