Thermally Enhanced Bedding Topper With Pocketed Springs for Heat Dissipation
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Solution Overview
Problem
Conventional toppers for bedding and seating products fail to effectively dissipate heat, leading to discomfort due to retained heat underneath users, which can disrupt sleep or cause thermal issues during use.
Innovation Solution
A topper design featuring a pocketed spring comfort layer sandwiched between thermally enhanced foam layers, where at least one of the foam layers incorporates materials like metallic particles, carbon nanotubes, or microencapsulated phase change materials for improved heat conduction and absorption, enhancing cooling efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional foam layers are used in the topper, then the structure is simple and cost-effective, but heat dissipates poorly causing heat buildup underneath users
Solution Approach 1:
The patent applies composite materials by infusing thermally conductive materials (such as metals, graphite, silicon carbide, carbon nanotubes) into the foam structure. This creates a composite foam material that maintains the cushioning properties of conventional foam while adding thermal conduction capabilities to dissipate heat effectively through the topper layers.
Solution Approach 2:
The patent changes the thermal parameters of the foam by incorporating thermally conductive additives. This modifies the thermal conductivity parameter of the foam material, transforming it from a heat-trapping material to a heat-dissipating material while maintaining the structural integrity and comfort properties of the original foam.
2Temperature
If thermally enhanced foam is used, then heat dissipation improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies preliminary action by incorporating the thermally conductive materials into the foam during the foam manufacturing process itself, rather than as a post-processing step. The thermally conductive materials are mixed with the foam precursor materials before curing, ensuring uniform distribution and eliminating the need for separate infusion or coating operations.
Solution Approach 2:
The patent merges the foam manufacturing process with the thermal enhancement process. By combining the incorporation of thermally conductive materials with the standard foam production steps, the patent eliminates the need for separate manufacturing operations, thereby reducing overall manufacturing complexity despite the added functional requirement.
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 topper effectively reduces heat buildup beneath users by facilitating heat conduction and convection through thermally enhanced foam, providing improved comfort and sleep quality by maintaining a cooler surface temperature.
Implementation Method 1
The thermally conductive materials are spread throughout the foam in-situ... at least one of the layers of foam being thermally enhanced foam for purposes of providing reducing heat below a person
Implementation Method 2
The fabric may allow air to flow between pockets and into and out of the pockets
Data Source
AI summary
A three-layered topper fora bedding or seating product has a first piece of foam, a second piece of foam and a pocketed spring comfort layer therebetween. The pocketed spring comfort layer has individually pocketed mini coil springs. At least one of the foam pieces may be infused with metallic particles to improve thermal conductivity. Alternatively, at least one of the foam pieces may be infused with microencapsulated phase change materials to improve heat absorption. At least one of the foam pieces may have a coating to further improve thermal conductivity or heat absorption.