Bedding product including composite layer and method of manufacture
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Solution Overview
Problem
All-foam mattresses and hybrid foam mattresses suffer from heat buildup and moisture retention due to high-density foams with low airflow, leading to user discomfort, and three-dimensional polymeric fiber layers face delamination and shear fatigue issues when used in mattress construction.
Innovation Solution
A composite layer comprising an extruded three-dimensional polymeric fiber layer with randomly oriented fibers and a foam layer injected into the free volume, forming a foam-fiber composite with distinct portions to enhance airflow, durability, and prevent delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-density foam is used in mattress assemblies, then support and durability are improved, but heat buildup and moisture retention increase due to low airflow
Solution Approach 1:
The patent combines foam material with three-dimensional polymer fiber material to create a composite mattress assembly. The foam provides support and durability, while the polymer fiber material with its three-dimensional structure creates channels for airflow, thereby reducing heat buildup and moisture retention while maintaining the supportive properties of the foam.
2Temperature
If three-dimensional polymer fiber layer is used to improve airflow, then heat dissipation is improved, but delamination and shear fatigue occur at fiber-foam interfaces
Solution Approach 1:
The patent merges the foam material and three-dimensional polymer fiber material into a single composite structure where the materials are integrated rather than simply layered. This combining approach ensures that the polymer fibers are embedded within the foam matrix, creating a unified structure that prevents delamination and shear fatigue while maintaining the airflow channels necessary for heat dissipation.
3Temperature
If three-dimensional polymer fiber layer is sandwiched between two foam layers, then heat dissipation is improved, but bonding strength decreases due to low surface area at interface
Solution Approach 1:
The patent utilizes the porous, three-dimensional structure of the polymer fiber material to create extensive internal surface area within the composite. The foam material penetrates into the three-dimensional fiber structure, creating numerous bonding interfaces throughout the volume rather than relying solely on a limited two-dimensional interface. This volumetric bonding approach significantly increases the total bonding strength while preserving the heat dissipation capabilities provided by the three-dimensional fiber architecture.
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 composite layer improves airflow, reduces heat buildup, enhances durability, and minimizes shear fatigue, providing a more comfortable and durable mattress with improved hygiene and noise reduction.
Implementation Method 1
the layer of the three dimensional polymer fibers can help alleviate the issues related to heat dissipation due to the amount of free space per unit volume which promotes airflow these materials provide
Implementation Method 2
the foam layer extends into a portion of the extruded three dimensional polymer fiber layer
Data Source
AI summary
A composite layer for use in a bedding product such as a mattress and a method of manufacture are disclosed. The composite layer generally includes an extruded three dimensional fibrous layer and a foam material, e.g., polyurethane, latex or the like, disposed within the fibrous layer and occupying at least a portion of the free volume in the layer. Also disclosed are processes for manufacturing a foam-fiber composite.