Infection control bedding products and methods of manufacture thereof

Solution Overview

Problem

Existing hermetically sealed infection control bedding products, such as pillows and mattresses, face challenges with inadequate airflow and bond strength between layers, particularly when using less expensive materials like polyester-backed polyurethane coated textiles, leading to potential cross-infection risks and discomfort due to slow air evacuation and surface tension issues.

Innovation Solution

The introduction of an adhesive micro-dotting layer provides a high airflow strengthening layer that enhances bond strength between the filter medium and outer cover, using a filter membrane with optimal pore sizes for air filtration and microbial removal, and a polyurethane gasket to ensure a strong and breathable seal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If less expensive materials like polyester-backed polyurethane coated textiles are used for the outer cover, then cost is reduced, but bond strength between layers deteriorates

Engineering Contradiction:

Improvebond strengthVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

An adhesive layer is introduced as an intermediary between the polyester-backed polyurethane coated textile and the filter medium layers. This adhesive layer enables adequate bonding between the layers when using the less expensive polyester material, resolving the contradiction between cost reduction and bond strength maintenance.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The outer cover uses a composite structure of polyester fabric backed with polyurethane coating, combining the mechanical strength of polyester with the waterproofing properties of polyurethane. This composite material approach allows cost-effective material selection while maintaining necessary performance characteristics when combined with the adhesive layer.

Inventive Principle:

Principle #40Composite materials

2Productivity

If conventional vapour permeable fabrics are used, then waterproofing is provided, but airflow rate deteriorates

Engineering Contradiction:

Improveairflow rateVSAvoidwaterproofing

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The filter medium incorporates a polyurethane foam layer with controlled porosity that allows high airflow rates while maintaining waterproofing through the polyurethane coating. The porous structure enables air molecules to pass through at sufficient rates for ventilation while the hydrophobic polyurethane coating prevents liquid penetration.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The fabric structure is designed with specific pore size distribution and coating density in different regions to optimize both airflow and waterproofing. The polyurethane coating is applied with controlled thickness and pore structure to allow vapour permeability while blocking liquid water, creating local quality variations that satisfy both requirements.

Inventive Principle:

Principle #3Local quality

3Reliability

If filter medium layers are bonded without adhesive, then manufacturing complexity is reduced, but bond strength deteriorates

Engineering Contradiction:

Improvebond strengthVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

An adhesive layer is introduced as an intermediary between the polyester-backed polyurethane coated textile and the filter medium layers. This adhesive layer enables adequate bonding between the layers when using the less expensive polyester material, resolving the contradiction between cost reduction and bond strength maintenance.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of operation

If slow air evacuation is tolerated, then manufacturing simplicity is maintained, but patient comfort deteriorates

Engineering Contradiction:

Improvepatient comfortVSAvoidventilation design

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The filter medium incorporates a polyurethane foam layer with controlled porosity that allows high airflow rates while maintaining waterproofing through the polyurethane coating. The porous structure enables air molecules to pass through at sufficient rates for ventilation while the hydrophobic polyurethane coating prevents liquid penetration.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The filter medium is pre-designed with optimized pore structure and thickness to ensure sufficient airflow capacity before assembly. The polyurethane foam is selected with specific density and cell structure characteristics that guarantee the required airflow rates, eliminating the need for additional active ventilation mechanisms.

Inventive Principle:

Principle #10Preliminary action

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

This solution significantly improves airflow and bond strength, reducing the risk of cross-infection and patient discomfort by ensuring effective ventilation and robust seam integrity, especially in larger volume devices like mattresses, while maintaining impermeability to liquids.

Implementation Method 1

adhesive applied in the form of a plurality of glue dots placed on the surface of the strengthening layer which is facing the filter membrane

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

a filter membrane for the removal of particles of microbial size

Methodology Applied

Scientific EffectPhysical filtration: Filter (physical)

Implementation Method 3

the thermoplastic (polyurethane) coating provides waterproofing

Methodology Applied

Scientific EffectHydrophobic barrier: Hydrophobe

Implementation Method 4

a thermoplastic coating, typically polyurethane, applied

Methodology Applied

Scientific EffectThermoplastic coating: Coatings

Data Source

PatentUS20210186227A1Infection control bedding products and methods of manufacture thereof

Publication Date: 2021.06.24 PNEUMA PURE I P

AI summary

An infection control bedding product such as a pillow, duvet, mattress, cushion or such like having a sealed cover, a resiliently deformable filling material, and a vent means in the cover, the vent means including a filter medium including a filter membrane for the removal of particles of microbial size, a strengthening layer of material for providing mechanical strength to the filter medium, and an adhesive layer, wherein the filter medium allows air flow therethrough but is substantially impermeable to liquid while maintaining a barrier to particles of microbial size; optionally, wherein the adhesive layer is formed from a plurality of dots of adhesive applied to the strengthening layer.