Saddle-riding Vehicle Seat Cushion Edge Structure
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Solution Overview
Problem
Existing seat cushions for saddle-riding vehicles, particularly those with edge portions, face challenges in manufacturing a molded product with a defined edge and adequate drainage, as current methods require significant ingenuity and do not leverage the full potential of mesh-shaped three-dimensional cushioning materials like ELK™.
Innovation Solution
A seat cushion with a three-dimensional fiber structure featuring core-sheath fusible fibers and skeletal fibers, thermally fused at intersections, providing a layered structure with varying densities and stiffnesses, including a higher density edge portion that acts as a shape-retaining framework without a separate reinforcement framework, and a method for manufacturing this structure using crimp-processed skeletal fibers and thermoplastic elastomer-coated core fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a separate reinforcement framework is used to maintain edge shape, then the edge shape is maintained, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the reinforcement framework function directly into the seat cushion body by creating a high-density edge portion within the cushion structure itself. This eliminates the need for separate reinforcement components while maintaining the edge shape, thereby reducing device complexity and manufacturing cost.
Solution Approach 2:
The patent applies local quality by creating a high-density edge portion with different density characteristics than the main body of the seat cushion. This localized density variation provides shape retention at the edges while keeping the overall structure simple and integrated.
2Strength
If the seat cushion material is made soft and cushioning, then cushioning effectiveness is improved, but the edge portion collapses inward when pushed by the skin
Solution Approach 1:
The patent creates a high-density edge portion with enhanced structural stability that resists collapse, while the main body of the seat cushion maintains soft and cushioning characteristics. This local differentiation allows the edge to maintain shape while the interior provides cushioning effectiveness.
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 enables the creation of a seat cushion with a rigid edge portion and improved drainage properties, similar to urethane resin foam, while simplifying attachment to the vehicle and maintaining cushioning effectiveness, as demonstrated by the unique three-dimensional fine mesh structure and body pressure dispersibility.
Implementation Method 1
heating and compressing them in a mold so as to be fused with each other
Implementation Method 2
heating and compressing them in a mold so as to be fused with each other
Data Source
AI summary
A seat cushion includes an edge portion and a three-dimensional fiber structure including core-sheath fusible fibers and skeletal fibers thermally fused at intersections thereof. The sheaths of the core-sheath fusible fibers are made of a thermoplastic elastomer to fuse the intersections and form a bulging portion at each of the fused intersections. The skeletal fibers and the cores of the core-sheath fusible fibers are made of a non-elastomer resin. The skeletal fibers are crimp-processed bulky fibers, and a fineness of the skeletal fibers and a fineness of the core-sheath fusible fibers are in a range of 1 to 200 dtex. The seat cushion has a layered structure including a plurality of layers fused together, each of the layers has the three-dimensional fiber structure, and the seat cushion has a density distribution based on regional variations of the layered structure and a stiffness distribution that depends on the density distribution.