Machine-washable viscoelastic foam and devices made therefrom
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Solution Overview
Problem
Viscoelastic foam devices, such as pillows and mattresses, are difficult to wash and dry due to their water-absorbing nature, requiring manual spot cleaning and additional machine-washable covers.
Innovation Solution
A machine-washable polyurethane viscoelastic foam with low density, low thickness, high airflow, and specific ILD ratings, integrated with quilting and polyester layers to prevent detachment and facilitate drying, allowing for machine washing and drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If viscoelastic foam is used for cushioning devices, then comfort and support are improved, but washability and drying efficiency deteriorate due to water absorption
Solution Approach 1:
The patent modifies the physical and chemical parameters of polyurethane foam to achieve machine-washability. Specifically, it controls density (1-3 lb/ft³), thickness (0.5-1.5 cm), ILD rating (3-12 lbs), recovery time (3-7 seconds), and airflow properties to create foam that dries quickly while maintaining viscoelastic comfort properties
Solution Approach 2:
The invention creates a composite structure integrating viscoelastic foam with machine-washable fabrics (cotton, polyester, microfiber) through quilting and bonding layers. This composite approach allows the foam core to provide comfort while the fabric layers enable machine washing and drying
2Productivity
If viscoelastic foam density is reduced to improve washability, then drying efficiency is improved, but structural integrity and support may deteriorate
Solution Approach 1:
The patent optimizes foam density within a specific range (1-3 lb/ft³) to balance drying efficiency and structural support. This parameter control ensures the foam has sufficient porosity for quick drying while maintaining adequate density for cushioning support
Solution Approach 2:
The invention applies different density characteristics to different regions or layers of the foam structure, with the core foam providing support and the integrated fabric layers providing structural reinforcement during washing and drying cycles
3Productivity
If viscoelastic foam thickness is reduced to improve drying time, then drying efficiency is improved, but cushioning performance may deteriorate
Solution Approach 1:
The patent specifies an optimal thickness range (0.5-1.5 cm) that balances drying time and cushioning performance. This controlled thickness ensures quick drying while maintaining sufficient material volume for effective cushioning support
Solution Approach 2:
The invention compensates for reduced foam thickness by integrating multiple fabric layers and quilting structures that provide additional cushioning and structural support, allowing the thin foam core to dry quickly while the composite structure maintains comfort
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
Enables the creation of washable cushioning devices like pillows and mattress pads that can be laundered without additional protective coverings, maintaining viscoelastic properties and drying efficiently.
Implementation Method 1
Viscoelastic foam, or 'memory foam,' is produced by reaction of polyol and isocyanate compounds, which results in a polyurethane foam having viscoelastic properties
Implementation Method 2
Viscoelastic foam tends to absorb and retain water
Implementation Method 3
polyurethane foam having viscoelastic properties
Implementation Method 4
recovery time of 3-7 seconds
Data Source
AI summary
A cushioning device includes a machine-washable polyurethan viscoelastic foam and a cavity for receiving a filler.