Cooling Sleep Mask Structure for Ergonomic Fit and Light Blocking
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Solution Overview
Problem
Current sleep masks lack ergonomic fit, durability, and integrated cooling capabilities, leading to poor user experience and low compliance due to heat retention and discomfort.
Innovation Solution
Sleep mask products featuring a layered foam structure with a phase change material (PCM) for cooling and a malleable wire fitting component for ergonomic fit, combined with a fabric layer for comfort and light blocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sleep masks are constructed with thick, bulky materials to provide robust structure, then durability is improved, but user comfort deteriorates due to poor-quality experience and heat retention
Solution Approach 1:
The sleep mask combines multiple materials with different properties: a breathable outer fabric layer for comfort and heat dissipation, a middle foam layer for structural support and light blocking, and an inner cooling layer with phase change material for thermal regulation. This composite structure achieves both durability and user comfort simultaneously.
Solution Approach 2:
Different regions of the sleep mask have different material properties tailored to specific functions: the outer layer uses breathable fabric for comfort, the middle layer uses dense foam for light blocking and structure, and the inner layer uses phase change material for cooling. Each local region optimizes its material properties to meet specific performance requirements.
2Ease of operation
If sleep masks are made thin to provide a comfortable, non-bulky user experience, then user comfort is improved, but structural robustness and light blocking capability deteriorate
Solution Approach 1:
The multi-layer composite structure allows the sleep mask to be thin overall while maintaining robust functionality. The breathable outer fabric provides comfort, the middle foam layer provides structural support and light blocking, and the inner cooling layer provides thermal regulation, achieving all requirements in a thin profile.
Solution Approach 2:
The sleep mask is segmented into three distinct functional layers, each with optimized thickness for its specific purpose. This segmentation allows the overall mask to remain thin while each layer contributes its specialized function, avoiding the need for a single thick layer that would compromise comfort.
3Ease of manufacture
If conventional sleep mask materials are used without integrated cooling, then manufacturing simplicity is maintained, but heat dissipation capability deteriorates causing heat trap around the mask
Solution Approach 1:
The inner layer incorporates phase change material that absorbs excess heat from the user's face by transitioning from solid to liquid state at body temperature, providing active cooling. This phase transition mechanism effectively dissipates heat without complex mechanical cooling systems, maintaining manufacturing simplicity while solving the heat trap problem.
Solution Approach 2:
The sleep mask combines conventional breathable fabric with phase change material in a composite structure. The fabric provides basic breathability and comfort, while the embedded phase change material provides enhanced active cooling, achieving superior heat dissipation without significantly complicating the manufacturing process.
4Device complexity
If sleep masks lack ergonomic fitting components, then device complexity is reduced, but fit quality and compliance deteriorate due to poor ergonomic fit
Solution Approach 1:
The sleep mask incorporates a malleable wire frame in the headband that can be dynamically shaped and bent to match different head shapes and sizes. This dynamic adaptability allows the mask to conform to each user's unique anatomy, providing excellent ergonomic fit without requiring multiple size options or complex adjustment mechanisms.
Solution Approach 2:
The malleable wire frame allows users to manually shape and customize the fit of the headband to their own head contour. This self-service approach enables each user to optimize the ergonomic fit themselves, eliminating the need for complex pre-adjusted sizing systems or professional fitting procedures.
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
Provides a comfortable, ergonomic, and effective sleep mask that blocks light and dissipates heat, enhancing sleep quality and user compliance.
Implementation Method 1
the second fabric inner surface comprises a phase change material thereon
Implementation Method 2
provide a sleep mask product with an integrated cooling component
Data Source
AI summary
The present disclosure relates to sleep mask products and methods of making same. Disclosed are sleep mask products comprising: a mask body and a mask strap; wherein the mask strap has a first attachment point to a first lateral edge of the mask body and a second attachment point to a second lateral edge of the mask body; and wherein the mask body comprises a first fabric layer; a second fabric layer; a first foam layer; and a second foam layer. The second fabric inner surface comprises a phase change material thereon. The second foam layer second surface contacts the phase change material, the second fabric inner surface, or a combination thereof. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.