DESC:TECHNICAL FIELD
[001] The embodiments herein generally relate to mattress assembly. More particularly but not exclusively, to a thermally conducive mattress assembly having heat transfer properties which includes thermally-conductive solids particles added to a memory foam layer/sheet to dissipate heat from the mattress assembly.
BACKGROUND
[002] Conventionally, the mattress consists of layers of foam in combination with fabrics and springs. Foam mattresses such as polyurethane foam, latex foam, and the like, are generally known in the art. But, the foam mattresses (due to higher density) have poor heat transfer abilities. Thus, when a person lies down, the contact surface of the mattress accumulates heat. To address user comfort, these mattresses are often fabricated with multiple foam layers having varying properties such as density and hardness, among others, to suit the needs of the intended user. Currently, manufacturers of these mattresses have employed memory foam, (commonly referred to as viscoelastic foams), which are generally a combination of polyurethane and one or more additives that increase foam density and viscosity, thereby increasing its viscoelasticity. The memory foam conforms to the shape of a user when the user exerts pressure onto the foam, and then returns to its original shape when the user and associated pressure are removed. Unfortunately, the high density of foams used in current mattress assemblies prevents proper ventilation.
[003] Heat transfer consists of combination of conduction, convection and radiation. In the conventional mattress the heat transfer by radiation is very limited in comparison with conduction and convection. Heat transfer by conduction and convection are the primary paths of dissipating heat in the existing mattress. Heat is conducted from a person’s body, through the compressed foam and transferred to the areas where the foam is not compressed. Due to the very low thermal conductivity of foam, the transfer of heat is very slow to the uncompressed areas and the heat gets accumulated at the compressed area which is in contact with the person’s body. As the mattress is unable to dissipate the heat generated through natural conduction and convection it results in uncomfortable sleeping.
[004] Therefore, there exists a need for a mattress having thermally conductive foam layer that eliminates the aforementioned drawbacks.
OBJECTS
[005] The principal object of an embodiment herein is to provide a mattress assembly having at least one thermally conductive foam layer to dissipate heat from the mattress assembly.
[006] Another object of an embodiment herein is to provide a mattress assembly having heat transfer properties which includes thermally-conductive solids particles added/infused to a memory foam layer.
[007] Yet another object of an embodiment herein is to provide a method of producing at least one thermally conductive foam layer for dissipating heat from the mattress assembly.
[008] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF DRAWINGS
[009] This invention is illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0010] FIG. 1a depicts a perspective sectional view of a thermally conducive mattress, according to an embodiment as disclosed herein;
[0011] FIG. 1b depicts the side view of a thermally conducive mattress including a person reclining on it, according to an embodiment as disclosed herein; and
[0012] Fig. 2 depicts a flowchart for a method of producing at least one thermally conductive foam layer for dissipating heat from a thermally conducive mattress.
DETAILED DESCRIPTION
[0013] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0014] The embodiments herein achieve a mattress assembly having at least one thermally conductive foam layer to dissipate heat from the mattress assembly. Further, the embodiments herein achieve a mattress assembly having heat transfer properties which includes thermally-conductive solids particles added/infused to a memory foam layer. Referring now to the drawings, and more particularly to FIGS. 1a through 2, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[0015] FIG. 1a depicts a perspective sectional view of a thermally conducive mattress, according to an embodiment as disclosed herein. In an embodiment, the thermally conducive mattress assembly 100 (also referred as mattress assembly) includes at least one fabric layer 102, at least one thermally conductive foam layer 104,at least one foam layer 106, at least one cotton felt layer 108, at least one layer having plurality of springs 110, and at least one panel 112.
[0016] In an embodiment, the at least one thermally conductive foam layer is selected from the group consisting of an open-celled polyurethane foam, partially open-celled polyurethane foam, open-celled polyester polyurethane foam, partially open-celled polyester polyurethane foam, and combinations thereof.
[0017] In an embodiment, the at least one thermally conductive foam layer 104 includes thermally conductive solid particles infused into at least one memory foam layer. In an embodiment, the thermally-conductive solids particles are selected from a group consisting of graphite, powder graphite, graphene sheets, graphene, synthetic graphite, graphite-based particulates, and combinations thereof.
[0018] In an embodiment, the layer of thermally conductive solid particles infused to the memory foam, is configured to spread the heat generated in the thermally conductive mattress 100 in at least two directions (i.e. laterally spreads out in the X and Y directions) (not shown). In an embodiment, the thermally conductive solid particles are dispersed in the memory foam such that there will be more surface area from which heat may be transferred to air or ambient environment.
