Mattress protectors, mattresses covered by mattress protectors, and related methods
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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 as they fail to conform to the shape of the sleeper.
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 while maintaining protection from liquids 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 protection from liquids and allergens, but it hinders the mattress from deforming and conforming to the body shape, creating higher pressure and discomfort
Solution Approach 1:
The patent changes the physical parameter of the mattress protector by incorporating elastomeric fibers (such as spandex) into the fabric composition, transforming it from a rigid, non-stretch material to an elastic, stretchable material that can deform with the mattress while maintaining its protective barrier properties against liquids and allergens
Solution Approach 2:
The patent uses a composite fabric structure combining traditional protective fibers with elastomeric fibers, creating a material that integrates both protective functionality and elastic deformability, allowing the mattress protector to simultaneously protect against contaminants and conform to body shape
2Reliability
If a stiff thermoplastic polyurethane layer is used in the mattress protector, then liquid penetration is prevented, but the mattress protector becomes relatively inelastic and non-stretchable
Solution Approach 1:
The patent creates a composite material system where a stretchable fabric coated with or laminated to thermoplastic polyurethane combines the liquid barrier properties of the polymer with the elastic properties of the fabric, achieving both liquid impermeability and stretchability simultaneously
Solution Approach 2:
The patent modifies the physical parameters of the mattress protector by selecting fabrics with high elastomeric fiber content (at least 10% by weight, preferably at least 20%), fundamentally changing the material from rigid to elastic while maintaining the protective polymer coating
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 fluids and allergens.
Implementation Method 1
The layer of thermoplastic polyurethane prevents liquid from penetrating into the mattress
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
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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.