Breathable Gel Cushioning With Segmented Airflow Gaps
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Solution Overview
Problem
Conventional gel cushioning materials often create discomfort due to their impermeable nature, which prevents gas flow and leads to accumulation of body heat and perspiration, as they typically include a plastic film that restricts gas penetration and can be structurally weak and sticky.
Innovation Solution
A breathable cushioning element comprising discrete segments of thermoplastic elastomeric gel heat-fused to a breathable material, allowing gas passage through the material and between segments, eliminating the need for an impermeable plastic film and enhancing strength and reduced stickiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a plastic film is used to cover the gel layer, then the structural strength is improved and stickiness is reduced, but gas flow is blocked and moisture accumulation occurs
Solution Approach 1:
The patent applies porous breathable material instead of impermeable plastic film to allow gas and moisture vapor to pass through while maintaining structural coverage. The porous structure enables moisture management through vapor transmission, eliminating the harmful moisture accumulation effect while preserving the protective function.
Solution Approach 2:
The patent uses composite construction by combining breathable material with gel layers in a multi-layer assembly. This composite structure integrates the protective and strength-providing function of the breathable material with the cushioning and temperature management properties of the gel, achieving both structural integrity and moisture management.
2Adaptability or versatility
If conventional gel is used without breathable material, then cushioning and temperature management are provided, but gas flow is blocked and perspiration accumulates
Solution Approach 1:
The breathable porous material is integrated with the gel layer to enable vapor transmission while maintaining the gel's temperature management properties. The porous structure allows perspiration to evaporate and moisture vapor to escape, preventing accumulation while the gel continues to provide thermal regulation.
Solution Approach 2:
The patent creates a composite structure combining breathable material with gel layers, where the breathable material enables gas flow and moisture management while the gel provides cushioning and temperature management. This composite approach maintains the beneficial thermal properties of gel while eliminating the harmful perspiration accumulation effect.
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 improved comfort by allowing gas flow, reducing moisture buildup, and offering enhanced strength and reduced stickiness, while maintaining effective temperature management and cushioning properties.
Implementation Method 1
a breathable material configured to allow gases to pass through at least a portion thereof, and a plurality of discrete segments of thermoplastic elastomeric gel heat-fused to the breathable material
Implementation Method 2
Gels may provide cushioning because the gels may hydrostatically flow to the shape of a cushioned object and may tend to relieve pressure peaks and/or reduce stresses from shear
Implementation Method 3
Gels may have high thermal mass and/or thermal conductivity, and may therefore be used for heating (such as in hot packs for sore muscles), cooling (such as in cold packs for sprains or for a feeling of coolness when lying on a mattress), or maintaining a given temperature
Implementation Method 4
a plurality of discrete segments of thermoplastic elastomeric gel heat-fused to the breathable material
Data Source
AI summary
Cushioning elements include a breathable material configured to allow gases to pass through at least a portion thereof, and a plurality of discrete segments of thermoplastic elastomeric gel (“gel”) heat-fused or otherwise attached to the breathable material. The gel comprises an elastomeric polymer and a plasticizer, with a plasticizer-to-polymer ratio of from about 0.3 to about 50. The plurality of discrete segments defines at least one breathable gap between adjacent discrete segments. Methods of forming cushioning elements include forming a plurality of discrete segments of gel, securing each segment to a breathable material, and providing a gas path through the breathable material and between adjacent segments. Another method includes providing molten gel within a mold, providing at least a second portion of the gel within a permeable material, and solidifying the gel to form discrete segments of gel.