Patent Publication Number: US-2016229126-A1

Title: Method for designing seat cushions

Description:
TECHNICAL FIELD 
     The present disclosure relates to seat cushions, and more specifically, to customized seat cushions designed as per ergonomics of a user. 
     BACKGROUND 
     In general, seat cushions are attached with a seat (also called a chair) as an additional support to provide added comfort and support to an operator (also called a user). During day to day operations, the seat cushions closely accommodate and support the operator, and thereby provide comfort to the operator. 
     Currently, the operator suffers from fatigue and other occupational hazards that are caused by poor ergonomically fitted seat cushions. In most of the cases, the design of the seat cushions is unable to accommodate a variety of the operators. The seat cushions available today are designed as one size fits all. The seat cushions are not designed as per the ergonomics of the operator, and hence unable to offer a practical solution. Further, there are various machines that require different types of seat cushions that make the one size fits all option unworkable. Further, there is a need for a method for customizing seat cushions. 
     PCT Publication Number “WO2015171856” (hereinafter referred as &#39;856) discloses a seat structure and a process for forming a frame. The seat structure includes at least one frame having one or more thin walled complex geometry structures. The thin walled complex geometry structures include one or more of multiple internal channels and ribs that defines a structure for supporting elements within the frame. The multiple channels and ribs defines one or more of structural loading paths and a channel for one or more of transporting fluids and receiving one or more components. Further, the process for forming the at least one frame via an additive manufacturing process is also disclosed. The &#39;856 reference discloses the seat structure and the process for forming the frame. Therefore, there is a need for designing seat cushions according to the ergonomics of the user. 
     SUMMARY OF THE DISCLOSURE 
     In one aspect of the present disclosure, a method for manufacturing a seat cushion for a user is provided. The method comprises positioning the user on a test seat, scanning a plurality of pressure points of the user while the user is seated on the test seat, recording the plurality of pressure points to generate a pressure map, and manufacturing, using one of an additive manufacturing process, an additive manufactured tool and a molding process, the seat cushion conforming to the pressure map of the user. 
     Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIG. 1  is a perspective view of a seat having seat cushions, in accordance with the concepts of the present disclosure; 
         FIG. 2  depicts a test seat for recording pressure points of a user, in accordance with the concepts of the present disclosure; 
         FIG. 3  is a side view of a test pad for recording the pressure points, in accordance with the concepts of the present disclosure; 
         FIG. 4  is a pressure map of the user, in accordance with the concepts of the present disclosure; and 
         FIG. 5  is a flowchart of a method for designing the seat cushions, in accordance with the concepts of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , a seat  10  having a first seat cushion  12 , a second seat cushion  14 , a base member  16 , a back member  18 , a head rest  20 , a head rest joint  22  and a head rest cushion  24 . In an embodiment, the seat  10  may be attached within a machine or vehicle (not shown) to carry out various operations. Alternatively, the seat  10  may also be attached in a stationary environment, such as an office, a control room to carry out various operations. It will be apparent to one skilled in the art that the seat  10  may be coupled at any other spot or location to carry out the operations, without departing from the meaning and scope of the disclosure. 
     Referring to  FIG. 1 , the first seat cushion  12  having a first surface  26  and a second surface  28 . The second seat cushion  14  having a third surface  30  and a fourth surface  32 . The second surface  28  of the first seat cushion  12  is positioned on a top surface  34  of the base member  16 . Further, the fourth surface  32  of the second seat cushion  14  is positioned over the back member  18  of the seat  10 . The first seat cushion  12 , and the second seat cushion  14  having the first surface  26  and the third surface  30  respectively for supporting a body. It will be apparent to one skilled in the art that methods proposed herein may also be utilized for designing other articles, such as shoes, gloves, jackets, among others without departing from the meaning and scope of the disclosure. 
     Referring to  FIG. 1 , a height of the base member  16  of the seat  10  is adjusted by activation of a first lever (not shown) as per the requirements. The angle of the back member  18  with respect to the base member  16  is also adjustable by a second lever (not shown). Further, the height of the head rest  20  is also adjustable by use of a ratchet or similar mechanism (not shown). It will be apparent to one skilled in the art that the seat  10  may have any other design, shape and elements, such as hand rests, cup holders (not shown) without departing from the meaning and scope of the disclosure. 
     Referring to  FIG. 2 , a user  36  is seated on a test pad  38  (described below in  FIG. 3 ) of a test seat  40 . In an embodiment, the test seat  40  is placed in a test room for carrying out various procedures. In an embodiment, the teat pad  38  is a separate component that is coupled with the test seat  40 . In another embodiment, the test pad  38  is inbuilt in the test seat  40 . An instructor  42  checks posture of the user  36  and makes adjustments to the user  36  as per the requirements. The instructor  42  scans a number of pressure points, i.e. the pressure points  60  (as shown in  FIG. 4 ) of the user  36 , while the user  36  is seated on the test seat  40 . A pressure map  58  (as shown in  FIG. 4 ) is generated on the basis of the pressure points  60  and is displayed on a monitor  44 . 
