Coated Polyurethane Foams for Thermal Cooling
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Solution Overview
Problem
Low resiliency, slow-recovering polyurethane foams used in cushioning applications trap heat, causing discomfort due to localized temperature rise, and existing phase change material solutions can be sticky and stiff when warm.
Innovation Solution
A flexible polyurethane foam with a cured coating of a solid, water-insoluble elastomeric polymer containing encapsulated phase change material and ceramic particles, which provides improved thermal cooling and persistence without stickiness or stiffness, suitable for comfort applications like bedding and seating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If phase change material is used as a surface topper, then cool touch sensation is improved, but heat trapping occurs due to impermeability
Solution Approach 1:
The patent uses a porous polymer foam structure as the base material, which allows air and heat to pass through while providing cushioning. This porous structure fundamentally changes the thermal behavior from heat trapping to heat dissipation, resolving the contradiction between cool touch and heat trapping.
Solution Approach 2:
The patent creates a composite material by infusing phase change material particles into a porous polymer foam matrix. This composite structure combines the cool touch property of phase change material with the breathable, heat-dissipating properties of porous foam, eliminating the heat trapping problem of solid gel toppers.
2Temperature
If large quantities of phase change material are used, then cool touch effect is enhanced, but the surface topper becomes stiff and brittle
Solution Approach 1:
The patent uses a flexible porous foam matrix that can accommodate phase change material particles while maintaining flexibility and softness. The foam structure acts as a flexible carrier that prevents the composite from becoming stiff or brittle, even with significant phase change material content.
Solution Approach 2:
By creating a composite where phase change material particles are distributed within a flexible porous foam matrix, the patent achieves both enhanced cool touch effect and maintained flexibility. The foam matrix provides structural continuity and flexibility while the particles provide thermal regulation.
3Temperature
If encapsulated phase change material is used in coating, then cool touch is achieved, but the coating becomes sticky when warm
Solution Approach 1:
The porous foam structure provides a three-dimensional network that holds phase change material particles without requiring sticky binders. The physical interlocking within the porous structure maintains particle position without adhesive tack, eliminating the stickiness problem.
Solution Approach 2:
The patent uses a disposable or replaceable foam insert containing phase change material particles, eliminating the need for permanent adhesive bonding. This approach avoids the stickiness issue by using mechanical retention within the porous structure rather than chemical adhesion.
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 manages heat dissipation, offering a comfortable 'cool touch' attribute with low microtexture roughness and adhesive tack, enhancing user experience in cushioning applications.
Implementation Method 1
the phase change material having a melting or glass transition temperature of 25 to 37° C.
Implementation Method 2
They effectively absorb body heat when touched, as the body heat causes the material to undergo its phase change.
Implementation Method 3
ceramic particles having a particle size of up to 50 μm
Data Source
AI summary
Articles useful for bedding and other comfort applications include a coated polyurethane foam. The coating includes an elastomeric polymer, a phase change material and ceramic particles. The coating provides desirable haptic properties, including a cool touch feature that creates a sensation of coolness when touched. The invention is also a coating composition for producing such a coating, and a method for producing the coating composition