Stretchable Composite Mattress Protector for Memory Foam Conformity
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Solution Overview
Problem
Traditional mattress protectors are non-stretch and stiff, which can hinder the deformation of modern mattresses like memory foam or air bladders, leading to discomfort due to increased pressure on the body.
Innovation Solution
A composite sheet with a fabric and a water-impermeable polymer that can stretch up to 115% of its original length without rupture or permanent wrinkling, allowing for better conformity to the body shape while maintaining protection from fluids and allergens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-stretch or low-stretch mattress protector is used, then the mattress protector provides adequate protection for traditional firm spring mattresses, but it hinders or prevents the mattress from fully deforming and conforming to the shape of the body, thus creating higher pressure and discomfort
Solution Approach 1:
The patent changes the physical parameters of the mattress protector by incorporating elastic fibers (such as spandex or elastane) into the fabric composition, enabling the material to stretch and recover. This allows the protector to dynamically adapt its dimensions while maintaining protective functions, resolving the contradiction between protection reliability and mattress deformability.
Solution Approach 2:
The patent uses composite materials combining traditional protective layers (polyurethane coating or laminate) with elastic fabric components. This composite structure integrates the protective properties of polyurethane with the stretchability of elastic fibers, allowing the mattress protector to both protect the mattress and accommodate its deformation during use.
2Object-affected harmful factors
If a thermoplastic polyurethane layer is used in the mattress protector, then liquid penetration is prevented, but the layer becomes relatively stiff and resistant to stretching
Solution Approach 1:
The patent applies local quality by differentiating the functional properties of different layers: the polyurethane coating or laminate provides local liquid barrier protection where needed, while the elastic fabric portions provide local stretchability. This spatial differentiation of properties allows the overall structure to achieve both liquid prevention and flexibility.
Solution Approach 2:
The patent creates a composite material system where the polyurethane layer is integrated with elastic fabric. The polyurethane provides liquid impermeability while the elastic fabric matrix provides stretchability, allowing the composite to exhibit both liquid barrier properties and mechanical flexibility simultaneously.
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 stretchable mattress protector enhances comfort by allowing the mattress to conform to the body without hindrance, reducing pressure and providing effective protection against liquids and allergens.
Implementation Method 1
a water impermeable polymer carried by the fabric
Implementation Method 2
The composite sheet is capable of repeatedly stretching to a deformed length of at least 115% of the non-deformed length and returning to within 8% of the non-deformed length without rupture or permanent wrinkling
Data Source
AI summary
A mattress protector includes a composite sheet having a non-deformed length and a non-deformed width. The composite sheet includes a fabric and a water impermeable polymer. The composite sheet is capable of repeatedly stretching to a deformed length of at least 115% of the non-deformed length and returning to within 8% of the non-deformed length without rupture or permanent wrinkling of the composite sheet. Mattresses may be covered and protected by such a mattress protector. Methods of forming mattress protectors include providing a water impermeable polymer on a fabric so as to form a composite sheet having a non-deformed length and a non-deformed width, and formulating and configuring the composite sheet so as to be capable of repeatedly stretching to a deformed length of at least 115% of the non-deformed length and returning to within 8% of the non-deformed length without rupture or permanent wrinkling of the composite sheet.