Seat Cushion Cellular Structure Design Using Occupant-Specific Data

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Solution Overview

Problem

Conventional seat cushions lack customization and optimal mechanical and thermal properties, leading to suboptimal comfort and safety for specific occupants, as they are not designed based on individual anatomical and loading data.

Innovation Solution

A method for manufacturing seat cushions using three-dimensional printing, which incorporates occupant-specific data to create customized cellular structures with varying mechanical and thermal properties, allowing direct assembly to a seat frame without additional components, and optimizing microstructures for enhanced comfort and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional seat cushions are manufactured with standard designs, then manufacturing simplicity is maintained, but comfort and safety are suboptimal for specific occupants

Engineering Contradiction:

Improvecustomization to occupantVSAvoiddesign complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The seat cushion employs a cellular structure where different regions have different cell sizes, shapes, and material properties tailored to specific anatomical regions. This allows localized optimization of comfort and support for individual occupant characteristics while maintaining a unified manufacturing approach through 3D printing.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention varies mechanical and thermal parameters of the cellular structure based on occupant data. By changing cell density, wall thickness, and material composition in different zones, the cushion adapts to specific occupant needs while the entire structure is manufactured as a single integrated component.

Inventive Principle:

Principle #35Parameter changes

2Strength

If additional components like spring wires and seat pans are used, then structural support is enhanced, but device complexity and assembly steps increase

Engineering Contradiction:

Improvestructural supportVSAvoidnumber of components

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The invention integrates multiple functions into a single seat cushion component. The cellular structure simultaneously provides structural support, comfort, and thermal management without requiring separate spring wires, seat pans, or other traditional components. This consolidation reduces assembly complexity while maintaining necessary structural properties.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If traditional manufacturing methods are used, then production simplicity is maintained, but manufacturing precision and customization capability are limited

Engineering Contradiction:

Improvecustomization precisionVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention replaces traditional mechanical manufacturing methods with additive manufacturing (3D printing). This substitution enables precise control of cellular structure geometry and material properties according to occupant data, achieving high customization precision while the automated printing process maintains manufacturing simplicity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If uniform cellular structure is used throughout the seat cushion, then manufacturing simplicity is maintained, but mechanical and thermal properties are not optimized for specific regions

Engineering Contradiction:

Improveregional property optimizationVSAvoidstructural precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The seat cushion features a non-uniform cellular structure where cell size, shape, density, and material composition vary by region to match anatomical requirements. This localized optimization is achieved through 3D printing technology that can precisely control structural parameters at different locations within the single component.

Inventive Principle:

Principle #3Local quality

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 customized seat cushions provide improved comfort, safety, and reduced weight by matching individual anatomical and loading profiles, while eliminating the need for additional components and allowing for exotic geometries not achievable with traditional materials.

Implementation Method 1

A method for manufacturing seat cushions using three-dimensional printing

Methodology Applied

Scientific Effect3D Printing: 3D Printing

Data Source

PatentUS11440791B2Seat cushion design manufacturing

Publication Date: 2022.09.13 LEAR CORP

AI summary

A method for manufacturing a seat cushion receives data of a specific occupant. A seat cushion is designed from the occupant data. The seat cushion is provided with a cellular structure from the occupant data. Another method for manufacturing a seat cushion receives boundary conditions for a seat cushion. Applicable mechanical properties are determined for the boundary conditions of the seat cushion. Applicable thermal properties are determined for the boundary conditions of the seat cushion. A seat cushion is designed with a varying cellular structure to satisfy the applicable mechanical properties and the applicable thermal properties.