Tiered void cells
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Solution Overview
Problem
Conventional cushioning systems lack optimal distribution of force and comfort due to limitations in their ability to adapt to varying loads and provide consistent resistance to deformation without relying on air pressure, leading to inadequate support and stability.
Innovation Solution
The implementation of tiered void cells with a base portion and a plunger portion connected by a living hinge, allowing for telescopic collapse and independent movement of each cell, which distributes compressive forces and maintains consistent resistance through varying geometries and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional cushioning systems use close-coupled air/water chambers or foam structures, then they provide basic cushioning support, but they lack adaptability to varying loads and do not provide optimal force distribution
Solution Approach 1:
The cushioning system is divided into multiple independent void cells, each capable of deforming independently. This segmentation allows each cell to adapt to local load variations while collectively providing consistent support across the entire cushioning surface.
Solution Approach 2:
The void cells incorporate movable plunger portions that can dynamically adjust their position and geometry in response to applied loads. This dynamic behavior enables the system to adapt to varying loads while maintaining reliable and consistent resistance through the elastic properties of the living hinges.
2Force
If conventional cushioning systems use close-coupled structures, then they provide structural support, but they lack the ability to distribute compressive forces effectively
Solution Approach 1:
The cushioning system consists of an array of discrete void cells with simple geometric structures. This segmentation distributes compressive forces across multiple independent units, improving force distribution while keeping each individual cell structurally simple and easy to manufacture.
Solution Approach 2:
The void cells utilize changes in geometric parameters (volume reduction, shape transformation) during compression to distribute forces. The living hinges provide the necessary mechanical advantage to achieve effective force distribution through simple geometric transformations rather than complex structural arrangements.
3Reliability
If conventional cushioning systems rely on air pressure, then they can provide cushioning support, but they add system complexity and potential failure points
Solution Approach 1:
The void cells are self-contained structures that provide cushioning support through their own elastic deformation mechanisms. The living hinges enable each cell to autonomously absorb and release energy without requiring external air pressure systems, thereby improving reliability while reducing overall system complexity.
Solution Approach 2:
The patent replaces complex pneumatic systems (air pressure-based cushioning) with a simpler mechanical system based on elastic deformation of the living hinges. This substitution maintains reliable cushioning support while eliminating the need for air pressure regulation systems, reducing complexity and potential failure points.
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 force distribution and comfort by allowing tiered void cells to adapt to different loads, providing consistent resistance and maintaining support without relying on air pressure, thus improving the overall performance of cushioning systems in applications like mattresses and seating.
Implementation Method 1
a living hinge elastically connecting an inner perimeter of the base portion to an outer perimeter of the plunger portion
Data Source
AI summary
The disclosed technology includes tiered void cells which provide protection, comfort, and stability during compression. The tiered void cells may be arranged in vertically stacked columns and include a stroke whereby tiers of a void cell can telescope into adjacent tiers of that void cell, as well as telescope into adjacent tiers of adjacent void cells in a column. Implementations described and claimed herein include a cushioning system comprising an array of tiered void cells, wherein each tiered void cell includes a base portion, a plunger portion, the plunger portion to collapse into the base portion under compression of the cushioning system, and a living hinge elastically connecting an inner perimeter of the base portion to an outer perimeter of the plunger portion.