Stretch-Opened Comfort Layer Passages for Ventilated Mattresses
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Solution Overview
Problem
Existing comfort layers in pillows and mattresses, such as those made of polyester fibers, natural or synthetic latex, and viscoelastic polyurethane foam, lose resilience and ventilation, leading to reduced comfort and increased perspiration due to closed cell structures that inhibit air circulation and sweat evaporation.
Innovation Solution
An improved comfort layer made of natural or synthetic latex or polyurethane foam with interrupted incisions along parallel lines, allowing the layer to be stretched and opened to create air-permeable passages, enhancing ventilation and adjustability for different softness and support zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a comfort layer made of natural or synthetic latex or viscoelastic polyurethane foam is used, then softness and body conforming are improved, but ventilation and perspiration removal are worsened due to closed cell structures
Solution Approach 1:
The comfort layer is designed with a porous structure featuring interrupted incisions that extend through the entire thickness, creating passages for air circulation. These incisions are distributed in a pattern that maintains both softness and ventilation, allowing the material to conform to the body while permitting perspiration to escape.
Solution Approach 2:
The comfort layer is segmented into multiple zones with different incision patterns and densities. Some zones have higher incision density for enhanced ventilation, while others maintain more continuity for softness. This segmentation allows different regions of the pillow or mattress to serve different functional purposes.
2Object-affected harmful factors
If interrupted incisions are provided and the layer is stretched to open passages, then ventilation is improved, but structural integrity and compactness are worsened
Solution Approach 1:
The incisions are pre-formed in the comfort layer before final assembly. This preliminary action allows the passages to be created while the material is still in a controlled state, ensuring that the structural integrity is maintained during manufacturing and only opened when the layer is stretched into its final configuration.
Solution Approach 2:
The comfort layer transitions from a compact state during storage and transport to an expanded state during use. The incisions remain closed or partially closed in the compact state, maintaining structural integrity, but open fully when the layer is stretched around the core, providing ventilation during actual use.
3Ease of operation
If the comfort layer is made softer to improve comfort, then ease of operation is improved, but durability and support are worsened
Solution Approach 1:
Different regions of the comfort layer have different properties. Zones requiring softness have higher incision density or larger incisions, while zones requiring support and durability have lower incision density. This local differentiation allows the overall product to provide both comfort and durability in appropriate locations.
Solution Approach 2:
The comfort layer combines multiple materials or layers with different properties. A softer outer layer with incisions provides comfort and ventilation, while a more durable inner layer or core provides structural support. This composite structure allows both softness and durability to coexist in different parts of the same product.
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 provides a highly air-permeable comfort layer that maintains softness and resilience, reduces material waste, and allows for customizable comfort zones, improving user comfort and reducing perspiration, while being economically viable and easy to produce.
Implementation Method 1
The most recent known comfort layer is made of viscoelastic polyurethane foam. This type of soft foam is subject to influences of temperature and behaves like a sort of thermoplastic, such that this comfort layer becomes softer as a result of the body temperature and so to say 'rolls' itself around the body or the head.
Implementation Method 2
in that said layer forms at least a part of a jacket around the core that is stretched in a lateral direction which is mainly transverse to the direction of the above-mentioned lines in order to open the incisions so as to form passages through the comfort layer
Data Source
Figure 1
Figure 2~3
AI summary
Improved pillow, mattress and the like with a comfort Layer (5) which is provided around the core (2) of the pillow or the like and which is made of natural or synthetic latex, polyurethane foam or another elastic material, characterised in that this comfort layer (S) is provided with interrupted incisions (6) through the layer (6), along mainly parallel lines (I), and in that said layer (5) forms at least a part of a jacket around the core (2) that is stretched in a lateral direction (P) which is mainly transverse to the direction of the above-mentioned lines (7) in order to open the incisions (6) so as to form passages (8) through the comfort layer (5).