Coated open-cell polyurethane foam structures with thermal absorption capabilities
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Solution Overview
Problem
Existing coated polyurethane foam structures for mattresses suffer from thermal and moisture discomfort issues due to their non-breathable nature, leading to warm sleep and elevated moisture levels, which are not effectively addressed by prior solutions.
Innovation Solution
A coated flexible open-cell polyurethane foam structure with a flexible heat conductive material covering 30 to 90% of its surface, featuring predefined gaps to balance heat and moisture transfer, utilizing encapsulated phase change materials or metals, and a polymeric membrane for improved thermal absorption and breathability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a solid polymer gel layer is coated on polyurethane foam to provide heat sink effect, then thermal absorption capability is improved, but breathability and moisture transfer are blocked
Solution Approach 1:
The patent uses open-cell polyurethane foam as the base material, which inherently provides porosity and breathability. The foam structure allows moisture vapor to pass through while the gel coating provides thermal absorption, creating a balanced system that addresses both thermal regulation and moisture management needs
Solution Approach 2:
The patent combines polyurethane foam with gel coating to create a composite material system. The foam provides structural support and breathability, while the gel layer provides thermal absorption capability. This composite approach allows both materials to contribute their advantageous properties without compromising each other's functionality
2Temperature
If flexible heat conductive material covers the foam surface to enhance thermal absorption, then heat transfer is improved, but moisture transfer capability deteriorates
Solution Approach 1:
The patent applies heat conductive material in specific patterns or zones on the foam surface rather than complete coverage. This localized application allows certain areas to provide enhanced thermal absorption while leaving other areas open for moisture vapor transmission, creating spatial differentiation of functions
Solution Approach 2:
The patent uses partial coverage of heat conductive material (covering only portions of the surface) rather than complete coverage. This partial action approach provides sufficient thermal absorption benefit while maintaining adequate moisture transfer pathways through the uncovered foam areas
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 effectively cools the skin surface while maintaining moisture levels, providing enhanced comfort by allowing for both heat and moisture transfer, thus addressing the limitations of prior art in mattress materials.
Implementation Method 1
the flexible heat conductive material contains an encapsulated phase change material. For the various embodiments, the encapsulated phase change material has a latent heat of transition of 80 to 300 joules per gram of the flexible heat conductive material
Implementation Method 2
a flexible heat conductive material covering 30 to 90 percent ('cov.', expressed in %) of a surface area of the first major surface of the flexible open-cell polyurethane foam
Data Source
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AI summary
The present disclosure provides for a coated flexible open-cell polyurethane foam structure. The coated flexible open-cell polyurethane foam structure includes a flexible open-cell polyurethane foam having a first major surface and a second major surface opposite the first major surface. The coated flexible open-cell polyurethane foam structure further includes a flexible heat conductive material covering 30 to 90 percent (cov., expressed in %) of a surface area of the first major surface of the flexible open-cell polyurethane foam in a predefined shape to provide one or more gaps exposing the flexible open-cell polyurethane foam between defined edges of the flexible heat conductive material, where each gap of the one or more gaps has a gap width according to Formula I: gap width (mm) < -0.196 x cov. (%) + 20.6 (Formula I) where a total surface area of the one or more gaps provides 70 to 10 percent of the surface area of the first major surface of the flexible open-cell polyurethane foam.