Body support article cover containing segments from stitching or quilting and having gel-type structures integrated with foam
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Solution Overview
Problem
Foam body support articles, such as mattresses and pillows, often fail to provide adequate support for all users due to uniform support distribution and tend to retain heat, leading to discomfort for users with different support preferences and those who sleep hot.
Innovation Solution
A body support article cover featuring stitched segments with integrated gel layers of varying geometric shapes and firmness, allowing for customizable support and improved heat dissipation by alternating gel lattice configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform foam support is used, then manufacturing simplicity is maintained, but user comfort and support customization deteriorate
Solution Approach 1:
The mattress is divided into multiple zones with different foam densities and firmness levels. The mattress includes a head region, shoulder region, hip region, and leg region, each with specifically tailored foam properties to provide customized support for different body parts while maintaining a unified manufacturing process.
Solution Approach 2:
Different regions of the mattress are assigned different foam densities and firmness characteristics. The head region uses one density, the shoulder region uses another, the hip region uses a third, and the leg region uses a fourth, allowing each local area to provide optimal support for the corresponding body part.
2Device complexity
If single-type foam is used, then material simplicity is maintained, but regional support adequacy deteriorates
Solution Approach 1:
The mattress employs multiple types of foam materials with different densities and firmness properties in different regions. The composite construction combines memory foam, polyurethane foam, and latex foam in specific configurations to provide appropriate support for each body region while maintaining overall structural integrity.
3Strength
If dense foam structure is used, then support firmness is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The mattress incorporates foam materials with controlled porosity and open-cell structures that allow air circulation while maintaining support firmness. The porous design enables heat and moisture to escape from the sleeping surface, preventing heat buildup while preserving the necessary support properties.
Solution Approach 2:
The mattress is divided into zones with varying foam densities and breathability characteristics. Regions requiring higher support use denser foam, while areas prioritizing heat dissipation use more porous, breathable materials, allowing simultaneous optimization of both support and thermal management across different mattress regions.
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 tailored support for multiple users with different preferences and reduces heat retention, enhancing comfort by allowing for adjustable firmness and improved airflow through the use of distinct gel lattice designs.
Implementation Method 1
Sleeping hot is commonly addressed by the inclusion of phase change materials (PCMs) which absorb heat as part of a transition between their solid and liquid forms or between crystal structures thereof.
Implementation Method 2
Each of the segments comprises a gel structure coupled to a foam layer and comprising a gel layer. The gel layer comprises a first gel lattice having a first geometric shape.
Data Source
AI summary
A body support article cover that includes a plurality of segments comprising a gel layer integrated with a foam layer is provided. The segments are enclosed by stitching. Each of the segments comprises a gel structure coupled with a foam layer, the gel structure comprising a gel layer. The gel layer comprises a first gel lattice having a first geometric shape. The first geometric shape has a first gel lattice height; a first gel lattice width; and a first gel lattice length. The first gel lattice comprises a plurality of first gel segments, wherein the first gel segments define a plurality of first gaps. The first gel lattice has a first firmness.