Foam Padding Thermal Band for Extended Heat Redistribution
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Solution Overview
Problem
Existing foam padding technologies fail to effectively manage thermal energy distribution, leading to overheating issues during extended use, as they either rely on inefficient thermal conductivity materials or methods that are not mechanically flexible, thus compromising comfort and durability.
Innovation Solution
A flexible band with a high thermal conductivity electrically conducting layer is strategically positioned within the foam padding to transport thermal energy from areas of high heat to areas of low heat, ensuring consistent thermal energy flow without disrupting comfort or durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If phase change material is used to absorb thermal energy, then cooling effect is achieved, but the material melts after 20-30 minutes and loses effectiveness
Solution Approach 1:
The patent introduces a copper band as an intermediary thermal conductor between the phase change material and the hollow volumes. The copper band has high thermal conductivity (401 Wm−1 K−1) compared to the phase change material (0.2-0.8 Wm−1 K−1), serving as a mediator to efficiently transport thermal energy from the melting phase change material to the hollow volumes, thereby extending the cooling duration beyond the initial 20-30 minute limitation
Solution Approach 2:
The patent utilizes the hollow volumes within the foam padding as thermal energy storage chambers. These hollow spaces act as thermal reservoirs that receive and store thermal energy transported by the copper band, effectively creating a thermal hydraulic system where heat flows from the phase change material through the copper conductor into the hollow volume network, extending the cooling effect
2Temperature
If copper band is added to transport thermal energy, then thermal conductivity is improved, but device complexity increases
Solution Approach 1:
The copper band serves multiple functions simultaneously: it acts as a structural reinforcement element within the mattress, a thermal conductor for heat transport, and a connector between the phase change material and hollow volumes. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity despite adding thermal management capability
Solution Approach 2:
The copper band is implemented as a thin, flexible element that can be integrated into the mattress structure without significantly increasing complexity. The thin-film approach allows the thermal conductor to be embedded within the existing mattress layers, maintaining flexibility and ease of manufacturing while achieving effective thermal energy transport
3Temperature
If phase change material is used, then thermal energy absorption is achieved, but flexibility is lost
Solution Approach 1:
The patent divides the thermal management system into separate functional segments: the phase change material is contained in discrete pockets or layers, the copper band is positioned as separate thermal conduits, and the hollow volumes are distributed throughout the foam structure. This segmentation allows each component to maintain its inherent flexibility characteristics while collectively providing thermal energy absorption and transport capabilities
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 reduces temperature in localized areas of the padding, maintaining comfort over extended periods by efficiently transferring thermal energy away from the user, outperforming traditional methods in both short-term and long-term thermal management.
Implementation Method 1
The flexible band with an electrically conducting layer is capable of transporting excess thermal energy from the hollow volumes in the foam padding and its surrounding material
Implementation Method 2
The phase change materials are filled with paraffin wax melting at certain predetermined temperature and thereby absorbing thermal energy
Data Source
AI summary
A foam padding (10) is disclosed. The foam padding (10) has sections (32, 34), each covering at least one hollow volume (12, 14) of the padding said padding (10) including a flexible elongated band (20) for transferring thermal energy from at least one hollow volume (12) in a first one of said sections (32) in the event of excess thermal energy towards at least one hollow volume (14) in a second section (34) in the padding (10) not containing excess thermal energy. The band (20) has a continuous electrically conducting layer (22) with a defined area extending from at least one first section (32) to another different second section (34).