Foam Mattress PCM Coating for Heat Buildup Reduction
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Solution Overview
Problem
Visco-elastic and latex foam mattresses suffer from heat concentration due to high density and low thermal conductivity, leading to discomfort during use.
Innovation Solution
Engineered foams with a surface application of micro-encapsulated phase change material (PCM) in combination with a binder are applied to the top layer of foam mattresses, enhancing thermal management by efficiently transferring heat away from the body and reducing heat accumulation at the body-mattress interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high density foam material is used to provide support and weight bearing, then support strength is improved, but thermal conductivity decreases leading to heat accumulation
Solution Approach 1:
The patent combines foam material with gel material to create a composite structure. The gel material is infused into the foam cells, creating a hybrid material that maintains the support properties of foam while adding the thermal management capabilities of gel. This composite approach resolves the contradiction by integrating two materials with complementary properties rather than relying on foam alone.
Solution Approach 2:
The gel material is selectively placed within the foam structure, specifically filling the interstitial spaces and cells of the foam. This localized placement allows different regions of the mattress to have different properties: the foam provides structural support while the gel-filled regions provide thermal management. This local differentiation resolves the contradiction between support and thermal properties.
2Strength
If closed-cell foam structure is used to increase compressive strength and dimensional stability, then mechanical strength is improved, but thermal conductivity remains low causing heat retention
Solution Approach 1:
The patent utilizes the porous cellular structure of the foam and fills these pores with gel material. The gel-infused foam maintains the open-cell porous structure necessary for both mechanical support and thermal management. The porous structure allows gel penetration while maintaining the foam's compressive strength and dimensional stability, resolving the contradiction between strength and heat retention.
3Temperature
If gel material is infused into foam to improve thermal management, then thermal conductivity is improved, but manufacturing complexity increases
Solution Approach 1:
The gel material is prepared in advance as a precursor solution that can be easily applied to the foam structure. The foam is first manufactured with its cellular structure, then the gel precursor is infused into the open cells. This preliminary preparation and sequential manufacturing approach simplifies the overall process compared to creating gel-foam composites from scratch, reducing manufacturing complexity while achieving thermal management.
Solution Approach 2:
The patent uses a gel precursor solution as an intermediary form that facilitates easier integration into the foam structure. The precursor can be applied in liquid form and then cured or transformed into the final gel state within the foam cells. This intermediary approach simplifies manufacturing by allowing separate processing of foam and gel components before their final integration.
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 surface application of PCM improves thermal transfer and reduces surface temperature, providing enhanced comfort by efficiently absorbing and releasing heat, while maintaining the support characteristics and feel of the foam.
Implementation Method 1
micro-encapsulated phase change material (PCM) in combination with a binder are applied to the top layer of foam mattresses, enhancing thermal management by efficiently transferring heat away from the body
Implementation Method 2
enhancing thermal management by efficiently transferring heat away from the body and reducing heat accumulation at the body-mattress interface
Data Source
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AI summary
The present invention is of foam mattress constructions made and engineered foams which contain additives for improved mechanical and thermal properties. In accordance with one aspect of the disclosure and inventions, there is provided engineered foam for use as a layer in a foam mattress construction having multiple layers including a top layer of foam and at least one additional layer of foam, and a coating of phase change material applied to a top surface of the top layer of foam. Surface application of phase change material to a top surface of a top layer of foam of a foam mattress provides more efficient transfer of heat away from a body on the mattress and reduced heat accumulation at the body-mattress interface.