Mattress Cover Mask Layer to Buffer Patterned Gel Texture Discomfort
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Solution Overview
Problem
Some individuals find the texture of patterned gel layers in mattresses uncomfortable, as they can feel the patterned gel layer when sitting or lying on the mattress, which is undesirable.
Innovation Solution
A mattress cover with a top panel and periphery that includes a mask layer, which can be made of compressible, resilient foam or stretchable batting, positioned over the patterned gel layer to mask, buffer, or dampen the texture of the upper surface without interfering with the compressibility of the gel layer, and can be securely attached to the outer or inner layer of the cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a stretchable fabric cover is used directly on the patterned gel layer, then the full cushioning and supportive effects of the gel layer are experienced, but the texture of the gel layer becomes uncomfortable and detectable to users
Solution Approach 1:
A mask layer is introduced as an intermediary component between the stretchable fabric cover and the patterned gel layer. This mask layer serves as a mediator that blocks the transmission of texture sensations from the gel layer to the user, while still allowing the cover to function effectively. The mask layer has sufficient thickness and material properties to dampen the gel layer texture without compromising the overall cushioning performance.
Solution Approach 2:
The mattress cover system becomes a composite structure consisting of multiple layers with different functions: the stretchable fabric cover for comfort and fit, the mask layer for texture dampening, and the patterned gel layer for cushioning and support. Each layer contributes specific properties that, when combined, resolve the contradiction between texture comfort and cushioning effectiveness.
2Object-affected harmful factors
If a mask layer is added to the mattress cover, then the texture of the gel layer is masked and buffered, but the device complexity increases
Solution Approach 1:
The mask layer is applied locally only where needed - specifically on the portions of the cover that contact the patterned gel layer and transmit texture sensations. This localized approach masks the gel layer texture without requiring complex modifications to the entire cover structure, thereby minimizing the increase in device complexity while effectively addressing the texture discomfort issue.
3Object-affected harmful factors
If the mask layer is made thick enough to buffer the texture, then texture masking is improved, but the compressibility of the upper cushioning element may be interfered with
Solution Approach 1:
The mask layer's material properties and thickness are carefully selected and optimized to achieve the right balance. The layer is made sufficiently thick to buffer and dampen the gel layer texture, but not so thick that it significantly interferes with the compressibility of the upper cushioning element. This parameter optimization allows the mask layer to perform its texture-blocking function while maintaining the overall compressive performance of the mattress system.
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 mattress cover effectively masks or buffers the texture of the patterned gel layer, providing a comfortable sleeping surface by allowing the upper cushioning element to deform without compromising its compressibility, thus enhancing user experience.
Implementation Method 1
The mask layer comprises a material that masks, buffers, or dampens a texture of the upper surface of the patterned gel layer
Implementation Method 2
The mask layer comprises a material that masks, buffers, or dampens a texture of the upper surface of the patterned gel layer
Implementation Method 3
The plurality of interconnected walls may define an array of cells. The interconnected walls and the array of cells may define a patterned gel layer
Data Source
AI summary
A mattress cover masks, buffers, or dampens the feel of the texture of the upper surface of a patterned gel layer of an upper cushioning element of a mattress. The mattress cover includes an outer surface, a mask layer, an outer periphery, and an optional bottom. A configuration of the mask layer enables it to mask, buffer, or dampen the feel of the texture of the upper surface of the patterned gel layer without interfering with a compressibility of the upper cushioning element. The mask layer may include a patterned gel layer with a different pattern than that of the patterned gel layer of the upper cushioning element of the mattress. Methods of manufacturing and installing mattress covers that mask, buffer, or dampen the feel of a patterned gel layer of an upper cushioning element of a mattress are also disclosed.