Air-permeable carrier having embedded temperature adjusting unit and manufacturing method thereof
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Solution Overview
Problem
Conventional mattresses with phase change microcapsules face issues such as disturbance of elasticity and smoothness when mixed into foam materials, inadequate heat dissipation due to surface coverage, and fixed placement between foam layers, leading to ineffective heat accumulation and increased costs.
Innovation Solution
An air-permeable carrier with embedded temperature adjusting units, comprising a flexible carrier body with pores and phase change microcapsules mixed with adhesive, distributed using an adhesive-dispensing injection process to create adjustable temperature regions for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If phase change microcapsules are mixed into foam material, then heat absorption capability is improved, but elasticity and smoothness of the mattress deteriorate
Solution Approach 1:
The mattress is divided into multiple layers with phase change microcapsules embedded only in specific layers (first and third layers) rather than mixing throughout the entire foam structure. This segmentation allows heat absorption functionality to be concentrated in specific zones while preserving the elasticity and smoothness of other layers.
Solution Approach 2:
Different layers of the mattress are assigned different functions: the first and third layers contain phase change microcapsules for heat absorption, while the second layer maintains pure foam properties for comfort and elasticity. This local differentiation ensures that heat absorption capability is improved without compromising overall mattress quality.
2Temperature
If phase change microcapsules are coated upon the surface of the mattress, then heat dissipation is improved, but surface area coverage is reduced when user lies down
Solution Approach 1:
Instead of placing microcapsules only on the surface (2D), they are embedded within the thickness (3D) of specific mattress layers. This dimensional transition ensures that microcapsules remain exposed to heat from the user's body even when surface coverage is reduced by body weight, as they are distributed throughout the layer depth.
Solution Approach 2:
Phase change microcapsules are nested within the foam matrix of specific layers rather than being placed on the outer surface. This nesting allows them to maintain contact with heat-generating areas while being protected within the mattress structure, ensuring continuous heat dissipation functionality.
3Stability of the object's composition
If phase change microcapsules are arranged between two layers of foam material, then placement depth is fixed, but adaptability to different requirements is reduced
Solution Approach 1:
The mattress is segmented into multiple layers with microcapsules embedded in specific layers (first and third layers) rather than being fixed between only two layers. This segmentation provides flexibility in designing different placement depths and configurations according to various practical requirements while maintaining stable composition within each layer.
4Stability of the object's composition
If multiple layers of foam material are used to arrange microcapsules, then manufacturing complexity is increased, but adhesion costs and time are increased
Solution Approach 1:
Multiple functional layers containing phase change microcapsules are merged into a single integrated mattress structure rather than being assembled as separate layers requiring adhesive bonding. This merging eliminates the need for additional adhesive materials and assembly steps, reducing both costs and manufacturing time while maintaining structural stability.
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 air-permeable carrier effectively dissipates heat by allowing phase change microcapsules to communicate with the environment through pores, maintaining comfort without electronic temperature adjustments and simplifying manufacturing, while avoiding the drawbacks of conventional methods.
Implementation Method 1
phase change microcapsules of the temperature adjusting unit can be communicated with air from the surrounding environment through pores formed on the carrier body, so as to achieve the effect of heat dissipation
Implementation Method 2
achieve the effect of heat dissipation
Data Source
AI summary
An air-permeable carrier includes at least one temperature adjusting unit and a carrier body having a plurality of pores. The temperature adjusting unit includes an adhesive and a plurality of phase change microcapsules. The temperature adjusting unit is distributed and fixedly embedded within the carrier body by an adhesive-dispensing injection process, such that the temperature adjusting unit is filled in at least one of the pores in a partial region of the carrier body to form at least one temperature adjusting region at a position corresponding and proximate to the temperature adjusting unit. Each horizontal distance or vertical distance between any two adjacent temperature adjusting units can be substantially the same or different, so that when a user leans against the carrier, phase change microcapsules can be communicated with air from the surrounding environment through the pores to achieve the effect of heat adjustment.