Multilayer Cushioning Pillars Vacuum Forming
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Solution Overview
Problem
Existing cushioning materials, such as open cell foams, tend to support the growth of microorganisms and are heavy, making them less desirable for body-contacting applications, and are difficult to tailor for complex shapes, limiting their effectiveness in providing impact and vibration absorption.
Innovation Solution
A multilayer material comprising a barrier layer, a polymeric material layer, and a stabilization layer with pillars and spacer regions, allowing for varying thickness and spacing to achieve desired cushioning characteristics, which can be molded to conform to complex shapes and provide effective impact and vibration absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If open cell foam is used for cushioning, then sufficient cushioning is provided, but the material supports growth of bacteria and fungi
Solution Approach 1:
The patent uses a closed-cell foam structure instead of open-cell foam. The closed-cell structure provides the necessary cushioning while preventing microorganism growth by eliminating the open pores that would otherwise support bacterial and fungal development.
Solution Approach 2:
The patent employs a multi-layer composite structure combining different materials: a barrier layer (such as metal foil or laminate) bonded to a closed-cell foam core. This composite approach provides both cushioning from the foam and microorganism protection from the barrier layer.
2Strength
If thickness and density of foam are increased to achieve desired cushioning, then cushioning performance is improved, but weight increases
Solution Approach 1:
The patent optimizes the foam density and thickness parameters to achieve the minimum required cushioning performance. By carefully selecting and adjusting these parameters, the design achieves adequate protection while minimizing weight, rather than using excessive thickness and density.
Solution Approach 2:
The multi-layer composite structure allows for more efficient use of material. The barrier layer provides additional functional benefits while the optimized foam core provides cushioning, achieving better performance-to-weight ratio than a single thick foam layer would provide.
3Strength
If open cell foam is used for complex shaped objects, then cushioning is provided, but it is difficult to tailor the shape to conform to the object
Solution Approach 1:
The patent employs multi-layer construction where the barrier layer and foam core can be independently optimized for different regions. This allows the cushioning structure to conform to complex shapes with varying requirements for protection and comfort across different areas of the same object.
Solution Approach 2:
The composite structure of barrier layer bonded to foam core enables better shape conformity than foam alone. The barrier layer can be cut and shaped to precise specifications while the foam core provides the cushioning, allowing the assembly to conform to complex object geometries more effectively.
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 method enables the creation of lightweight, flexible cushioning materials with tailored properties for impact and vibration absorption, suitable for body-contacting applications, while minimizing the growth of microorganisms and accommodating complex shapes.
Implementation Method 1
drawing the barrier layer against the surface of the first mold section under the influence of a vacuum
Implementation Method 2
allowing the precursor to cure to form the cushioning member
Data Source
AI summary
The present disclosure relates to cushioning members, methods of making and methods of using, particularly to cushioning members comprising a plurality of spaced apart pillars comprising a polymeric material.