Tiered void cells
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Solution Overview
Problem
Existing cushioning systems fail to provide optimal protection, comfort, and stability during compression due to limitations in force distribution and collapsibility.
Innovation Solution
A cushioning system comprising an array of tiered void cells, each with a base portion and a plunger portion connected by a living hinge, allowing for telescopic collapse and independent movement, which distributes forces and enhances comfort and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional cushioning structures (close-coupled springs, foam, or air chambers) are used, then the system provides basic cushioning support, but the force distribution is uneven and comfort is reduced during compression
Solution Approach 1:
The cushioning system divides the compression space into multiple independent void cells arranged in tiers. Each cell contains separate base portions and plunger portions that can collapse independently, segmenting the force distribution across many small units rather than relying on a few large springs or foam regions. This segmentation enables more uniform force distribution while maintaining comfort.
Solution Approach 2:
The living hinges connecting base portions to plunger portions are designed to be elastically deformable, allowing the structure to dynamically adapt during compression. The hinges enable controlled collapse of plunger portions into base portions, creating a dynamic response that distributes forces evenly throughout the array of void cells rather than creating localized stress points.
2Reliability
If close-coupled springs or foam structures are used, then the system provides impact protection, but the structure lacks controlled collapsibility and stability during compression
Solution Approach 1:
The void cells are arranged in nested tiers with plunger portions that can collapse into base portions, creating a telescopic nesting effect. During compression, plunger portions from upper tiers collapse into their corresponding base portions, while lower tiers remain stable until needed. This nested arrangement provides controlled collapsibility that enhances stability during impact events.
Solution Approach 2:
The living hinges are pre-designed with specific elastic properties to control the collapse sequence and timing. Before impact occurs, the hinges are positioned to allow gradual collapse of plunger portions, providing beforehand cushioning that prepares the structure to absorb incoming forces in a controlled manner, enhancing overall stability and reliability.
3Object-affected harmful factors
If traditional air chambers or foam are used, then the system provides cushioning, but the structure cannot isolate forces effectively during deformation
Solution Approach 1:
The array of individually defined void cells segments the force isolation function across multiple discrete units. Each cell acts as an independent force-isolating element, preventing force transmission between adjacent cells. This segmentation allows the system to maintain overall structural strength while effectively isolating localized deformation forces, improving protection without sacrificing resistance to deformation.
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 tiered void cells provide consistent resistance to deformation, ensuring even force distribution and improved comfort by allowing for controlled collapse and isolation of forces, thus enhancing protection and stability.
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.