Viscoelastic Foam Mattress Structure for Cooling and Support

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Solution Overview

Problem

Current foam-based mattresses, despite advancements in viscoelastic polyurethane foams, still face challenges in providing optimal comfort and support due to heat retention and breathability issues, leading to discomfort during prolonged use.

Innovation Solution

A multi-layered mattress design featuring a viscoelastic foam top layer with gel infusion and phase change materials, an intermediate open-cell foam layer for enhanced breathability, and a bottom support layer, combined with individually pocketed spring coils for improved support and comfort, and optionally incorporating antimicrobial elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If viscoelastic polyurethane foam is used for comfort, then comfort is improved, but heat retention increases causing discomfort

Engineering Contradiction:

ImprovecomfortVSAvoidheat retention

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The mattress is divided into multiple functional layers: a comfort layer with viscoelastic foam for pressure relief, a cooling layer with phase change materials and gel infusion to manage heat, and a support layer for structural integrity. This segmentation allows each layer to perform its specific function independently, resolving the contradiction between comfort and heat retention.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Phase change materials and gel infusion act as intermediaries between the body and the viscoelastic foam. These materials absorb and dissipate heat, preventing heat buildup while allowing the viscoelastic foam to maintain its comfort properties. The intermediary layer transfers heat away from the body without compromising the comfort function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If conventional foam structure is used, then manufacturing is simple, but breathability is insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidbreathability

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The mattress incorporates porous materials including open-cell foam structures and phase change material infusions that create channels for air circulation. These porous structures maintain manufacturing simplicity while dramatically improving breathability and heat dissipation compared to conventional dense foam structures.

Inventive Principle:

Principle #31Porous materials

3Ease of operation

If multiple layers are added for improved comfort, then comfort and support are enhanced, but device complexity increases

Engineering Contradiction:

Improvecomfort and supportVSAvoidmattress structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The mattress is segmented into distinct functional layers, each with a specific purpose: comfort layer, cooling layer, and support layer. This segmentation allows for optimized performance in each area while maintaining a relatively simple overall structure that is straightforward to manufacture and assemble.

Inventive Principle:

Principle #1Segmentation

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 improved comfort and support by reducing heat retention, enhancing breathability, and increasing support through the combination of viscoelastic foam, open-cell foam, and spring coils, resulting in a more comfortable and supportive sleeping surface.

Implementation Method 1

An intermediate layer of foam having an open cell structure may be provided. The open cell structure provides for increased breathability and may facilitate the transfer of body heat through the viscoelastic foam layer.

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

The viscoelastic foam may be of a closed or open cell structure. The viscoelastic foam may be gel infused and/or contain other elements including phase change materials

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 3

The viscoelastic foam may be gel infused and/or contain other elements including phase change materials

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9339117B1Mattress with a visco elastic polyurethane foam layer

Publication Date: 2016.05.17 HICKORY SPRINGS MFG

AI summary

A foam mattress is provided having a body facing surface comprising a viscoelastic foam layer. The body facing surface further comprises a recess or cavity into which a layer including a core of springs may be provided. The foam mattress further having a layer of open cell foam beneath the viscoelastic foam layer. The open cell, or reticulated, foam layer provides increased breathability. Support for the mattress may further be provided by a bottom layer of conventional foam.