Molded foam body

Solution Overview

Problem

Existing molded foam bodies struggle to mitigate rocking of occupants when lateral loads are applied, as they lack sufficient support and stability.

Innovation Solution

A molded foam body design featuring a combination of first and second synthetic resin materials, where the upper part is made of the softer material, the sides are made of a harder material, and the middle part is integrated with the upper part, with specific geometric configurations to enhance support and stability, including a pair of second synthetic resin materials forming the lower part with varying gaps to distribute load effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the entire molded foam body is made of a single soft synthetic resin material, then ride comfort is improved, but the ability to mitigate rocking under lateral loads deteriorates

Engineering Contradiction:

Improveride comfortVSAvoidrocking mitigation

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent applies local quality by using different synthetic resin materials with different hardness levels in different regions of the molded foam body. The upper part uses a softer material for comfort, while the lower part uses a harder material for stability and rocking mitigation. This spatial differentiation of material properties resolves the contradiction between comfort and stability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining multiple synthetic resin materials with different hardness characteristics within a single molded foam body. The first synthetic resin material (softer) and second synthetic resin material (harder) are integrated in specific regions to achieve both comfort and rocking mitigation functions simultaneously.

Inventive Principle:

Principle #40Composite materials

2Reliability

If the entire molded foam body is made of a hard synthetic resin material, then rocking mitigation is improved, but ride comfort deteriorates

Engineering Contradiction:

Improverocking mitigationVSAvoidride comfort

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent applies local quality by using different synthetic resin materials with different hardness levels in different regions of the molded foam body. The upper part uses a softer material for comfort, while the lower part uses a harder material for stability and rocking mitigation. This spatial differentiation of material properties resolves the contradiction between comfort and stability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining multiple synthetic resin materials with different hardness characteristics within a single molded foam body. The first synthetic resin material (softer) and second synthetic resin material (harder) are integrated in specific regions to achieve both comfort and rocking mitigation functions simultaneously.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If the molded foam body uses a uniform material composition throughout, then manufacturing simplicity is maintained, but the ability to provide differentiated support for different body parts deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoiddifferentiated support

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent applies local quality by using different synthetic resin materials with different hardness levels in different regions of the molded foam body. The upper part uses a softer material for comfort, while the lower part uses a harder material for stability and rocking mitigation. This spatial differentiation of material properties resolves the contradiction between comfort and stability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining multiple synthetic resin materials with different hardness characteristics within a single molded foam body. The first synthetic resin material (softer) and second synthetic resin material (harder) are integrated in specific regions to achieve both comfort and rocking mitigation functions simultaneously.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS10919424B2Molded foam body

Publication Date: 2021.02.16 ARCHEM INC

AI summary

According to the present invention, in a plan view of a seat surface (10a), a plane area of a part surrounded by an inner edge (17a) of a rear part (17) in a left-right direction (X) and a contour (L) is larger than a plane area of a part sandwiched by an inner edge (18a) of a front part (18) in the left-right direction (X) and the contour (L) in the left-right direction (X). In addition, a part of a pair of left and right second synthetic resin materials forming a lower part having a maximum gap therebetween in the left-right direction (X) is positioned in a thigh rest part (14) and a part having a minimum gap is positioned in a hip rest part (15), and a maximum value (W1) of the gap between the pair of left and right second synthetic resin materials forming the lower part in the left-right direction (X) is two times or more a minimum value (W2) of the gap in the left-right direction (X).