[0019] FIG. 1b depicts the side view of a thermally conducive mattress including a person reclining on it, according to an embodiment as disclosed herein. In an embodiment, the thermally conductive mattress 100 includes the at least one base layer disposed below the at least one thermally conductive foam layer 104. In an embodiment, the at least one base layer (not shown) disclosed herein include the at least one fabric layer 102, the at least one foam layer 106, the at least one cotton felt layer 108, the at least one layer having plurality of springs 110, the at least one panel 112 and combination thereof. In an embodiment, the at least one fabric layer may be disposed above the at least one thermally conductive foam layer 104. In an embodiment the at least one foam layer 106 may be disposed below the at least one thermally conductive foam layer 104. In an embodiment, the at least one cotton felt layer 108 may be disposed below the at least one foam layer 106. In an embodiment, the at least one layer having plurality of springs 110 is disposed below the at least one cotton felt layer 108. In an embodiment, the at least one panel 112 is located below the at least one layer having plurality of springs 110. In an embodiment, the at least one panel 112 forms a bottom layer of the thermally conductive mattress assembly 100.
[0020] For the purpose of this description and ease of understanding, the thermally conductive foam layer and the base layer is explained herein below with reference to be provided in a thermally conductive mattress. However, it is also within the scope of the invention to implement/practice the construction of the thermally conductive mattress assembly in any form and/or add or omit few foam layers without otherwise deterring the intended function of the thermally conductive mattress as can be deduced from the description and corresponding drawings.
[0021] Fig. 2 depicts a flowchart for a method of producing at least one thermally conductive foam layer for dissipating heat from a thermally conducive mattress. In an embodiment, the method 200 includes, at step 202, adding thermally conductive solid particles with at least one polyol. At step 204, the method includes mixing the thermally conductive solid particles with the at least one polyol to get a uniform mixture. At step 206, the method includes adding at least one catalytic, at least one isocyanate group and at least one surfactant with the uniform mixture of the thermally conductive solid particles and the at least one polyol to produce at least one thermally conductive foam layer 104.
[0022] In an embodiment, the at least one catalytic includes stannous Octoate Catalyst, the at least one isocyanate group includes Toluene Diisocyanate and the at least one surfactant includes at least one of water, silicone surfactant.
[0023] In an embodiment, the method 200 includes, the thermal conductive solid particulates being added to the at least one polyol (not shown). In an embodiment, the thermal conductive solid particulates and the at least one polyol is mixed well in a high-speed mixing vessel (not shown). Further, the at least one polyol and thermal conductive solid particulates is mixed with the at least one isocyanate (i.e. Toluene Diisocyanate (TDI)) along with the at least one surfactant (i.e. water, silicone surfactant) and the at least one catalyst (i.e. stannous Octoate Catalyst) in the high-speed mixing vessel. In an embodiment, the speed of mixing is approximately 1500 rpm. However, the speed of mixing may vary in accordance to the desired mixing required. This ensures uniform distribution of particles in the high-speed mixing vessel. Thus, a chemical reaction occurs (i.e. foaming) resulting in generation of the thermally conductive foam layer 104.In an embodiment, the mixture is spread on a moving conveyor or into a mold, and the thermally conductive foam is produced which incorporates, thermally conductive solid particles (i.e. graphite flakes particulates) in the foam matrix.
[0024] In an embodiment, the at least one thermally conductive foam layer 104 includes the of thermally conductive solid particles ranging between 5-10 grams per100 grams of the at least one thermally conductive foam layer 104. In an embodiment, the thermally conductive foam consists of graphite in the range between 5-15 %. In an embodiment, the at least one thermally conductive foam layer 104includes a density ranging from 60 kg/m3 to 70 kg/m3. In an embodiment, the thermally conductive solid particles includes an average particle size ranging from 1 to 1000 microns.
[0025] The thermally conductive solid particles used in the compositions herein is selected from a group consisting of the following, non-limiting, functional materials such as natural flake graphite, powder graphite, graphite sheets, synthetic graphite, graphite-based particulates, and combinations thereof. In an embodiment, the at least one thermally conductive foam layer 104 comprises a structure selected from the group consisting of a solid sheet, perforated sheet, non-planar sheet, planar sheet, textured sheet, and combinations thereof.
[0026] In one embodiment, one or more thermal conductive foam layer 104 may be added within or on the surface or added in any location for making molded products such as, but not limited to, medical cushioning foams, mattresses, pillows, bedding products, mattress pillow toppers, quilted mattress toppers, mattress topper pads, indoor cushioning foams, outdoor cushioning foams, outdoor bedding pads, outdoor pillows, and combinations thereof.
