Molded Load Bearing Surface With Rigid Edge Orientation
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Solution Overview
Problem
Molded load bearing surfaces, such as chair seats or bed supports, often lack durability, comfort, and tunability to meet varying load characteristics, resulting in uncomfortable and ergonomically unacceptable experiences due to their linear force/deflection profiles and limited design control.
Innovation Solution
A load bearing surface assembly featuring an oriented, molded surface intersecured with a rigid orienting member, which includes interlocking features like apertures to provide mechanical interlock and facilitate orientation and mounting, allowing for customizable stiffness and comfort through the use of elastomeric properties and adjustable orienting members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional molded plastic surfaces are used, then manufacturing cost is reduced and production is simplified, but comfort and ergonomic support deteriorate due to linear force/deflection profiles
Solution Approach 1:
The load bearing surface is segmented into multiple independent elastomeric elements (bladders or cells) that can be individually tuned. Each element acts as an independent load-bearing unit, allowing the overall surface to provide non-linear force/deflection characteristics while maintaining manufacturing simplicity through modular construction.
Solution Approach 2:
The patent applies parameter changes by varying the stiffness, volume, and pre-pressure of individual elastomeric elements to create a non-linear force/deflection profile. This allows the surface to be soft initially for comfort but progressively stiffer under higher loads, improving ergonomic support without complicating the molding process.
2Ease of manufacture
If molded load bearing surfaces are used, then manufacturing cost is reduced, but tunability and control over load characteristics deteriorate
Solution Approach 1:
The patent introduces dynamics by making the load bearing surface adjustable and reconfigurable. Individual elastomeric elements can be independently tuned in terms of stiffness, volume, and pre-pressure, allowing the same basic molded structure to adapt to different applications and user requirements without requiring custom molds for each configuration.
Solution Approach 2:
The elastomeric elements are pre-charged or pre pressurized during manufacturing or installation to establish desired initial characteristics. This preliminary action allows the surface to be tuned for specific applications before use, providing versatility while maintaining a simple molded construction approach.
3Ease of operation
If oriented load bearing surfaces are used, then comfort and support are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the load bearing surface with the orienting members into a single integrated molded structure. The elastomeric elements are directly molded onto rigid orienting members that provide structural support and orientation, eliminating the need for separate attachment components and reducing overall structural complexity while maintaining the comfort benefits of oriented construction.
Solution Approach 2:
The patent uses composite construction by combining elastomeric materials with rigid orienting members in a single molded assembly. This composite approach allows the flexible elastomeric surface to provide comfort while the rigid orienting members provide structural integrity and orientation, achieving both comfort and simplicity through material integration.
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 durable, comfortable, and tunable load bearing surface that can be easily manufactured and mounted, offering improved ergonomics and support by allowing controlled deformation and elongation, thereby enhancing user experience across different applications.
Implementation Method 1
The load bearing surface has elastomeric properties that allow the load bearing surface to flex under anticipated loads
Implementation Method 2
The interlocking features are apertures that are filled with load bearing surface material when the load bearing surface is molded onto the orienting member
Data Source
AI summary
A load bearing surface assembly has an oriented, molded load bearing surface intersecured with a relatively rigid orienting member. The characteristics of the orienting member are selected such that the orienting member provides a rigid edge member for holding the load bearing surface during the orienting process and/or for mounting the load bearing surface to a support structure. A pair of orienting members are mounted to opposed edges of the load bearing surface. The load bearing surface may be integrally molded into a unitary construction with the orienting member(s). Methods for manufacturing a load bearing surface having an orienting member and a load bearing surface assembly with a load bearing surface and an orienting member are also disclosed.