Coated open-cell polyurethane foam structures with thermal absorption capabilities
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Solution Overview
Problem
Existing coated polyurethane foam structures fail to effectively manage heat and moisture transfer, leading to discomfort due to the non-breathable nature of solid polymer gel coatings, which exacerbate warm sleep issues and moisture accumulation.
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, where the gap width is determined by a specific formula to expose the foam and allow for breathability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a solid polymer gel coating is applied to polyurethane foam, then heat transfer capability is improved, but moisture breathability deteriorates
Solution Approach 1:
The coating is segmented into discrete phase change material capsules distributed throughout the foam structure, rather than a continuous solid layer. This segmentation allows heat transfer through the capsules while maintaining moisture vapor transmission through the foam's open-cell structure, resolving the contradiction between thermal performance and breathability.
Solution Approach 2:
The invention utilizes the open-cell porous structure of the polyurethane foam as the primary matrix, which inherently provides moisture breathability. The phase change material is encapsulated within this porous framework rather than forming a solid barrier, allowing moisture vapor to pass through while the capsules provide thermal regulation through phase change absorption and release.
2Temperature
If a solid polymer gel coating is applied to polyurethane foam, then thermal mass is increased, but breathability is reduced
Solution Approach 1:
The invention changes the physical state parameter of the thermal regulation material from solid gel to encapsulated phase change capsules. This parameter change allows the material to provide thermal mass through phase change (latent heat) rather than relying on solid mass, thereby maintaining breathability while achieving thermal regulation. The capsules can undergo phase transition between solid and liquid states depending on temperature.
Solution Approach 2:
The invention creates a composite structure combining polyurethane foam with encapsulated phase change material capsules. The foam provides structural support and breathability, while the phase change capsules provide thermal mass and temperature regulation. This composite approach allows both breathability and thermal mass to coexist without compromise.
3Temperature
If phase change material is encapsulated in flexible heat conductive material, then thermal absorption capability is improved, but structural complexity increases
Solution Approach 1:
The phase change material is encapsulated in flexible thin-walled capsules that conform to the foam structure. These flexible shells provide minimal structural resistance while containing the phase change material, allowing the capsules to be distributed throughout the foam without creating significant structural complexity. The thin-film encapsulation enables thermal absorption capability while maintaining simplicity of the overall structure.
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 improved comfort by allowing for both heat dissipation and moisture evaporation, thus addressing the limitations of prior art in thermal and moisture management.
Implementation Method 1
a flexible heat conductive material covering 30 to 90 percent ('cov.', expressed in %) of a surface area of the first major surface
Implementation Method 2
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
Implementation Method 3
open-cell polyurethane foam structures... flexible open-cell polyurethane foam having a first major surface and a second major surface opposite the first major surface
Data Source
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×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.