Seat Padding Structure Using Gel-Elastomer Layers for Lightweight Comfort
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Solution Overview
Problem
Existing padding elements for seats and body supports often lack a balance between comfort and aesthetic appeal, and may have drawbacks such as high production costs and weight due to the use of conventional materials like foams and gel layers.
Innovation Solution
A padding element comprising a polyurethane gel layer coupled with a compact elastomeric layer, integrated with a waterproof and aesthetically designed polyurethane film or covering, providing a soft and comfortable surface while being lightweight and durable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional materials like foams and gel layers are used for padding elements, then comfort and weight distribution are improved, but weight and production costs increase
Solution Approach 1:
The patent applies composite materials by combining polyurethane gel with compact elastomeric material in a single integrated layer. This composite structure maintains the weight distribution and comfort benefits of gel while reducing overall weight through the elastomeric component, directly resolving the contradiction between comfort and weight.
Solution Approach 2:
The patent changes the physical and chemical parameters of the material by using polyurethane gel with specific hardness ranges (Shore 00 0-60) combined with compact elastomeric material having different mechanical properties. This parameter optimization allows the padding to achieve both comfort performance and reduced weight.
2Reliability
If conventional materials like foams and gel layers are used for padding elements, then comfort and weight distribution are improved, but production costs increase
Solution Approach 1:
The patent merges multiple functions into a single integrated padding layer that combines polyurethane gel and compact elastomeric material. This eliminates the need for separate gel layers and foam layers, reducing manufacturing steps, material handling costs, and production complexity while maintaining comfort performance.
Solution Approach 2:
The composite polyurethane gel-elastomeric material structure provides both comfort performance and manufacturing efficiency. The integrated composite can be produced as a single unit through controlled chemical reactions, reducing the need for assembly operations and lowering production costs.
3Weight of moving object
If gel layer is coupled to expanded foam layer to reduce weight, then weight is reduced, but structural integrity and durability may be compromised
Solution Approach 1:
The patent uses a composite of polyurethane gel with compact elastomeric material that provides both weight reduction and structural integrity. The elastomeric component offers the mechanical strength needed for durability while the gel portion maintains comfort, and their chemical bonding ensures structural unity.
Solution Approach 2:
The patent optimizes material parameters by selecting polyurethane gel with Shore 00 hardness of 0-60 and combining it with compact elastomeric material having complementary mechanical properties. This parameter selection ensures the composite achieves both reduced weight and sufficient structural strength for long-term durability.
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 enhanced comfort and aesthetic appeal, reduces production costs, and maintains durability by using a monolithic structure with a polyurethane gel and compact elastomeric layer, ensuring effective weight distribution and resistance to deformation.
Implementation Method 1
the gel has mechanical characteristics capable of allowing a suitable support and three-dimensional distribution of the weight of a user
Implementation Method 2
integrated with a waterproof and aesthetically designed polyurethane film or covering
Data Source
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AI summary
Padding element (1) for seats such as sofas, armchairs, chairs and armrests, wherein such seats have a support structure (30), or similar supporting structure for the human body or parts thereof, such as rest or anti-fatigue mats, anti-decubitus mattresses, shower mats, anti-impact mats, wherein the padding element (1) is provided with a support surface (2) for a user, wherein the padding element (1) comprises a film or covering (4), one gel layer (5) adhering to part of the film or covering (4) and a compact elastomeric layer (6) having a surface (7) for contact with the gel layer (5) and with at least part of the film or covering and a surface (8) for contact with the seat and/or with the support structure (30) of the seat, wherein the compact elastomeric layer (6) adheres to the gel layer (5) and the film or covering (4); method for obtaining such padding element (1).