Multi-Layer Phase Change Material Cushion for Extended Cooling
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Solution Overview
Problem
Memory foam body support cushions tend to 'sleep hot' due to limited cooling technologies, which are either short-lived, costly, or negatively impact the cushion's feel and functionality, failing to provide sustained comfort for users.
Innovation Solution
A multi-layer foam cushion with phase change material (PCM) integrated into both the outer cover and the foam layers, combining viscoelastic and high resilience foams, along with reticulated structures, to enhance airflow and heat management, providing an extended cool dermal sensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If memory foam is used to provide body support and contouring, then body support effectiveness is improved, but the cushion sleeps hot due to heat retention
Solution Approach 1:
The patent combines memory foam with phase change material (PCM) in a multi-layer construction. The PCM layers are integrated between and within the memory foam layers, creating a composite structure that maintains the contouring and support properties of memory foam while adding thermal regulation capabilities through the PCM's heat absorption and release properties.
2Temperature
If phase change material is added to provide cooling, then cooling sensation is improved, but the cooling effect is short-lived
Solution Approach 1:
The patent divides the PCM into multiple separate layers distributed throughout the cushion structure, rather than using a single large PCM layer. This segmentation allows different PCM layers to be at different thermal states simultaneously, ensuring that as some layers become saturated, others remain capable of absorbing heat, thereby extending the overall cooling duration.
Solution Approach 2:
The patent transitions from a single-layer PCM design to a multi-layer PCM architecture distributed through the cushion's depth. This dimensional distribution creates a gradient of thermal zones, allowing the system to manage heat over an extended period by progressively engaging different PCM layers as the user's body heat penetrates deeper into the cushion.
3Temperature
If gel is used to provide cooling, then momentary coolness is improved, but the gel becomes saturated and holds heat
Solution Approach 1:
The patent replaces gel-based cooling with phase change material (PCM) in a multi-layer configuration. The PCM maintains its solid structure while undergoing phase change, providing more reliable and sustained cooling compared to gel that becomes saturated. The composite structure of multiple PCM layers ensures continuous cooling capability as each layer can be independently charged and discharged.
4Temperature
If cooling blankets with pumps are used to provide cooling, then cooling effect is improved, but device complexity and cost increase
Solution Approach 1:
The patent employs passive phase change material that automatically absorbs and releases heat based on temperature conditions, eliminating the need for active cooling systems with pumps, electricity, or control mechanisms. The PCM layers self-regulate the thermal environment through their inherent phase change properties, providing cooling without external energy input or mechanical complexity.
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 multi-layer design with PCM in both the cover and foam layers offers a prolonged cooling effect, maintaining a comfortable temperature for users by absorbing and managing heat effectively, addressing the issue of 'sleeping hot' while maintaining the supportive benefits of memory foam.
Implementation Method 1
Portions of the outer cover and the foam cushion comprise phase change material (PCM) to provide an extended cool dermal sensation to a user resting on the cushion
Implementation Method 2
the PCM will absorb heat from the supported body part and hold that heat until the supported body part is withdrawn
Implementation Method 3
Body support cushions made from temperature-sensitive viscoelastic material, such as TEMPUR® material
Implementation Method 4
one or more layers of the multi-layer construction may include reticulated viscoelastic foam
Data Source
AI summary
A body support cushion, e.g., mattress, has multiple foam layers, including a viscoelastic foam layer and a reticulated foam layer, and an outer cover. At least one of the foam layers and the outer cover each includes phase change material having latent heat properties that provide two intervals of dermal cooling.