Washable Layered Cushion With Porous Foam and Void-Cell Support
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Solution Overview
Problem
Conventional cushions, particularly in camping, military, and hospital applications, are difficult to clean, retain fluids, and cause pressure points due to increasing resistance to deflection, leading to discomfort and potential fire hazards.
Innovation Solution
A layered cushion system comprising a porous foam layer, a separation layer, and a layer of void cells, designed for easy disassembly and cleaning, with a cover that allows fluid permeability and includes a structure layer for support, reducing pressure points and enhancing comfort while being fire-resistant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional cushions use coupled cells or springs to provide support, then structural support is improved, but cleaning difficulty increases and fluid retention occurs
Solution Approach 1:
The cushion is divided into multiple removable layers including a cover layer, comfort layer, support layer, and base layer. Each layer can be independently removed and cleaned, eliminating the cleaning difficulties associated with integrated coupled cell or spring structures. The segmentation allows fluid to drain through each layer separately rather than being trapped in interconnected cells.
2Strength
If conventional cushions use coupled cells or springs, then support structure is improved, but pressure points on user body increase
Solution Approach 1:
The comfort layer contains localized gel inserts positioned at specific body contact points (shoulders, hips, knees) to distribute pressure evenly. The support layer uses independently adjustable springs that can be individually tuned to provide uniform support without creating concentrated pressure points. This local customization of support characteristics eliminates the pressure point problem while maintaining structural support.
3Ease of operation
If conventional foam mattresses are used, then comfort is provided, but thermosetting and discomfort occur
Solution Approach 1:
The cushion uses a composite structure combining foam material with gel inserts and adjustable spring elements. The gel inserts remain stable at body temperature while providing pressure distribution. The adjustable springs provide mechanical support that does not undergo thermosetting. This composite approach eliminates the thermosetting discomfort problem while maintaining comfort through multiple material properties.
4Weight of moving object
If conventional mattresses are designed for portability, then transportability is improved, but comfort is reduced
Solution Approach 1:
The mattress is segmented into multiple lightweight layers that can be easily separated for transport. Each layer is individually compressible and can be rolled or folded independently. The adjustable components (springs, gel inserts) are designed to be removable or collapsible, reducing the overall volume and weight during transport while maintaining full comfort functionality when assembled.
5Strength
If conventional cushions retain fluids, then cushioning effect is improved, but cleaning difficulty and contamination increase
Solution Approach 1:
The cushion layers are constructed from porous materials with controlled permeability that allow fluid to pass through rather than be retained. The porous structure provides cushioning through distributed compression while enabling complete drainage of fluids and particles. This eliminates the contamination problem while maintaining the cushioning effect through the porous matrix structure.
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 layered cushion system provides easy cleaning, reduces pressure points, and enhances comfort by allowing fluid transmission, while being durable and resistant to compression set and fire, making it suitable for repeated use in various environments.
Implementation Method 1
The foam layer (102) is porous and has low density that permits the easy transmission of fluids there through
Implementation Method 2
The foam layer 102 may be made of, for example, urethane, an organic (e.g., polyolefin) or an inorganic (e.g., silicone-based) polymer, rubber, or any other material that is conformable, resilient, and has a porous structure that allows fluids and particles to move freely through the foam layer 102
Data Source
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AI summary
A layered cushion (300) that may be fully disassembled for easy cleaning is disclosed herein. The sleep system is durable and fire retardant. The layered cushion (300) may include a foam layer (302), a layer of void cells (304), and a cover (308). The foam (302) permits fluids to move freely there through and contours to a users body to maximize comfort and reduce interface pressure. The reticulated foam layer (302) resists compression set and thermosetting. The layer of void cells (304) also permits fluids to move freely there through and provide additional support to the users body. The individual void cells of the void cell layer (304) are perforated to allow the transmission of fluids there through. The cover (308) couples the other layers together to form the layered cushion (300) and prevents the layers from deteriorating. The cover (308) is removable to permit cleaning each of the layers independently.