Open-Cell Mattress Side Rail Assembly for Heat and Moisture Dissipation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current foam mattress assemblies, particularly those with memory foam layers, suffer from poor ventilation due to high density, leading to discomfort from heat and moisture retention, and side rail assemblies act as air dams, further reducing airflow and increasing heat and moisture within the mattress.
Innovation Solution
The implementation of a side rail assembly using open cellular polyurethane foam with a specific density and hardness range, configured to allow fluid flow, which is integrated with a viscoelastic foam layer to enhance airflow and dissipate user heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If high density memory foam is used to provide load-bearing capabilities and conformability, then user comfort through pressure point minimization is improved, but ventilation and airflow are blocked causing heat and moisture retention
Solution Approach 1:
The patent applies different foam densities and cellular structures to different regions of the mattress. The comfort layers use memory foam for pressure relief, while the core support layers and side rails use lower density foams with higher airflow characteristics. This local differentiation allows the mattress to provide both comfort and ventilation where needed.
Solution Approach 2:
The patent employs foam materials with controlled porosity and open-cell structures, particularly in the core support layers and side rail assemblies. These porous materials allow air and moisture vapor to pass through, preventing heat and moisture buildup while maintaining structural support capabilities.
2Strength
If side rail assemblies are made with traditional foam structures to provide edge support, then structural integrity is improved, but airflow is blocked acting as an air dam
Solution Approach 1:
The side rail assemblies are constructed using foam materials with open-cell structures and controlled porosity that allow air and moisture vapor to pass through. This maintains edge support structural integrity while eliminating the air dam effect of traditional solid foam side rails.
Solution Approach 2:
The side rail assemblies may incorporate composite constructions combining different foam densities and potentially other materials that provide both structural support and airflow characteristics, optimizing both strength and ventilation performance.
3Productivity
If reticulated memory foam is used to increase airflow, then ventilation is improved, but load-bearing capabilities and structural strength are reduced
Solution Approach 1:
The patent applies reticulated or highly porous foam materials specifically in regions where airflow is prioritized (core support layers and side rails), while maintaining denser memory foam in comfort layers where load-bearing and conformability are critical. This spatial differentiation resolves the contradiction between airflow and strength.
Solution Approach 2:
The mattress construction uses composite material strategies combining different foam types and densities in specific layers, allowing each material to optimize its properties for its intended function while working together as an integrated 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 solution improves user comfort by effectively dissipating heat and moisture through the mattress assembly, reducing heat retention and discomfort, while maintaining structural integrity and load-bearing capabilities.
Implementation Method 1
a layer of a polyurethane foam comprising an open cellular structure, wherein the open cellular structure comprises about 10 to about 40 cells per inch
Implementation Method 2
manufacturers have employed so called memory foam, also commonly referred to as viscoelastic foams, which are generally a combination of polyurethane and one or more additives that increase foam density and viscosity, thereby increasing its viscoelasticity
Data Source
AI summary
A side rail assembly for supporting an edge of a mattress includes a layer of a polyurethane foam comprising an open cellular structure, wherein the open cellular structure comprises about 10 to about 40 cells per inch, a hardness of about 35 pounds-force to about 100 pounds-force, and a density of about 1.2 pounds per cubic foot to about 2.0 pounds per cubic foot, wherein the layer is configured to be disposed about a perimeter of an inner core of the mattress and is configured to permit the flow of fluid from and to the inner core through the layer.