Foam Hardness Research Articles

Vibrational comfort improvement for a passenger car driver seat

Abstract This paper presents an experimental study aimed at providing new insights into passenger vehicle driver seat vibration. The study investigates the effects of various driver seat components on the damping coefficient. By employing a design for six sigma method, an optimized seating solution is proposed to enhance seat comfort levels. The control factors used in this study include seat cushion upholstery, topper foam, cushion foam, pulmaflex, torsion bar and seat structure. Seat position, foam thickness and body mass are considered as potential noise factors. Subjective evaluation of seat comfort is conducted using the SAE J 1441-2016, comparing three different passenger car driver seats. The seats are disassembled from the vehicles and mounted on a six-degree-of-freedom shaker test bench. Vertical vibration data are filtered, and transmissibility curves are experimentally obtained from the seat rail to the seat cushion via a pad. Uncomfortable seat prototypes are then manufactured, and alternative configurations are tested on the shaker. The objective and subjective evaluations of the seat prototypes reveal that lower foam hardness, higher foam density, and flexible upholstery contribute to improved comfort levels. Moreover, the prototype seat with optimum parameters receives a subjective evaluation SAE score of +0.75, indicating an enhancement in comfort.

Transmission of vertical vibration through a seat cushion at the seat pan: Effect of foam physical properties during different excitation magnitudes

The vibration characteristics of car seats directly influence the ride comfort. Polyurethane foam is the key part of a seat, and its physical parameters have an important impact on the seat. In this study, the influence of the foam thickness and foam hardness on the vibration characteristics of seat cushion with different excitation magnitudes was investigated by using transmissibility and seat effective amplitude transmissibility (SEAT) value. First, vibration tests were carried out at a vertical vibration simulator with width-limited white noise vibration frequencies from 0.5 to 20 Hz with root-mean-square (r.m.s.) values of 0.4, 0.8, and 1.2 m/s2, the acceleration at the platform and the body-foam interfaces were measured to calculate the transmissibility, and the influence of the foam physical properties on the transmissibility was analyzed. Then, the SEAT value was introduced to assess the vibration isolation efficiency of the foam cushion, and the influence of the foam physical properties of the foam cushion on the vibration isolation efficiency was analyzed. With increasing thickness of the foam and decreasing hardness of the foam at the seat pan, the peak transmissibility increased and the resonance frequency decreased. The SEAT values show that increasing the foam thickness is beneficial to the improvement of the vibration isolation efficiency of the seat, but there is a diminishing return; the combination of physical parameters of low hardness and high thickness could make the vibration isolation performance of the seat better. In addition, the nonlinearity of human-seat system during different vibration magnitude was found.

Nanoindentation tests of heavy-ion-irradiated Au foams—molecular dynamics simulation

Irradiation by light ions may change the mechanical properties of nanofoams. Using molecular-dynamics simulation, we study the effect of irradiating a Au foam (porosity, 50%, and ligament diameter, 3 nm) with heavy ions: here, 10 keV Au ions up to a dose of 4 × 1016 m−2. We demonstrate that in consequence, the ligament morphology changes in the irradiated region, caused by local melting. The changes in mechanical properties are monitored by simulated nanoindentation tests. We find that the foam hardness is only around 1/3 of the hardness of a bulk Au crystal. Irradiation increases the hardness of the foam by around 10% in the central irradiated area. The plastic zone extends to only 1.5 ac, where ac denotes the contact radius; this value is unchanged under irradiation. The hardness increase after irradiation is attributed to two concurring effects. To begin with, irradiation induces melting and annealing of the ligaments, leading to their coarsening and alleviating surface stress, which in turn increases the dislocation nucleation threshold. In addition, irradiation introduces a stacking fault forest that acts as an obstacle to dislocation motion.

Properties and corrosion behavior of Al based nanocomposite foams produced by the sintering-dissolution process

The properties of Al based nanocomposite metal foams and their corrosion behaviors were investigated in this study. For this, the composite metal foams with different relative densities (porosity) reinforced with alumina nanoparticles were prepared using a powder metallurgy- based sintering-dissolution process (SDP) and NaCl particles were used as space holders. Then, the effect of nanoparticle reinforcement and different amounts of NaCl space holders (corresponding porosity) on the microstructure, morphology, density, hardness, and electrochemical specifications of the samples were investigated. It was found that as the relative density increased from 60% to 70%, the wall thickness increased from about 200 to 300 μm, which led to a decrease in pore size. Also, the addition of nanoparticle reinforcement and the increased relative density result in increasing metal foam hardness. Moreover, electrochemical test results indicated that increasing the Al2O3 content reduced the corrosion rate, but increasing the porosity enhanced it.

A simple method for preparation of polymer microcellular foams by in situ generation of supercritical carbon dioxide from dry ice

In this work, poly(methyl methacrylate) (PMMA) and PMMA/nanoclay nanocomposite microcellular foams were successfully prepared using a simple method based on in situ generation of supercritical carbon dioxide (CO2) from dry ice. The method was compared with conventional methods exempted from high pressure pump and a separate CO2 tank. Effect of various processing conditions such as saturation temperature and pressure and clay concentration on cellular morphology and hardness of the prepared microcellular foams was examined. State of the clay dispersion in the prepared PMMA/clay nanocomposites was characterized using X-ray diffraction and transmission electron microscopy techniques. Field emission scanning electron microscopy was used to study cellular morphology of the prepared foams. It was observed that elevation of saturation temperature from 85 to 105 °C at constant saturation pressure increased cell density and decreased average cell size of the prepared PMMA foams. Furthermore, an increase in saturation pressure from 120 to 180 bar resulted in a reduction in average cell diameter and an increase in cell density of the prepared PMMA foams. On the basis of the gathered results, optimum conditions for preparation of PMMA microcellular foams were determined and applied for preparation of PMMA/nanoclay microcellular foams. It was shown that incorporation of clay into the polymer matrix resulted in a finer and more uniform cellular morphology in the final microcellular foams. It was also observed that incorporation of nanoclay into the prepared foams, up to 3 wt%, led to a moderate increase in the foam hardness.

