Tiered void cells
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Solution Overview
Problem
Conventional cushioning systems lack effective distribution of compressive forces and comfort, particularly in applications like mattresses and seating, where varying load distribution and isolation are required.
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 under compression, which enables independent movement of each tier and efficient force distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional cushioning systems use close-coupled springs or foam structures, then structural simplicity is maintained, but compressive force distribution and comfort are insufficient
Solution Approach 1:
The cushioning system is divided into multiple independent pocketed spring assemblies, each containing individual springs that can move independently. This segmentation allows each spring to respond to localized pressure, improving comfort and force distribution while maintaining overall structural organization through the pocketed configuration.
2Adaptability or versatility
If uniform cushioning structures are used throughout, then manufacturing simplicity is maintained, but varying load distribution and isolation requirements cannot be met
Solution Approach 1:
The system employs pocketed spring assemblies that can be configured with varying spring rates, densities, and arrangements in different zones. This allows local customization of cushioning characteristics to match specific load distribution requirements and isolation needs, while each pocketed unit remains a standardized manufacturable component.
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 design provides enhanced comfort and isolation by evenly distributing compressive forces, allowing for customizable reaction forces per unit of deflection, thus improving the overall cushioning performance.
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
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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.