Infection Control Bedding Vent Filter for Airflow and Bond Strength
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Solution Overview
Problem
Existing hermetically sealed infection control bedding products, such as pillows and mattresses, face challenges with inadequate airflow and bond strength between layers, particularly when using less expensive materials like polyester backed polyurethane coated textiles, leading to issues like 'strikethrough' and increased risk of cross-infection, especially in medical settings where larger volumes require more rapid airflow.
Innovation Solution
The introduction of an adhesive micro-dotting layer provides a high airflow strengthening layer that enhances bond strength between the filter medium and outer cover, using a filter medium with a non-woven membrane and a polypropylene strengthening layer bonded with glue dots, which allows for improved airflow and mechanical strength, especially in larger volume devices like mattresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polyester backed polyurethane coated textiles are used for the outer cover instead of polyamide, then manufacturing cost is reduced, but bond strength between the filter layers deteriorates
Solution Approach 1:
A strengthening layer is introduced as an intermediary component between the filter membrane and the polyester backed polyurethane coated textile. This strengthening layer provides a bonding interface that achieves adequate bond strength between layers while allowing the use of less expensive polyester material instead of polyamide for the outer cover.
2Productivity
If traditional filter membranes are used in standard cushioning devices, then manufacturing cost is controlled, but airflow rate is insufficient for larger volume devices
Solution Approach 1:
The filter assembly is constructed as a composite structure combining a filter membrane with a strengthening layer. This composite configuration increases the airflow rate capability to handle larger volume devices such as mattresses, while maintaining structural integrity and managing the complexity through a systematic layered design.
3Productivity
If slower airflow through the filter is present in larger cushioning devices, then manufacturing cost is reduced, but patient comfort and skin tissue safety deteriorate
Solution Approach 1:
The composite filter assembly with strengthening layer enables high airflow rates necessary for larger cushioning devices like mattresses. This rapid airflow prevents the balloon effect that creates surface tension and capillary occlusion, thereby eliminating the risk of skin tissue damage and decubitus ulcers in patients.
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
This solution significantly increases airflow and bond strength, reducing the risk of cross-infection and skin tissue damage by ensuring effective ventilation and robust seam integrity, making the products more comfortable and safer for patients.
Implementation Method 1
a filter medium comprising a filter membrane and a strengthening layer bonded together by adhesive applied in the form of a plurality of dots
Implementation Method 2
the vent means comprises a filter medium including a filter membrane for the removal of particles of microbial size
Implementation Method 3
a thermoplastic coating, typically polyurethane, applied... the thermoplastic (polyurethane) coating provides waterproofing
Data Source
Figure 1
Figure 2
Figure 2A(i)~2A(iv)
AI summary
A hermetically sealed infection control bedding product such as a pillow, duvet, mattress, cushion or such like having a sealed cover and having a resiliently deformable filling material, comprising a vent means in the cover, characterised in that the vent means comprises a filter medium including a filter membrane for the removal of particles of microbial size and wherein the filter medium also comprises a strengthening layer of material for providing mechanical strength to the filter medium wherein the filter medium also comprises an adhesive layer whereby the filter medium allows air flow therethrough but is substantially impermeable to liquid while maintaining a barrier to particles of microbial size; optionally, wherein the adhesive layer is formed from a plurality of dots of adhesive applied to the strengthening layer.