Enhancing polyurethane properties via soft segment crystallization

Semi-crystalline polyester diols with relatively high melting points and enthalpies of crystallization are shown to form nearly co-continuous lamellar structures in thermoplastic polyurethanes using polyether soft segments. This high aspect ratio crystalline structure results in materials with exceptional tensile and elastic properties compared to materials made with conventional semi-crystalline soft segments such as polycaprolactone or polybutylene adipate. Additions of semi-crystalline soft segment to foam formulations also result in increased hardness measured by standard foam hardness tests. Halpin–Tsai and percolation model analyses of the results suggest that the crystalline regions exert a global influence on the elastomer structure.

Application of Ethoxylated Inulin in Water-Blown Polyurethane Foams

Inulin, a polydisperse reserve polysaccharide from chicory, was chemically modified via alkoxylation using ethylene oxide, in a water free medium. The reaction resulted in a range of products with very distinct properties, such as a highly increased water solubility, moderate surface-active properties and high cloud points in electrolyte media. Because of the unique characteristics of inulin, such as its molecular weight range, and because of the high water solubility of the ethoxylates, the products were evaluated as additive in water-blown polyurethane foams. The addition of inulin ethoxylates resulted in an increased foam hardness and density, the latter in fact being unwanted. The foam properties were evaluated based on the indentation test, the foam density, the SAG factor, and the hysteresis curves of standard cubes. Based on these parameters inulin ethoxylates were shown to have a beneficial effect on the foam properties. The inulin ethoxylate with a theoretical degree of substitution of 0.5 proved to be the best derivative, since the increase in hardness was the highest, while the increase in density was negligible.

Factors affecting static seat cushion comfort

To improve the understanding of factors affecting automobile seat cushion comfort in static conditions (i.e. without vibration), relationships between the static physical characteristics of a seat cushion and seat comfort have been investigated. The static seat comfort of four automobile cushions, with the same foam hardness but diOEerent foam compositions, was investigated using Scheffe?s method of paired comparisons. The comfort judgements were correlated with sample stiOEness, given by the gradient of a force-deflection curve at 490 N (= 50 kgf). Samples with lower stiffness were judged to be more comfortable than samples with greater stiffness. A similar comfort evaluation was conducted using five rectangular foam samples of the same composition but different foam hardness (and a wider range than in the first experiment). There was no linear relationship between the sample stiffness and seat comfort for these samples. Static seat cushion comfort seemed to be affected by two factors, a ‘bottoming feeling’ and a ‘foam hardness feeling’. The bottoming feeling was reflected in the sample stiffness when loaded to 490 N, while the foam hardness feeling was reflected in foam characteristics at relatively low forces. The pressures underneath the buttocks of subjects were compared with the comfort judgements. The total pressure over a 4 cm × cm area beneath the ischial bones was correlated with static seat comfort, even when the differences among samples were great; samples with less total pressure in this area were judged to be more comfortable than samples with greater total pressure. It is concluded that the pressure beneath the ischial bones may reflect both comfort factors: the bottoming feeling and the foam hardness feeling.

The physics of sub-bandage pressure measurement.

Compression therapy is the principal treatment for leg ulcers associated with venous disease. The extent of compression generally can be estimated from the general Laplace equation relating pressure, bandage tension and leg radius. This study aimed to investigate the physical forces under long stretch bandages applied under constant tensions to cylinders of three defined radii ('model limbs'). Force expressed as pressure was measured under one, two and three layers of eight long stretch bandages and a plastic film (control) using temperature-compensated, strain-gauge pressure transducers. The bandages were applied at the manufactures' recommended extensions/tensions and at constant tensions (2-10N) to three rigid plastic tubes of increasing size, covered with a layer of soft foam. Foams of different hardnesses ranging from 20 to 230N were assessed. The median applied pressure and observed bandage characteristics changed with bandage type. The median applied pressure also changed with tension, number of layers, tube radius and foam hardness. The inter-layer shear component also tended to increase with the number of layers. An increase in sub-bandage pressure was observed relative to the radius, tension, foam hardness and number of layers but the relationship was not directly proportional. The shear force tended to be associated with increased bandage layers.

Interface pressure and the prediction of car seat discomfort

The technique of interface pressure measurement has generated considerable interest in the automotive industry as a method, which could be used to predict driver discomfort during the development of prototype seat designs. Two repeated measures experiments were carried out to evaluate the practical application of the technique. The variables of foam density and posture were used to create discomfort, the whole emphasis of the work being to generate results with real-world applicability. A clear, simple and consistent relationship between interface pressure and driving discomfort was not identified. Future studies using this technique should provide information regarding such factors as gender, body mass, anthropometric data, posture and foam hardness due to the confounding nature of these variables.