Increasing the Heat Flow of Flexible Cellular Foam Through the Incorporation of Highly Thermally Conductive Solids

Abstract

Methods and combinations of mattress support surfaces comprising one or more flexible polyurethane foam layers containing highly thermally-conductive solids, such as diamond or silicon carbide, and said layer combination is capable of transferring heat from a warm surface, such as a person sleeping on a bed, to a cooler region at a faster rate throughout the mattress than the thermal dissipation rate obtained from flexible polyurethane foam without highly thermally-conductive solids.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application claims the benefit of U.S. Provisional Patent Application No. 61 / 746,369 filed Dec. 27, 2012, incorporated herein by reference in its entirety.TECHNICAL FIELD[0002]This invention relates to incorporating highly thermally-conductive solids in a polyurethane foam polymer matrix, wherein said combination is used in bedding and seating articles, and more particularly this invention relates to articles that transfer heat from a warm surface, such as a person sleeping on a bed, to a cooler region at a faster rate than the heat dissipation rate obtained from flexible polyurethane foam without highly thermally conductive solids incorporated therein.TECHNICAL BACKGROUND[0003]Typically, high density flexible polyurethane foams have low thermal conductivities in the range of 0.02-0.04 W / (m-° K) in an uncompressed state. High density polyurethane foams have a tendency to trap heat and slowly diffuse heat through conduction and convect...

AI Technical Summary

Benefits of technology

The patent is about methods of making flexible foam with highly thermally-conductive solids, which can be used in bedding and seating articles. The foam is made by adding a combination of flexible polyurethane foam or polyester foam and highly thermally-conductive solids, such as silicon carbide, diamond crystal powder, or boron nitride. The foam can be cut or molded into various shapes, and can also be combined with other substrates like flexible polyurethane foam or latex foam to create products like mattresses, pillows, or cushioning products. The technical effect of this patent is that it provides a way to create flexible foam with improved heat conduction, which can improve the performance and comfort of bedding and seating articles.

Problems solved by technology

High density polyurethane foams have a tendency to trap heat and slowly diffuse heat through conduction and convection.

In particular, high density memory foam has the tendency to “sleep hotter” than traditional flexible foam, due to reduced open void space within the foam.

Prior patents do not teach adding highly thermally conductive solids to flexible polyurethane foam to increase the foam thermal conductivity and using said increased thermally conductive flexible polyurethane foam as one or more layers in a mattress or seating article.

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