Seat Support Element Structure for Precise Reinforcement Control
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Solution Overview
Problem
Existing seat support elements face challenges in ensuring good cohesion and precise modulation of reinforcement, particularly when using foam precursor materials from natural resources, which complicates the manufacturing process.
Innovation Solution
The use of discrete structural elements and bonding fibers to form the body of the seat support element, eliminating the need for conventional foam precursor molding, allowing for simpler and more precise reinforcement control, and sourcing materials from various sources, including recycled materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If foam precursor material is used to produce the body by expansion molding, then the body can be formed with reinforcement fibers, but the cohesion of the body becomes complex to ensure and the reinforcement modulation becomes imprecise
Solution Approach 1:
The body is segmented into discrete structural elements instead of using continuous foam material. These discrete elements can be individually controlled and assembled, allowing precise modulation of reinforcement without compromising cohesion. The segmentation enables independent optimization of each element's properties while maintaining overall body integrity.
Solution Approach 2:
The invention uses composite materials by combining discrete structural elements with bonding fibers. This composite approach allows precise control over reinforcement properties through the selection and arrangement of different materials, while the bonding fibers ensure coherent assembly. The composite structure enables independent optimization of structural support and bonding functions.
2Ease of manufacture
If conventional foam precursor molding is used, then the body can be produced with reinforcement, but the manufacturing process becomes complex and less controllable
Solution Approach 1:
By segmenting the body into discrete structural elements, the manufacturing process becomes simpler as each element can be produced independently using standard fabrication techniques. The segmentation allows for precise control of reinforcement properties in each element, and the elements are subsequently assembled using bonding fibers, which simplifies the overall manufacturing workflow while maintaining high precision.
Solution Approach 2:
Bonding fibers serve as an intermediary between discrete structural elements during assembly. This intermediary approach simplifies manufacturing by providing a straightforward bonding mechanism that does not require complex molding processes, while still enabling precise positioning and secure attachment of reinforcement elements to achieve the desired structural integrity.
3Adaptability or versatility
If foam precursor material from natural resources is used, then the body can be formed, but the environmental impact increases and material sourcing options are limited
Solution Approach 1:
The invention enables discarding of traditional foam precursor materials from natural resources and recovering or replacing them with discrete structural elements made from alternative, potentially recycled or synthetic materials. This approach reduces environmental impact by eliminating the need for petroleum-based foam precursors and allows for the use of sustainable or recyclable materials in the discrete elements, thereby increasing adaptability in material sourcing.
Solution Approach 2:
By using composite materials in the discrete structural elements, the invention provides versatility in material selection, allowing the use of eco-friendly, recycled, or synthetic materials instead of traditional foam precursors. This composite approach enables customization of material properties while reducing environmental impact through selective material usage and potential recyclability.
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
This approach ensures effective body cohesion and accurate reinforcement modulation while reducing environmental impact by using recycled materials, offering alternatives to traditional foam-based manufacturing methods.
Implementation Method 1
the bonding fibers comprise a central core and a sheath covering the core, the sheath being made of a material that melts when subjected to a melting temperature
Data Source
AI summary
A seat support element has a body that includes at least one portion having a plurality of discrete structural elements and a plurality of connecting fibers, the discrete structural elements being joined together via the connecting fibers to form the portion of the body.