Multi-Layer Coating Method for Extended Cooling in Support Cushions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing support cushions, particularly those made of visco-elastic foam, tend to become uncomfortably warm over an extended period, and phase change materials provide only short-term cooling.
Innovation Solution
A method of producing a cooling support cushion using a plurality of surface coatings applied to a base layer of flexible foam, allowing airflow and incorporating phase change materials to enhance the cooling effect, with each coating layer allowing air flow and increasing thermal mass for extended cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If phase change materials are used to provide cooling effect, then cooling effect is improved, but duration of cooling action is limited to short span
Solution Approach 1:
The cooling system is segmented into multiple functional layers: a base layer of flexible foam and multiple surface coatings containing phase change materials. This segmentation allows different layers to contribute differently to the cooling effect, with the phase change material layers providing sustained cooling over time as they sequentially melt and absorb heat.
Solution Approach 2:
The invention uses composite material construction combining flexible foam base layer with multiple surface coatings containing phase change materials. This composite structure integrates the thermal properties of different materials to achieve extended cooling duration while maintaining comfort and breathability.
2Duration of action of moving object
If multiple surface coatings are applied to increase thermal mass, then duration of cooling action is improved, but device complexity increases
Solution Approach 1:
The cooling system is segmented into multiple functional layers: a base layer of flexible foam and multiple surface coatings containing phase change materials. This segmentation allows different layers to contribute differently to the cooling effect, with the phase change material layers providing sustained cooling over time as they sequentially melt and absorb heat.
Solution Approach 2:
The invention uses thin film coatings applied to the flexible foam base layer. These thin film coatings containing phase change materials provide extended cooling duration without significantly increasing overall structure complexity, as the coatings are applied as relatively thin layers that maintain flexibility and breathability.
3Temperature
If surface coatings are applied to provide cooling effect, then thermal effusivity is improved, but airflow through the cushion may be restricted
Solution Approach 1:
The flexible foam base layer has an open-cell porous structure that allows air to flow through it. The surface coatings are applied in a way that maintains this airflow capability, ensuring that the coatings do not completely seal the pores. This porous structure enables both thermal effusivity improvement from the phase change materials and adequate airflow for breathability.
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 method provides a significant and extended cooling effect, maintaining airflow and thermal efficiency, keeping the support surface cooler for longer periods by increasing thermal effusivity and the amount of phase change material used.
Implementation Method 1
phase change materials that absorb heat as they change from a solid to a liquid phase, i.e., melt
Implementation Method 2
phase change materials that absorb heat as they change from a solid to a liquid phase
Implementation Method 3
configured to allow air to flow through both the plurality of surface coatings and the base layer
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a method of producing a support cushion (10), comprising the steps of: providing a base layer (20) having a lower surface (22) and an upper surface (24); applying a plurality of surface coatings (32,34,36) to the upper surface (24) of the base layer (20), the plurality of surface coatings (32,34,36) configured to allow an amount of air to flow through the base layer (20) and the plurality of surface coatings (32,34,36) and further configured to provide a cooling effect.