Piston-Like Projection Membrane for Variable Load Seating Surfaces
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Solution Overview
Problem
Current cushioned load bearing surfaces, such as seat bottoms and backs, face challenges in achieving durable, low-mass, and inexpensive designs that provide variable load support, comfort, and efficient thermal management while minimizing space and energy consumption, as well as limiting styling and packaging constraints.
Innovation Solution
A cushioned load bearing seating surface comprising a suspension layer, a membrane with oriented piston-like projections, and a load distribution layer, where the membrane is formed from a polymeric material with compressible projections and intermediate portions that flex to accommodate load, allowing for adjustable air flow and integration of heating/cooling elements, and is molded to provide tunable comfort and reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single density foam is used for cushioning, then manufacturing is simple, but load bearing characteristics cannot be varied across the surface
Solution Approach 1:
The foam layer is segmented into multiple zones with different densities, allowing each zone to provide different levels of support. This is achieved by varying the foam density across the surface during the molding process, creating regions of high, medium, and low density foam to match the specific load bearing requirements of different body areas.
Solution Approach 2:
Different regions of the foam are given different local properties through variable density construction. The foam density is tailored locally to match the pressure distribution requirements, with higher density in areas requiring more support and lower density in areas requiring more compliance, all within a single molded layer.
2Ease of operation
If thick foam is used to achieve desired comfort levels, then comfort is improved, but packaging space and vehicle interior space are reduced
Solution Approach 1:
The foam density parameter is varied across different zones of the foam layer, allowing thin sections to provide equivalent comfort support to much thicker uniform foam. By optimizing the density distribution, the overall thickness is reduced while maintaining or improving comfort characteristics, thereby reducing packaging space requirements.
3Ease of operation
If foam is used for cushioning, then comfort is provided, but thermal insulation increases energy consumption for heating and cooling
Solution Approach 1:
The foam density is optimized to balance thermal insulation and breathability. By creating a variable density structure with optimized porosity, the foam provides necessary comfort while reducing thermal insulation effects that would trap heat, thereby lowering the energy required for thermal management of the seating.
4Ease of manufacture
If single durometer foam is used, then manufacturing is simple, but reaction force requirements cannot be tuned across the surface
Solution Approach 1:
The foam is segmented into multiple density zones within a single layer, each zone providing different reaction force characteristics. This segmentation is achieved through controlled variation of foam density during molding, allowing independent tuning of support characteristics in different areas without requiring multiple foam layers or additional components.
5Ease of operation
If foam is used for cushioning, then comfort is provided, but fastening items to the surface becomes difficult
Solution Approach 1:
The foam structure incorporates local variations in density and porosity that create optimal zones for fastening. Certain regions are designed with enhanced mechanical properties that facilitate secure attachment of components such as wire harnesses, baffles, and heating elements, while other regions maintain the comfort-oriented foam characteristics.
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 offers a durable, lightweight, and adjustable seating surface with improved comfort and thermal management, reducing energy consumption and packaging requirements, while allowing for dynamic compliance and adjustable reaction forces, enhancing overall seating experience.
Implementation Method 1
The projections are compressible from a first state to a compressed state under load and return to the first state upon removal of the load
Implementation Method 2
The intermediate portions flex to accommodate at least a portion of the projections as the projections are compressed
Data Source
AI summary
A cushioned load bearing seating surface includes a suspension layer, a membrane and a load distribution layer. The membrane is positioned between the suspension layer and the load distribution layer. The membrane includes a base and a plurality of molded, oriented, piston-like projections extending from the base. The membrane defines intermediate portions between each projection and the base that extend in a direction opposite the projections. The projections are compressible from a first state to a compressed state under load and return to the first state upon removing the load. The intermediate portions flex to accommodate at least a portion of the projections as the projections are compressed. A molded, piston pixelated membrane and a method for making the membrane are disclosed.