3D Fabric Mattress Padding Structure for Airflow and Shape Support
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Solution Overview
Problem
Multi-layer bodies for padding, such as mattresses, face issues with poor adaptability to shape, deformation under compression, low transpiration capability, and laborious and costly layer coupling methods, leading to hygiene problems and reduced durability.
Innovation Solution
A multi-layer body comprising a flexible or visco-elastic polyurethane layer with three-dimensional fabric support and a polyurethane foam frame, featuring circular holes for air passage and elastic filaments that act as springs, combined with a base layer and an outer polyurethane frame for anchoring, allowing for efficient air circulation and improved mechanical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyurethane material is used for padding, then high elastic recovery is achieved, but poor shape adaptability and deformation under compression occur
Solution Approach 1:
The patent combines polyurethane foam with a three-dimensional fabric structure to create a composite padding material. The polyurethane provides elastic recovery while the 3D fabric structure maintains shape stability and prevents excessive deformation, resolving the contradiction between high elastic recovery and poor shape adaptability.
Solution Approach 2:
The three-dimensional fabric structure introduces localized rigid elements (the fabric framework) within the flexible polyurethane matrix. This creates regions of different mechanical properties: the fabric provides shape-maintaining rigidity while the polyurethane provides elastic recovery, achieving both shape adaptability and elastic recovery simultaneously.
2Reliability
If polyurethane material is used for padding, then high elastic recovery is achieved, but poor transpiration capability occurs
Solution Approach 1:
The three-dimensional fabric structure inherently creates a porous network with channels and voids that allow air circulation. This porous structure enables transpiration while the polyurethane foam fills the spaces to provide elastic recovery, thus resolving the contradiction between elastic recovery and transpiration capability.
3Stability of the object's composition
If textile support elements are anchored by gluing, then layer coupling is achieved, but long processing time and high cost occur
Solution Approach 1:
The patent replaces the chemical gluing process with a mechanical interlocking system. The three-dimensional fabric structure physically integrates with the polyurethane foam through its porous framework, eliminating the need for spray glues and their associated dispensing and activation times, thus reducing processing time while maintaining layer coupling stability.
Solution Approach 2:
The fabric structure and polyurethane foam are combined into a single integrated composite material rather than separate layers requiring assembly. This merging eliminates the coupling step entirely, as the fabric and foam form a unified structure during the foam expansion process, significantly reducing processing time and cost.
4Stability of the object's composition
If textile support elements are anchored by hot processes, then layer coupling is achieved, but complex operations and high cost occur
Solution Approach 1:
The patent replaces thermal coupling processes with mechanical interlocking through the three-dimensional fabric structure. This substitution eliminates the need for heating equipment, temperature control systems, and calendering machinery, thereby reducing device complexity while achieving stable layer coupling.
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 solution provides enhanced adaptability, reduced deformation, improved transpiration, and increased durability, while simplifying the manufacturing process and ensuring efficient layer anchoring, resulting in improved comfort and hygiene.
Implementation Method 1
The body (1) comprises an outer frame (5) made of flexible polyurethane and distributed in liquid form to be solidified subsequently, which permeates at least partially within the filaments (4) that constitute the three-dimensional fabric, anchoring, once it is solidified, to the filaments (4)
Implementation Method 2
each filament (4) is made of elastic material... the filaments (4) behave as individual springs, and maintain the surfaces (3a, 3b) mutually distanced
Implementation Method 3
the filaments (4) behave as individual springs, and maintain the surfaces (3a, 3b) mutually distanced allowing the circulation of air
Implementation Method 4
The layer (2) made of flexible or visco-elastic material presents, on both surfaces, preferably circular through holes, to allow the passage of air
Implementation Method 5
the outer frame (5) is made of flexible polyurethane and it is distributed in liquid form to be solidified subsequently
Data Source
AI summary
A multi-layer body for the fabrication of mattresses, chairs or the like, and method for its manufacture; the body presenting at least one layer (2) made of flexible or visco-elastic polyurethane and a three-dimensional support layer (3) presenting a first surface (3a) coupled to the layer (2) of flexible or visco-elastic polyurethane, and a second surface (3b) opposite to the first surface (3a); an outer frame (5) is also provided, which extends along the entire peripheral development of the multi-layer body, in order stably to anchor the polyurethane layer (2) with the support layer (3).