Layered Thermoplastic Structure With Reduceable-Volume Suspension
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Solution Overview
Problem
Conventional articles providing suspension comfort, such as seats and sofas, often rely on non-recyclable thermoset materials like Polyurethane, Polyvinyl chloride, or Ethylene-vinyl acetate, contributing to environmental waste, and lack efficient mechanisms for maintenance and assembly.
Innovation Solution
A hybrid structure comprising a thin rigid covering layer connected to a thick rigid core member via a reduceable volume layer, which flexes under force to provide suspension quality without using elastic foam, utilizing a quick-connection fitting arrangement and materials that allow recycling without separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thermoset materials (PU, PVC, EVA) are used for suspension layers, then suspension quality is provided, but environmental waste increases and recyclability is lost
Solution Approach 1:
The patent changes the material parameter from thermoset to thermoplastic polymer, which fundamentally alters the recyclability and environmental impact while maintaining suspension functionality through the layered structure and air gaps
Solution Approach 2:
The invention creates a composite structure combining rigid thermoplastic layers with air gaps, replacing conventional foam materials while achieving similar suspension effects through the hybrid arrangement of solid and void spaces
2Strength
If conventional adhesive joining methods are used for layer assembly, then structural integrity is achieved, but manufacturing complexity and environmental harm increase
Solution Approach 1:
The patent replaces chemical joining (adhesives) with mechanical interlocking through integrated attachment elements, eliminating the need for separate adhesive application and curing processes while maintaining strong structural bonds
Solution Approach 2:
The attachment elements are integrated directly into the covering layer structure, merging the fastening function with the structural component itself, thereby reducing the number of separate parts and assembly steps
3Ease of manufacture
If thermoplastic polymer materials are used for covering layer and core member, then recyclability is enabled, but connection complexity increases without quick-connection fittings
Solution Approach 1:
The quick-connection fitting arrangement enables dynamic assembly and disassembly of the hybrid structure, allowing the covering layer to be easily attached and detached from the core member without permanent bonding, which facilitates both assembly simplicity and recyclability
Solution Approach 2:
The structure is segmented into distinct modular components (covering layer with attachment elements, core member with receiving features) that can be independently manufactured and assembled, simplifying both production and recycling 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 hybrid structure achieves suspension comfort similar to elastic foam while being environmentally friendly by using recyclable materials and facilitating easy assembly and maintenance, reducing waste and operational costs.
Implementation Method 1
when a flexing force is applied to an area of the covering layer overlying the reduceable volume, this area flexes into the reduceable volume while maintaining the thickness of the covering layer at said area, and flexes back, thereby providing a suspension quality
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2~3
AI summary
A hybrid structure having suspension quality, comprises a core member having an outer surface, a reduceable-volume layer associated with the outer surface of the core member and having a reduceable volume at least at a number of regions thereof, and a covering layer having an exterior and an interior surface and connected to the core member via the reduceable-volume layer by a connection arrangement. The reduceable volume can be constituted by air gaps spaced from each other; or such gaps and an elastic foam layer portions accommodated within said gaps; or an elastic foam layer sandwiched between the outer surface of the core member and the covering layer, the elastic foam layer constituting a plurality of said regions free of any spacing therebetween. The covering layer is made of such material and has such thickness between said interior and exterior surfaces that areas thereof overlying the reduceable volume are capable of flexing into the reduceable volume, when a flexing force is applied to such area, while maintaining the thickness of the covering layer at said area, and flexing back when the flexing force is released, thereby providing the suspension quality to the hybrid structure.