Functionalized latex based foam
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Solution Overview
Problem
Existing latex foams for bedding and seating products face challenges in achieving efficient thermal properties without compromising the original properties such as air/moisture regulation and breathability, often requiring adjustments to the foaming process and using excessive amounts of functional additives.
Innovation Solution
The method involves impregnating the surface of latex foam with functional additives like phase change materials, fire retardants, and antimicrobial agents using a spraying technique, ensuring these additives are only present in the surface layer, reducing the total amount needed and maintaining the foam's properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If functional additives are incorporated throughout the entire foam structure, then thermal properties are improved, but the original foam properties such as breathability and uniformity are compromised
Solution Approach 1:
The patent applies functional additives only to the surface layer of the foam (top 1-5 mm) rather than throughout the entire structure. This localized application provides thermal regulation where the user contacts the foam while preserving the breathability and structural uniformity of the deeper foam layers.
Solution Approach 2:
The foam is divided into distinct zones: a surface layer (1-5 mm) containing functional additives for thermal properties, and an underlying bulk foam structure maintaining original breathability and mechanical properties. This segmentation allows each zone to fulfill its specific function independently.
2Adaptability or versatility
If functional additives are applied in large quantities, then functionality is enhanced, but cost and complexity increase
Solution Approach 1:
The patent applies functional additives only to the extent necessary for the surface layer (1-5 mm depth), using just enough material to achieve the desired thermal properties without excessive application. This partial action reduces both material cost and processing complexity while maintaining adequate functionality.
Solution Approach 2:
The patent controls the concentration and distribution parameters of functional additives by limiting their presence to specific depth ranges (1-5 mm from surface) and using controlled spraying techniques, thereby optimizing the balance between functionality and cost-effectiveness.
3Manufacturing precision
If functional additives are mixed into the foaming mixture, then uniform distribution is achieved, but the foaming process requires significant adjustments
Solution Approach 1:
The functional additives are applied to the foam surface after the foam structure is already formed, rather than being mixed into the foaming mixture beforehand. This preliminary action of forming the foam first, then adding functionality, eliminates the need for complex adjustments to the foaming process while achieving uniform surface distribution through spraying.
Solution Approach 2:
The patent separates the foam formation process from the functional additive application process. The foam is produced first using conventional methods, then the functional additives are extracted-applied separately to the surface layer, eliminating interference with the foaming chemistry and process parameters.
4Temperature
If the foam structure is modified to improve heat dissipation, then thermal comfort is enhanced, but the structural integrity and original properties are compromised
Solution Approach 1:
Thermal management functionality is localized to the surface layer (1-5 mm) where heat exchange with the user occurs, while the bulk foam structure remains unmodified to maintain its structural integrity, support properties, and breathability characteristics.
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 approach enhances the thermal and moisture regulation of latex foams while maintaining their breathability and original properties, providing improved comfort and functionality without significant adjustments to conventional foaming processes or increased costs.
Implementation Method 1
the additive is applied in the form of a solution, emulsion or dispersion and the impregnation is achieved by a spraying technique
Implementation Method 2
An example of such additive are phase change materials (PCM)
Data Source
AI summary
An integral latex foam having a first layer foam and a second and/or subsequent layer of latex foam is disclosed. The first layer foam contains an additive that is applied in the form of a solution, emulsion or dispersion. The first layer has a thickness from 0.01 to 9 mm.