     Referring to  FIG. 3 , the test pad  38  having a textile layer  46 , a foam layer  48 , an outer shell  50 , and an inner shell  52 . The test pad  38  optionally uses a gel  54  spread over foam  56 . It will be apparent to one skilled in the art that other materials, such as plastic, elastomers, fibers may also be used in place of a textile without departing from the meaning and scope of the disclosure. The test pad  38  utilizes a number of pressure sensors or pressure sensing devices (not shown) inside the test pad  38  that are configured to record and measure the pressure points  60  of the user  36  and generate the pressure map  58 . It will be apparent to one skilled in the art that the test seat  40  may utilize various other types of pressure mapping system for recording the pressure points  60  of the user  36  without departing from the meaning and scope of the disclosure. 
     Referring to  FIGS. 3 and 4 , the pressure map  58  is generated from the pressure points  60  of the user  36 . The pressure map  58  includes multiple pressure points  60  of the user  36  as generated by the pressure sensors (not shown) within the test pad  38 . The pressure map  58  having regions for high pressure points  62 , moderate pressure points  64 , and low pressure points  66  as shown on a scale  68 . The high pressure points  62  refer to points on the test pad  38  that bears a maximum pressure from the user  36 , while the moderate pressure points  64  bears relatively lesser pressure on the test pad  38 . 
     The pressure points  60  of the pressure map  58  are used to create a profile of the seat cushions, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24  specifically suiting the user  36 . A software program develops a 3D cloud on the basis of the pressure map  58 , which is then converted into a 3D model. A seat cushion profile is created using a 3D printing which is then fed into an additive manufacturing machine in which an object is created by laying down successive layers of materials. It will be apparent to one skilled in the art that the pressure map  58  is used for designing of the seat cushions, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24  using other techniques, not limited to, additive manufacturing processes and control software, such as 3D printing, scanning technologies known in the art without departing from the meaning and scope of the disclosure. 
     A designer uses a process in which the pressure map  58  is used to create a model for the seat cushions, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24  and this process is more manual. Further, additive manufacturing creates a tool/mold to create the seat cushions, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24 . The materials used for additive manufacturing include, but are not limited to, different polymer types, metals, elastomers, and materials with varying density and hardness levels which are strategically placed or used in customizing the seat cushions, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24  to optimize user ergonomics. The pressure map  58  determines areas where high/moderate support is required and model a series of supporting structures (i.e. ribs, honeycomb) to provide support or flexibility where needed. There are also some 3D cloud programs that give the ability to add inputs as constraints to achieve specific design or functional requirements (i.e. loads, stresses). 
     The seat cushions, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24  are fabricated after analyzing the pressure map  58  of the user  36 . Alternatively, the seat cushions, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24  are defined by having the user  36  sit on a mold material to get desired pressure patterns that are further processed. The seat cushions, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24  may be made from plastic, or foam, or a low hardness elastomeric material, The seat cushions, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24  may be manufactured from other processes or fabrication techniques, software other than described herein without departing from the meaning and scope of the disclosure. 
     It will be apparent to one skilled in the art that the measurements of the pressure map  58  may also be taken on a vehicle (not shown) during operation not necessarily in the test room. During vehicle operations, the test seat  40  and along with the test pad  38  are fitted in the vehicle and the pressure points  60  are scanned and saved in a storage device for further processing without departing from the meaning and scope of the disclosure. Further, the method for creating the pressure map  58  takes into account dynamic machine motion that is helpful in designing the seat cushions, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24 . It is also possible to use a machine simulator to generate the dynamic machine motion. 
     Industrial Applicability 
     Referring to  FIG. 5 , a method  70  for designing the seat cushions, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24  is described in conjunction with the  FIGS. 1-4 . 
     At step  72 , the user  36  is positioned on the test seat  40 . 
     At step  74 , the pressure points  60  of the user  36  are scanned. 
     At step  76 , the pressure points  60  of the user  36  are recorded to generate the pressure map  58 . 
     At step  78 , the seat cushion, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24  are manufactured conforming to the pressure map  58  using an additive manufacturing process or an additive manufactured tool and a molding process. 
     Referring to  FIGS. 1 and 2 , customization of the seat cushions, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24  improve working efficiency of the user  36 . The first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24  are customized according to a body shape and structure of the user  36 . The first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24  are easy to retrofit over a variety of seats, i.e. the seat  10  as per user requirements. The first seat cushions  12 , the second seat cushion  14  and the head rest cushion  24  are designed for ease of assembly to the seat  10  that make it easy for the user  36  to replace during a shift change. 
     Further, the method disclosed herein offers cost effective way for customizing the seat cushions, i.e. the first seat cushion  12 , the second seat cushion  14  and the head rest cushion  24 . Further, advancements in 3D printing and scanning technologies enables optimized seat cushion design and minimizes wastages. 
     While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.