Segmented Foam Cushion Structure Using Bending for Lightweight Support
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Solution Overview
Problem
Conventional seat cushions for vehicles face challenges in weight reduction, recyclability, and providing optimal cushioning and comfort, especially during vehicle movements, due to the limitations of polyurethane foam in terms of density, flexibility, and durability.
Innovation Solution
The use of synthetic resin foam with specific bending deflection and load properties, structured with rod-like or flat plate-like elements that can deform by bending, supported by leg bodies or frames, to enhance weight reduction, recyclability, and comfort while maintaining adequate cushioning properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyurethane foam is used as cushion material to achieve high cushioning properties and comfort, then cushioning performance is improved, but weight increases and recyclability deteriorates
Solution Approach 1:
The cushion body is divided into multiple independent supporting bodies (rod-like or plate-like elements) made of synthetic resin foam, arranged in arrays. Each supporting body acts as an independent cushioning element, allowing the system to achieve high cushioning performance through collective action of multiple lightweight components rather than a single heavy foam block.
Solution Approach 2:
The invention changes the material parameter from polyurethane foam to synthetic resin foam (such as polypropylene or polyethylene foam), and changes the deformation mode from compression to bending. This parameter change enables the cushion to achieve comparable cushioning properties with significantly reduced weight and improved recyclability.
2Reliability
If polyurethane foam density is increased to achieve adequate rigidity and support, then cushioning performance is improved, but weight increases
Solution Approach 1:
The supporting bodies are designed to be flexible and deformable by bending rather than rigid structures. This dynamic design allows the cushion to adapt to varying loads and maintain adequate support through the collective rigidity of multiple elements rather than requiring high-density material, thereby reducing weight.
3Reliability
If conventional compression-based cushioning is used, then cushioning function is achieved, but space utilization is inefficient and weight reduction is limited
Solution Approach 1:
The invention transitions from compression-based cushioning (one-dimensional deformation) to bending-based cushioning (two-dimensional deformation). The rod-like or plate-like supporting bodies can bend in multiple directions, enabling more efficient space utilization and providing cushioning function with reduced material volume and weight.
4Weight of moving object
If synthetic resin foam is used to reduce weight and improve recyclability, then weight reduction and recyclability are improved, but cushioning properties deteriorate
Solution Approach 1:
By segmenting the cushion into multiple supporting bodies made of lightweight synthetic resin foam, the system achieves high cushioning performance through the collective action of many elements rather than relying on the density of a single material block, thus maintaining cushioning properties while using lighter materials.
Solution Approach 2:
The invention changes the deformation mode from compression to bending for the synthetic resin foam supporting bodies. This parameter change enables synthetic resin foam to achieve adequate cushioning properties through bending deflection, overcoming the limitation that synthetic resin foam is typically considered inferior for cushioning applications.
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 synthetic resin foam cushion body achieves weight reduction, improved recyclability, and enhanced comfort and durability, providing effective support and cushioning even during long-term use, while allowing for design flexibility and uniform deflection to accommodate varying loads.
Implementation Method 1
a cushion body 1 which is provided with a plurality of supporting bodies 2 of rod-like elements 10 or flat plate-like elements 11 which are constructed by a synthetic resin foam and are allowed to be deformed by bending
Implementation Method 2
vibration and shock applied to the cushion material has been lightened mainly by reaction force, restoring force and deflection when the soft cushion material such as the polyurethane foam interposed between the structure body and the surface cover deflects in a compression direction
Data Source
AI summary
The present invention solves the problem of realizing a lighter cushion body that has ample cushioning properties when a person sits or lies thereon by: providing a plurality of rod-shaped or flat plate-shaped support bodies (2) comprising a synthetic resin foam that has a bending deflection amount of 20 mm or more as measured according to the method described in JIS K7221-2:2006 and a pressing force of 2-100 N at 20 mm of deflection, and legs (3) on which the support bodies (2) are placed or fixed; using the support bodies and the legs to form a space (5) that makes it possible to bend and deform the support bodies; and arranging the plurality of rod-shaped or flat plate-shaped support bodies (2) in a row so as to be deformable.