Linked Void Cell Arrays With Porous Layer for Pressure Relief
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Solution Overview
Problem
Existing methods for manufacturing sheets of protruding resiliently compressible void cells, such as those used in cushioning systems, face limitations in geometry and independence of cells due to the same material being used for both cells and binding layers, leading to reduced cell independence and increased pressure points on the body.
Innovation Solution
The use of a separate, porous binding layer attached to individually formed void cells, manufactured through processes like thermoforming, extrusion, injection molding, and blow molding, allows for greater independence and customized force-deflection characteristics by using different materials for the cells and binding layer, enabling better load distribution and reduced pressure points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the same material is used for both void cells and binding layers, then manufacturing is simplified, but cell independence is reduced and pressure points increase
Solution Approach 1:
The patent divides the cushioning system into separate components: individually formed void cells and a separate binding layer. This segmentation allows each component to be optimized independently - void cells can be designed for maximum independence and cushioning performance, while the binding layer provides structural support. The separate binding layer is attached to the void cells, creating a modular structure that maintains cell independence while simplifying manufacturing through specialized component production.
2Ease of manufacture
If void cells are directly coupled together, then manufacturing is simplified, but pressure points increase on the body
Solution Approach 1:
The patent introduces a separate binding layer as an intermediary between the void cells and the body. This binding layer distributes the applied load across multiple void cells, preventing direct pressure concentration on single cells. The binding layer acts as a mediator that transfers and distributes forces evenly, eliminating pressure points while maintaining the simplicity of direct cell coupling in the manufacturing process.
3Reliability
If a separate porous binding layer is used, then cell independence and load distribution improve, but device complexity increases
Solution Approach 1:
The separate binding layer serves multiple functions simultaneously: it binds the void cells together into a cohesive array, allows fluid flow between cells for independence, distributes loads evenly to prevent pressure points, and provides structural support. By consolidating these multiple functions into a single component, the patent achieves high cell independence and load distribution performance without proportionally increasing device 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
This approach enhances the independence of void cells, reducing pressure points and improving load distribution by allowing fluid flow and customizable force-deflection characteristics, resulting in a more effective cushioning system.
Implementation Method 1
The separate porous binding layer permits fluid flow between adjacent individual void cells
Implementation Method 2
The void cells are hollow chambers that resist deflection due to compressive forces, similar to compression springs
Data Source
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AI summary
Implementations described and claimed herein include methods of manufacturing related to a spaced array of individually formed void cells, which are linked together. The void cells are protruding, resiliently compressible cells manufactured by thermoforming, extrusion, injection molding, laminating, and/or blow molding processes. The individual void cells are molded and arranged in an array. A separate, porous binding layer is attached to the individual void cells in the array. In one implementation, two arrays may each comprise of linked individually formed void cells, wherein each array is aligned with the other array, and linked individually formed void cells of one array are positioned opposite the linked individually formed void cells of the other array, sharing the same binding layer. In another implementation, multiple arrays can be stacked upon one another. In another implementation, the linked individually formed void cells have substantially different force-deflection characteristics.