Breathable Elastomeric Foam Cushioning for Thermal Management
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Solution Overview
Problem
Conventional gel layers in cushioning materials act as a barrier to gases, leading to discomfort due to accumulation of body heat and perspiration, as gases cannot penetrate through the plastic film or gel, constricting lateral gas flow paths when compressed.
Innovation Solution
A breathable cushioning element featuring a porous foam with interconnected cell walls coated with an elastomeric material containing an elastomeric polymer and plasticizer, allowing gases to pass through, which is formed by coating the cell walls with a liquid elastomeric material and providing a gas path through the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a gel layer with plastic film is used for cushioning and temperature management, then cushioning performance and thermal management are improved, but gas permeability deteriorates causing accumulation of body heat and perspiration
Solution Approach 1:
The patent uses open-cell foam as the cushioning material, which inherently possesses porous structure allowing gas and vapor transmission. The foam cells are interconnected, creating pathways for perspiration and heat to escape while maintaining cushioning properties. This resolves the contradiction by providing both thermal management through the foam structure and gas permeability to prevent accumulation.
Solution Approach 2:
The patent combines open-cell foam with elastomeric coating to create a composite material that integrates the breathability of foam with the comfort and pressure distribution of elastomeric gel. The elastomeric material is applied as a coating on the foam surface, forming a composite structure that maintains gas permeability while providing enhanced cushioning and thermal management properties.
2Ease of operation
If conventional gel layers are used, then cushioning comfort is improved, but breathability deteriorates as gases cannot penetrate through the plastic film or gel
Solution Approach 1:
The open-cell foam structure provides inherent porosity with interconnected cells that allow free movement of gases and vapors. This porous architecture maintains breathability while the foam material itself provides cushioning comfort, eliminating the need for impermeable plastic films that block gas transmission.
Solution Approach 2:
The elastomeric coating is applied locally on the surface of the open-cell foam rather than using a complete impermeable barrier. This localized application allows the underlying foam to maintain its breathability while the elastomeric layer provides enhanced comfort and pressure distribution at the contact surface.
3Strength
If plastic film covers the gel layer to prevent sticking, then structural strength is improved, but gas flow paths are constricted when compressed
Solution Approach 1:
The open-cell foam provides structural integrity through its three-dimensional cellular network while maintaining open pathways for gas flow. The interconnected cells create a robust yet breathable structure that does not constrict gas paths even when compressed, as the porous architecture allows deformation while preserving flow channels.
Solution Approach 2:
The patent removes the plastic film component entirely, relying on the open-cell foam structure and elastomeric coating to provide both strength and breathability. By extracting the impermeable film, the design eliminates the gas flow constriction problem while maintaining necessary structural support through the foam's inherent cellular framework.
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 enables effective gas flow through the cushioning material, alleviating discomfort by allowing gases to escape, maintaining breathability and comfort while providing enhanced cushioning and thermal management properties.
Implementation Method 1
The porous foam is configured to allow gases to pass through at least a portion thereof
Data Source
AI summary
Cushioning elements include a porous foam comprising a series of interconnected cell walls and an elastomeric material formed over at least a portion of the interconnected cell walls. The porous foam is configured to allow gases to pass through at least a portion thereof. Methods of forming cushioning elements may include coating interconnected cell walls of a breathable porous foam with a liquid comprising an elastomeric material, solidifying at least a portion of the elastomeric material, and providing a gas path through the elastomeric material. Other methods include pressing sheets of foam together at a pinch point, disposing a liquid between the foam over the pinch point, coating the foam with the liquid, and separating the sheets beyond the pinch point. Some methods include consolidating a plurality of portions of porous foam into a continuous cushioning material.