Foam Mattress Spring Element With Airflow Recesses
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Solution Overview
Problem
Existing cushioning elements, such as mattresses, experience heat and moisture buildup due to the accumulation of these substances between the body and the cushioning material, particularly when covered with a blanket, leading to discomfort.
Innovation Solution
A spring element unit made entirely of elastic polyurethane soft foam with recesses to facilitate airflow and moisture removal, allowing for improved breathability and heat dissipation, and featuring a cohesive connection of spring elements with varying material characteristics for customizable support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal springs and foam padding are used, then structural support is provided, but heat and moisture buildup occurs between the body and cushioning element
Solution Approach 1:
The spring element is constructed from foam material with integrated recesses that create porous pathways throughout the structure. These recesses form air channels that allow heat and moisture to escape while the foam material itself provides structural support, eliminating the need for dense metal springs that trap heat and moisture.
Solution Approach 2:
The recesses extend through the spring element in the axial direction, creating three-dimensional air channels that provide multiple pathways for heat and moisture removal. This dimensional approach allows ventilation throughout the volume of the spring element rather than just at the surface.
2Strength
If metal springs are used for structural support, then mechanical strength is achieved, but magnetic radiation emission occurs affecting sensitive individuals
Solution Approach 1:
The patent replaces the traditional metal spring mechanical system with a foam-based spring element that achieves structural support through foam density and structural design rather than metallic coils. This substitution eliminates magnetic radiation emission while maintaining the necessary mechanical support function.
3Object-affected harmful factors
If foam material is used for the spring element, then breathability and heat removal are improved, but manufacturing complexity increases due to molding requirements
Solution Approach 1:
The recesses are integrated into the spring element design from the beginning of the molding process rather than being added as separate components. The mold cavity is designed to directly form the recesses during foam curing, eliminating the need for post-manufacturing operations and simplifying the overall manufacturing process.
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 effectively prevents heat and moisture buildup, providing enhanced comfort and support by allowing airflow and moisture removal, while being suitable for sensitive individuals due to the absence of metal components and offering long-term resilience and adaptability in shape and elasticity.
Implementation Method 1
The recess serves to remove heat and moisture or to allow air to flow towards the support surface
Implementation Method 2
the spring element should be formed entirely from an elastic polyurethane soft foam
Implementation Method 3
soft polyurethane foam proves to be advantageous in terms of long-term or long-term resilience
Data Source
Figure 1a~4
Figure 5a~5b
Figure 6a~6b
AI summary
The upholstery spring (10), especially for a mattress, is of a molded open-cell soft polyurethane foam. The spring is octagonal, with side surfaces (16,18) and upper/lower sides (14,15) parallel to the mattress lying surface. It has at least one central opening (12) through it between the end sides.