Oriented Molded Load Bearing Surface for Tunable Ergonomic Support
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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 material control options.
Innovation Solution
The integration of oriented, molded load bearing surfaces with intersecured rigid orienting members, featuring interlocking apertures that extend perpendicular to tensile loads, allowing for mechanical interlock and controlled elongation to enhance durability and comfort by providing a customizable force/deflection profile.
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 elements or zones with varying thicknesses, material properties, or orientations. This segmentation allows different regions to provide different levels of support and comfort, creating a non-linear force/deflection profile that improves ergonomic support while maintaining molded construction advantages
Solution Approach 2:
Different regions of the load bearing surface are given different local properties such as varying material composition, thickness, density, or orientation. This allows specific areas to be optimized for comfort while others provide structural support, resolving the contradiction between simple molding and ergonomic performance
2Ease of manufacture
If molded load bearing surfaces are used, then manufacturing cost is reduced, but tunability and control over load characteristics are insufficient
Solution Approach 1:
The invention utilizes parameters such as material composition, thickness variations, density gradients, and orientation angles as design variables to tune the load characteristics. By systematically varying these parameters across different regions or configurations, the surface can be customized for different applications while remaining manufacturable through molding processes
Solution Approach 2:
The load bearing surface incorporates composite material structures combining different materials with complementary properties. This allows independent optimization of various characteristics such as stiffness, resiliency, and durability, providing enhanced tunability while maintaining the advantages of molded construction
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 desired orientation and configuration of the load bearing surface elements are established during the initial molding process rather than requiring post-manufacturing orientation steps. Molds are designed with built-in orientation features, inserts, or flow patterns that automatically create the required element alignment, thereby achieving oriented surfaces without adding manufacturing complexity
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
This solution provides a durable, comfortable, and tunable load bearing surface assembly that can be easily manufactured and mounted, offering improved ergonomic support by controlling the mechanical interlock and elongation, thus addressing the limitations of traditional molded surfaces.
Implementation Method 1
The load bearing surface material flows through and mechanically interlocks with the orienting member through apertures in the projection
Implementation Method 2
The orienting apparatus mates with both orienting members and moves the orienting members away from one another to elongate the load bearing surface
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The present invention provides a load bearing surface assembly (10) having an oriented, molded load bearing surface (12) intersecured with a relatively rigid orienting member (14, 16) The characteristics of the orienting member (14, 16) are selected such that the orienting member (14, 16) provides a rigid edge member for holding the load bearing surface (12) during the orienting process and/or for mounting the load bearing surfac(12)e to a support structure In one embodiment, the load bearing surface includes a pair of orienting members (14, 16) mounted to opposed edges of the load bearing surface (12). The load bearing surface (12) may be integrally molded into a unitary construction with the orienting member (s) (14, 16) The present invention also provides methods for manufacturing a load bearing surface (10) having an orienting member (14, 10) and a load bearing surface assembly (10) with a load bearing surface (12) and an orienting member (14, 16)