An external comfort layer for covering a ready-to-use sleeping support item
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Solution Overview
Problem
Existing sleeping support items, such as mattresses and pillows, face challenges in preventing local moist buildup, which can lead to discomfort and potentially exacerbate issues like bedsores. Current solutions, like barrier layers, either fail to effectively manage moisture or compromise sleeping comfort.
Innovation Solution
An external comfort layer comprising a porous polyester core with a porosity of at least 85% and a continuous polyester sheeting made of polyethylene terephthalate (PET) materials. This design allows for effective absorption and transport of moist away from the site of production, maintaining a dry feel and enhancing comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a barrier layer is used to prevent moist from entering the porous core, then moist management is improved, but sleeping comfort deteriorates because the barrier layer gets wet and feels uncomfortable
Solution Approach 1:
The patent applies porous materials by using a porous polyester core with at least 85% porosity that allows moist to be absorbed and transported through the material structure. The pores enable capillary action to move moist away from the surface while maintaining breathability, resolving the contradiction between moist management and comfort.
Solution Approach 2:
The patent uses composite materials by combining a porous polyester core with a continuous polyester sheeting covering. This composite structure integrates the moisture-absorbing capability of the porous core with the protective and comfortable surface properties of the sheeting, achieving both effective moist management and sleeping comfort.
2Reliability
If a barrier layer is used to prevent moist from entering the porous core, then moist management is improved, but the local tension in the top layer increases when it deforms locally
Solution Approach 1:
The porous structure of the polyester core provides flexibility and compliance when the mattress deforms locally. The pores can expand and contract with the underlying structure, preventing stress concentration and reducing local tension in the top layer while maintaining moist management functionality.
Solution Approach 2:
The composite construction of porous core plus continuous sheeting creates a layered system where the porous core absorbs deformation energy and the sheeting provides a stable surface. This division of functions reduces the tension burden on any single layer during local deformation.
3Reliability
If the porosity of the core is increased to improve moist absorption, then moist management is improved, but the mechanical integrity of the core decreases
Solution Approach 1:
The patent specifies a porosity of at least 85% for the polyester core, optimized to balance moist absorption capability with structural integrity. This high porosity enables effective capillary action for moist transport while the polyester material composition and pore structure design maintain sufficient mechanical strength for mattress application.
Solution Approach 2:
The composite structure of porous polyester core combined with continuous polyester sheeting distributes mechanical loads. The sheeting layer provides additional structural support that compensates for the high porosity of the core, maintaining overall mechanical integrity while enabling superior moist absorption.
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 external comfort layer significantly improves sleeping comfort by effectively managing moist buildup, even for heavy sweaters, and reduces the risk of bedsores. It maintains a dry feel for an extended period and has a shorter drying time compared to traditional support items.
Implementation Method 1
a porous polyester core having a porosity of at least 85% (with a practical maximum of 99%, above that porosity the mechanical integrity is typically too low to provide for a long-term durable core) and having pores that are open towards a top surface of the said core
Data Source
Figure 1~2
AI summary
The present invention pertains to an external comfort layer for covering a horizontally extending top surface of a ready-to-use sleeping support item, the external comfort layer comprising a porous polyester core (5) having a porosity of at least 85% and having pores that are open towards a top surface of the said core (5), and a continuous polyester sheeting (4) covering the top surface of the porous polyester core (5), the polyester sheeting (4) having polyester yarns that extend in the horizontal direction, and wherein both the porous polyester core (5) and the continuous polyester sheeting (4) are polyethylene terephthalate (PET) materials.