Methods for producing continuous slabstock flexible polyurethane foam including magnetite particles as a stress and pain reducing material
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Solution Overview
Problem
Current methods for producing flexible polyurethane foam do not effectively incorporate magnetite particles to alleviate mechanical pain and reduce stress, which are known benefits of magnetic fields, particularly in mattress and bedding materials.
Innovation Solution
Incorporating natural or produced magnetite particles into the polyol during the production of continuous slabstock flexible polyurethane foam or coating them onto the foam's surface using a binder to create a magnetic field that mimics the Earth's magnetic field, providing pain relief and stress reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetite particles are added to polyol during continuous slabstock flexible polyurethane foam production, then the foam gains magnetic properties for pain relief and stress reduction, but the production process complexity increases
Solution Approach 1:
The patent combines magnetite particles with polyol to create a magnetite-polyol mixture that is then incorporated into the foam production process. This merging of magnetic particles with the base polymer material allows the foam to gain therapeutic magnetic properties while maintaining production efficiency through a unified mixing and application process.
Solution Approach 2:
The polyol acts as an intermediary carrier that facilitates the incorporation of magnetite particles into the flexible polyurethane foam. By dissolving or suspending magnetite particles in polyol before mixing with other foam components, the process simplifies particle distribution and integration without requiring separate complex application equipment.
2Reliability
If magnetite particles are coated onto the foam surface using a binder, then the magnetic field effect is enhanced, but the manufacturing steps increase
Solution Approach 1:
The patent applies magnetite particles to the foam surface before the foam fully cures or while it is still in a pliable state. This preliminary action allows particles to be embedded or adhered more easily without requiring additional complex coating equipment or post-processing steps, thereby enhancing magnetic effect while maintaining manufacturing simplicity.
Solution Approach 2:
The patent creates a composite structure by combining magnetite particles with a binder material on the foam surface. This composite approach enhances the magnetic field effectiveness by concentrating magnetic particles in a adhered layer, while the binder ensures proper attachment without requiring overly complex application processes.
3Quantity of substance
If natural magnetite particles are used instead of produced particles, then the production cost decreases, but the particle consistency varies
Solution Approach 1:
The patent specifies particular parameters for natural magnetite particles including particle size range, magnetic strength, and purity level. By defining and controlling these parameters, the invention maintains particle consistency despite using natural sources, thereby achieving cost effectiveness without sacrificing manufacturing precision.
Solution Approach 2:
The patent applies different requirements to different aspects of the magnetite particles: natural sourcing for cost effectiveness, but controlled particle size distribution and magnetic properties for consistency. This local quality approach allows using inexpensive natural particles while ensuring sufficient uniformity for therapeutic effectiveness through selective parameter control.
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 resulting foam products with magnetite particles effectively reduce mechanical pain and stress, offering a new approach to pain relief in mattresses and bedding, suitable for hospital and rehabilitation use.
Implementation Method 1
the addition of produced as a suspension of magnetite particles (1) in polyol or mixture of natural magnetite particles (1) and polyol into the continuous slabstock flexible polyurethane foam (2) during production or with the addition of natural magnetite particles (1) or mixed with magnetite particles (1) or coating (4) of the magnetite particles (1) by means of a binder (3) onto the upper surface of the slabstock flexible polyurethane foam (2) after its production
Data Source
Figure 1~2
AI summary
The invention relates to polyurethane composite material that reduce waist and back pain occurring in the human body and remove stress on the human body. The invention is a composite material obtained by addition of magnetite particles (1) into the slabstock flexible polyurethane foam (2) during the production or coating application of the magnetite particles (1) onto the upper part of the continuous slabstock flexible polyurethane foam (2) after the production.