Curved Void Cell Cushioning for Buckling-Resistant Impact Support
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Solution Overview
Problem
Conventional cushioning systems with closed or open cells or springs often experience buckling and loss of support during high-impact events due to stress concentrations, leading to reduced comfort and effectiveness in shock absorption.
Innovation Solution
A cushioning structure comprising mutated void cells with multiple outwardly curved surfaces of varying radius measurements, which absorb energy and prevent buckling by distributing compressive forces effectively, allowing for maximum comfort and support during multiple compressions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional closed or open cells or springs are used in cushioning systems, then the structure is simple and easy to manufacture, but the cells experience buckling and loss of support during high-impact events due to stress concentrations
Solution Approach 1:
The patent applies curvature by forming outwardly curved surfaces on the void cells instead of using flat surfaces. This curvature distributes stress more evenly across the cell structure during compression, preventing buckling and maintaining support during high-impact events. The curved geometry transforms the stress distribution pattern from concentrated at flat surfaces to distributed across the curved surfaces, thereby improving reliability without significantly complicating the manufacturing process.
2Loss of energy
If outwardly curved surfaces with varying radii are introduced to prevent buckling, then impact energy absorption is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes parameter changes by varying the radius measurements of the outwardly curved surfaces to optimize energy absorption characteristics. Different radius values are applied to different portions of the cell structure to create zones with different compliance levels, allowing the cushioning system to absorb impact energy more effectively across a range of compression levels.
Solution Approach 2:
The patent applies local quality by introducing outwardly curved surfaces with specific radius variations at particular locations on the void cells. Rather than uniformly curving all surfaces, the curvature is strategically applied where it provides maximum benefit for stress distribution and energy absorption, while maintaining simpler geometries in other areas to reduce manufacturing complexity.
3Ease of operation
If void cells with outwardly curved surfaces are used, then comfort and impact protection are enhanced, but the device complexity increases
Solution Approach 1:
The outwardly curved surfaces create a more compliant and comfortable cushioning experience by distributing compression forces more evenly across the contact area. The curved geometry allows for progressive collapse during compression, providing a smoother compression cycle that enhances comfort while maintaining structural integrity.
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 cushioning structure provides enhanced comfort and impact protection by maintaining support and absorbing energy effectively, with the ability to withstand significant loads without significant degradation, suitable for various applications including footwear and mattresses.
Implementation Method 1
The outwardly curved surfaces prevent buckling and provide support for high impact by absorbing energy
Data Source
AI summary
Implementation described and claimed herein include a cushioning structure and method for manufacturing a cellular cushioning system, which allows for maximum comfort through the compression and shock cycle. Specifically, a cushioning structure comprises void cells formed in an array, which comprise multiple outwardly curved surfaces, with varying radius measurements. Stiffness in the void cells can vary by varying the Radii. Outwardly curved surfaces prevent buckling and provide support for high impact by absorbing energy.