Cooling bedding product
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Solution Overview
Problem
Existing bedding products face challenges in efficiently providing a cooling function while maintaining a pleasant feel, particularly during warm weather conditions, and require complex manufacturing processes.
Innovation Solution
A cooling bedding product with a flexible gel layer and memory foam layer, integrated with a textile covering layer featuring vents for air flow, is designed to efficiently dissipate heat, using a polyurethane composition for the gel and memory foam layers and a mixture of polyolefin and polyester fibers for the textile layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If bedding products use gel layers and memory foam layers to provide cooling function, then cooling effect is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines the gel layer and memory foam layer into a single integrated structure where the gel layer is embedded within the memory foam layer. This merging eliminates the need for separate manufacturing and assembly processes for these two components, reducing manufacturing complexity while maintaining the cooling effect provided by the gel layer and the support properties of the memory foam layer.
Solution Approach 2:
The patent uses a composite structure combining gel material and memory foam material in a single bedding product. This composite approach allows both materials to work together synergistically - the gel provides cooling through heat conduction while the memory foam provides pressure relief and support - while the integrated manufacturing process simplifies production compared to assembling separate components.
2Temperature
If bedding products use multiple layers with air conduits and vents for heat dissipation, then cooling function is improved, but structural complexity increases
Solution Approach 1:
The patent incorporates air conduits within the memory foam layer and vents in the textile covering layer, creating a porous structure that facilitates air flow through the bedding product. This porous design enables efficient heat dissipation by allowing air to circulate through the layers, carrying heat away from the user's body, while the integrated structure keeps the overall design relatively simple.
Solution Approach 2:
The patent segments the heat dissipation function across multiple components - air conduits within the memory foam layer for internal air circulation and vents in the textile covering for external air exchange. This segmentation of the cooling function into distributed air flow paths improves heat dissipation efficiency while maintaining a relatively simple overall structure compared to complex active cooling systems.
3Productivity
If bedding products use integrated gel and memory foam layers, then manufacturing efficiency is improved, but production process complexity increases
Solution Approach 1:
The patent merges the gel layer and memory foam layer into a single integrated component that is manufactured as one unit rather than as separate parts requiring assembly. This integration significantly improves manufacturing efficiency by eliminating handling, positioning, and bonding operations between separate layers, while the production process complexity increases only moderately due to the specialized foam formulation and curing process.
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 a bedding product with a simplified manufacturing process that effectively maintains a cooling effect, enhancing comfort during sleep by efficiently dissipating heat through air conduits and vents.
Implementation Method 1
The flexible gel layer contains a plurality of hexagonal prism-shaped protrusions on the outside surface thereof
Implementation Method 2
The flexible gel layer and memory foam layer have a plurality of air conduits therein for air flow communication with the at least one vent
Data Source
AI summary
A bedding product having a cooling layer and a method therefor. The bedding product has a gel layer having an outside surface, a bonding surface opposite the outside surface, and a perimeter. A memory foam layer surrounds the perimeter and is disposed on the bonding surface. A textile layer having a first rectangular portion and a second rectangular portion affixed on a perimeter thereof to the first rectangular portion retains the gel layer and memory foam layer therebetween. The textile layer has a cooling surface, an opposing surface opposite the cooling surface, and at least one vent disposed adjacent to an edge portion of the first or second rectangular portion. The gel layer contains a plurality of hexagonal prism-shaped peaks and valleys on the outside surface thereof, and the gel layer and memory foam layer have a plurality of air conduits for air flow communication with the vent.