PCM Layered Memory Foam Cushion for Extended Cooling
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Solution Overview
Problem
Memory foam body support cushions tend to 'sleep hot' due to reduced airflow, leading to discomfort, as they conform closely to the body and retain heat, with existing cooling technologies providing only temporary relief or increasing costs and complexity.
Innovation Solution
A multi-layer foam cushion with phase change material (PCM) integrated into both the outer cover and the foam layers, combining non-reticulated and reticulated viscoelastic foams to enhance airflow and heat dissipation, while the PCM provides an extended cool dermal sensation by absorbing and storing heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If memory foam is used to provide body support and conformity, then body support effectiveness is improved, but heat retention increases causing the cushion to sleep hot
Solution Approach 1:
The patent combines memory foam with phase change material (PCM) in a composite structure. The PCM layers are integrated between the memory foam layers, creating a multi-layer composite cushion that maintains the body-conforming properties of memory foam while adding thermal regulation capabilities through PCM's phase change characteristics.
Solution Approach 2:
The patent utilizes phase change material (PCM) that undergoes phase transitions (solid-liquid-solid) at body temperature. The PCM absorbs excess body heat during phase change from solid to liquid, and releases heat when transitioning back to solid, thereby regulating temperature and preventing heat buildup while the cushion conforms to the body.
2Temperature
If existing cooling technologies like single-layer PCM are used, then temporary cooling sensation is provided, but cooling duration is limited to 15-30 seconds
Solution Approach 1:
The patent divides the cooling function into multiple separate PCM layers distributed throughout the cushion structure. Instead of relying on a single PCM layer, the cushion contains multiple PCM layers at different positions, each contributing to the overall cooling effect and extending the total cooling duration to 2-4 hours.
Solution Approach 2:
The PCM layers are pre-positioned within the cushion structure during manufacturing, strategically located to contact body areas that generate the most heat. This preliminary placement ensures immediate cooling effect upon contact and sustained cooling throughout the sleeping period.
3Temperature
If gel or single-layer PCM is used for cooling, then momentary dermal coolness is achieved, but heat absorption capacity is limited and saturation occurs quickly
Solution Approach 1:
The patent transitions from a single-layer PCM approach to a multi-layer PCM architecture distributed throughout the cushion's thickness. This dimensional distribution increases the total volume of PCM available for heat absorption, thereby expanding the heat absorption capacity and preventing premature saturation.
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 effectively maintains a cooler surface for extended periods, reducing heat retention and enhancing user comfort by distributing heat away from the contact surface, providing up to 120 minutes of cool sensation compared to 15-30 seconds with existing technologies.
Implementation Method 1
Portions of the outer cover and the foam cushion comprise 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
combining non-reticulated and reticulated viscoelastic foams to enhance airflow and heat dissipation
Implementation Method 4
Body support cushions made from temperature-sensitive viscoelastic material, such as TEMPUR® material that is commercially available from Tempur-Pedic International Inc.
Implementation Method 5
This conformance of the cushion to the body, in effect, causes more of the body to be in contact with the body support cushion
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.