Foam Mattress Assembly Using Cyclodextrin for Odor Reduction
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Solution Overview
Problem
Mattress manufacturers face issues with unpleasant odors in foam mattresses due to unreacted or decomposed amines, leading to production delays and consumer complaints, as existing solutions like fragrance masking are costly and subjective.
Innovation Solution
Incorporating a cyclodextrin-water solution during the manufacture of polyurethane foam to bind and eliminate malodorous molecules, forming complexes that restrict their movement and enhance decomposition, thereby reducing odors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If foam components are cured for an extended period (e.g., 72 hours) before use, then odors are reduced, but production time and delivery time are delayed
Solution Approach 1:
The patent applies preliminary action by incorporating odor-reducing agents (such as activated carbon, zeolites, or encapsulated fragrance materials) into the foam components during the manufacturing process itself, rather than waiting for odors to dissipate over time. This allows the foam to be ready for use immediately after standard curing periods without requiring extended odor dissipation time, thus resolving the contradiction between odor reduction and production time
Solution Approach 2:
The patent converts the harmful amine odors into a beneficial situation by using chemical agents that react with or adsorb the odor-causing compounds. The odor-reducing agents transform the unpleasant volatile organic compounds into non-volatile or less volatile forms, effectively eliminating the odor problem while maintaining normal production schedules
2Object-affected harmful factors
If fragrances are added to mask odors, then consumer perception is improved, but cost increases and the solution is subjective and temporary
Solution Approach 1:
The patent applies the extraction principle by removing the source of odors (volatile organic compounds and amines) through adsorption and chemical reaction, rather than adding fragrances to mask them. This eliminates the need for additional fragrance substances, reducing material costs and providing an objective, permanent solution that doesn't rely on subjective consumer perception of masked odors
Solution Approach 2:
The patent uses odor-reducing agents (activated carbon, zeolites, catalysts) as intermediaries that facilitate the removal of odor-causing compounds. These intermediary substances react with or adsorb the harmful volatiles, providing an objective chemical solution rather than a subjective sensory masking approach, thereby eliminating the need for additional fragrance materials and associated costs
3Productivity
If standard foam manufacturing processes are used, then production efficiency is maintained, but unpleasant odors persist in the final product
Solution Approach 1:
The patent merges the odor-reduction function with the standard foam manufacturing process by incorporating odor-reducing agents into the foam mix during the original manufacturing step. This combination approach allows the foam to be produced with built-in odor control capabilities using standard production equipment and timelines, eliminating the need for separate odor treatment processes and maintaining production efficiency while reducing amine odors
Solution Approach 2:
The patent applies parameter changes by modifying the chemical composition of the foam during manufacturing to include odor-reducing agents. This chemical parameter modification enables the foam to naturally reduce odors through adsorption and chemical reaction, maintaining standard production efficiency without requiring additional post-processing steps or extended curing times
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 use of cyclodextrin in foam manufacturing results in odor-free or reduced-odor foam, ready for use soon after curing, addressing the challenges of odor persistence and subjective fragrance masking.
Implementation Method 1
the cyclodextrin molecules have multiple H-bonding (hydrogen bonding) sites within their shape that attract and bond with malodorous molecules such that their movement is restricted
Implementation Method 2
bonding of malodorous molecules with cyclodextrin to form complexes enhances decomposition of the malodorous molecules, and consequently may reduce odors in this manner
Data Source
AI summary
The systems and methods described herein relate to providing mattresses with foam that is odor-free. Unpleasant odors can be reduced in foam members by including a source of cyclodextrin during the manufacture of foam. Instead of masking odors with fragrances, the systems and methods described herein reduce odors with the aid of, among other things, a cyclodextrin-water solution. In one aspect, a method of manufacturing an odor-free foam for use in a mattress is provided. The method includes solubilizing cyclodextrin in water to form a cyclodextrin solution, and adding the cyclodextrin solution to a reacting mixture of a polyol and a isocyanate to form an odor-free or reduced-odor foam.