Segmented Resin-Foam Cushion Structure for Lightweight Comfort
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Solution Overview
Problem
Conventional seat cushions for vehicles and mattresses face challenges in achieving optimal weight reduction, recyclability, and comfort due to limitations in polyurethane foam's cushioning properties, which result in inadequate support and durability, especially during vehicle movements and long-term use.
Innovation Solution
The use of synthetic resin foam with specific bending deflection and restoration properties, such as polypropylene or polyethylene foams, which are designed to deform by bending and provide enhanced rigidity and comfort, while being lightweight and recyclable, replaces traditional polyurethane foam structures to create a cushioning system that supports optimal seating and sleeping positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyurethane foam is used as cushion material, then cushioning properties and comfort are improved, but weight reduction and recyclability are worsened
Solution Approach 1:
The cushion body is divided into multiple independent rod-like elements instead of using a single continuous foam block. Each rod element can deflect independently, providing cushioning functionality while using less material overall, thus reducing weight while maintaining comfort properties.
Solution Approach 2:
The rod-like elements are constructed with a porous structure that allows bending deformation. This porous design reduces material usage and weight while maintaining the cushioning properties through the flexibility and elasticity of the porous framework.
2Reliability
If polyurethane foam is used as cushion material, then cushioning properties are improved, but recyclability is worsened
Solution Approach 1:
The cushion body consists of multiple separate rod-like elements that can be individually replaced or recycled. This segmentation makes the cushion more recyclable compared to monolithic polyurethane foam, as individual elements can be recovered and processed separately.
Solution Approach 2:
The invention changes the material parameter from traditional polyurethane foam to rod-like elements made of recyclable materials with specific bending characteristics. This parameter change enables both cushioning functionality and improved recyclability.
3Strength
If density of cushion material is increased to obtain rigidity, then support function is improved, but weight reduction is worsened
Solution Approach 1:
The cushion is segmented into multiple thin rod-like elements rather than using a single dense block. The collective arrangement of these thin rods provides the necessary rigidity and support function while each individual rod remains lightweight, achieving overall weight reduction.
Solution Approach 2:
The invention transitions from a three-dimensional dense foam block to a structured arrangement of one-dimensional rods. This dimensional change allows the system to achieve rigidity through geometric arrangement rather than material density, reducing weight while maintaining support function.
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 solution enhances the cushioning properties and comfort by allowing controlled deformation, maintaining durability over long-term use, and achieving significant weight reduction while ensuring recyclability, thus addressing the limitations of traditional foam materials.
Implementation Method 1
a plurality of rod-like elements 10 or flat plate-like elements 11 supporting bodies 2 which are constructed by a synthetic resin foam having a bending deflection amount equal to or larger than 20 mm and a load 9 between 2 and 100 N at the 20 mm deflection time
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
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.