Support Element Surface Inserts Molding
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Solution Overview
Problem
Current support elements for the human body, such as saddles and handgrips, face issues with durability and resistance to wear and weather conditions, as well as high production costs and environmental impact, particularly when incorporating visually distinct portions with different mechanical and functional properties.
Innovation Solution
A support element with integrated surface inserts made from various materials, such as polyurethane foam, elastomeric materials, or metal, which are molded together with a soft and yieldable layer to create a single, durable, and weather-resistant surface with differentiated appearance and functionality, using a single molding step and compatible materials to enhance durability and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If portions with different appearance are directly connected to the surface of the support element, then the visibility and identification of support surfaces is improved, but the resistance to wear and weather conditions deteriorates
Solution Approach 1:
The patent merges the portions with different appearance directly into the soft and yieldable layer through the molding process, creating an integrated structure where the differentiated portions and the main body form a single unified component. This integration eliminates separate connections that would be prone to deterioration, separation, and scratching, while maintaining the visibility and identification functions of the differentiated portions.
Solution Approach 2:
The patent uses composite materials by incorporating portions made from materials different from the soft and yieldable layer (such as rigid materials, materials with different surface properties, or transparent materials) directly into the molded structure. This allows the differentiated portions to have both their specific functional properties and strong integration with the main body, improving both visibility and weather resistance simultaneously.
2Ease of manufacture
If tampography or pad printing is used to create portions with different appearance, then the production process is simplified, but the durability and resistance to deterioration worsens
Solution Approach 1:
The patent combines the creation of portions with different appearance directly into the molding process itself, rather than using subsequent surface treatment methods like tampography or pad printing. This integration ensures that the differentiated portions become an intrinsic part of the molded structure, eliminating the problems of deterioration, separation, and scratching that affect surface-applied treatments, while maintaining manufacturing efficiency.
3Adaptability or versatility
If multiple production steps are used to create support structures with ornamental elements, then the appearance and functionality are improved, but the production complexity and labor requirements increase
Solution Approach 1:
The patent merges multiple production operations into a single molding step by directly forming portions with different appearance and properties within the molded support element. This eliminates the need for separate steps such as making the gel transparent, arranging ornamental elements, and laying additional layers, thereby reducing production complexity and labor requirements while maintaining the desired appearance and functionality.
Solution Approach 2:
The patent performs the creation of portions with different appearance during the initial molding process itself, rather than adding them in subsequent steps. This preliminary action allows the differentiated portions to be formed simultaneously with the main body structure, eliminating the need for later assembly operations and reducing overall production complexity.
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 provides a support element with improved resistance to wear and weather conditions, enhanced comfort, and reduced environmental impact, while optimizing production costs and efficiency, ensuring longer product lifespan and better user interaction.
Implementation Method 1
exploiting the adhesion characteristics that the polyurethane of the padding exerts, during its foaming reaction, both on the felt and on the covering material, thus obtaining a perfect joining of the three components
Implementation Method 2
a layer of soft and yieldable material such as a polyurethane foam... during its foaming reaction
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
A support element (e.g. a seat, a saddle or a handgrip) for the human body comprising a layer (3; 103; 203) made from soft and yieldable material and at least one surface insert (4; 104; 204) with different characteristics in terms of appearance and/or comfort, in which said surface insert comprises a visible surface (6; 106; 206) to be in contact with the user, wherein said visible surface has a smaller size than said layer and wherein said surface insert comprises at least one portion (5; 105; 205) embedded in said layer. A process for making the support element is also presented.