[0027] In an embodiment, the introduction of the thermally conductive solid particles in the thermally conductive foam increases the heat dissipation by 50%. In an embodiment, the thermally conducive mattress100 with enhanced thermal conductivity will lower the surface temperature of the mattress in contact with the person’s body.
[0028] In an embodiment, the compositions of the thermally conductive mattress assembly may include Visco Elastic Poly ether Polyol ranging from 80 kg-120 kg, Graphite Flakes ranging from 5 kg – 15 kg, TDI (Toluene Diisocyanate) ranging from 28 kg – 38 kg, Silicone Surfactant ranging from 0.5 kg – 2 kg, and Stannous Octoate Catalyst ranging from 0.1 kg – 0.25kg.
[0029] For the purpose of this description and ease of understanding, the composition of the thermally conductive foam layer is explained herein below with reference to be provided in a thermally conductive mattress. However, it is also within the scope of the invention to practice the composition of the thermally conductive mattress assembly in any form and/or add or omit certain composition without otherwise deterring the intended function of the thermally conductive mattress as can be deduced from the description and corresponding drawings.
[0030] In an embodiment, the compositions of the thermally conductive mattress assembly for example may include Visco Elastic Poly ether Polyol-100.00 Kg, Graphite Flakes -10.00 kg, TDI (Toluene Diisocyanate) -33.25 kg, Silicone Surfactant -1.00 kg, and Stannous Octoate Catalyst -0.15 kg.
[0031] In an embodiment, a method of assembling the thermally conductive mattress assembly includes steps of, providing at least one thermally conductive foam layer 104 and placing the at least one thermally conductive foam layer 104 above at least one base layer. In an embodiment, the at least one thermally conductive foam layer104 is configured to spreads heat generated in the mattress in at least two directions (i.e. X direction and Y direction).
[0032] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
,CLAIMS:STATEMENT OF CLAIMS
I/We claim,
1. A thermally conducive mattress assembly 100, comprising:
at least one thermally conductive foam layer 104, wherein the at least one thermally conductive foam layer104 includes thermally conductive solid particles infused into at least one memory foam layer; and
at least one base layer disposed below the at least one thermally conductive foam layer 104,
wherein
the thermally-conductive solids particles are selected from a group consisting of graphite, powder graphite, graphene sheets, graphene, synthetic graphite, graphite-based particulates, and combinations thereof;
the at least one thermally conductive foam layer 104is configured to spreads heat generated in the mattress assembly 100 in at least two directions (i.e. X direction and Y direction).
2. The mattress assembly100 as claimed in claim 1, wherein the at least one thermally conductive foam layer104 is produced by a process comprising polymerizing at least one polyol with at least one isocyanate group.
3. The mattress assembly100 as claimed in claim 2, wherein the at least one polyol is a visco elastic polyether polyol and the at least one isocyanate group includes Toluene Diisocyanate.
4.The mattress assembly100 as claimed in claim 1, wherein the at least one thermally conductive foam layer 104 includes a density ranging from 60 kg/m3 to 70 kg/m3.
5. The mattress assembly100 as claimed in claim 1, wherein the at least one thermally conductive foam layer 104 includes the of thermally conductive solid particles ranging between 5-10 grams per100 grams of the at least one thermally conductive foam layer 104.
6. The mattress assembly100 as claimed in claim 1, wherein the thermally conductive solid particles includes an average particle size ranging from 1 to 1000 microns.
7. The mattress assembly100 as claimed in claim 1,wherein the at least one thermally conductive foam layer 104 comprises a structure selected from the group consisting of a solid sheet, perforated sheet, non-planar sheet, planar sheet, textured sheet, and combinations thereof.
8. The mattress assembly 100 as claimed in claim 1, wherein the at least one base layer is selected from a group consisting of at least one fabric layer 102, at least one foam layer106, at least one cotton felt layer 108, at least one layer having plurality of springs 110, at least one panel 112 and combination thereof.
9. A method 200 of producing at least one thermally conductive foam layer 104 for dissipating heat from a thermally conducive mattress assembly, the method 200 comprising steps of:
adding thermally conductive solid particles with at least one polyol;
mixing the thermally conductive solid particles with the at least one polyol to get a uniform mixture; and
adding at least one catalytic, at least one isocyanate group and at least one surfactant with the uniform mixture of the thermally conductive solid particles and the at least one polyol to produce at least one thermally conductive foam layer 104.
10. The method as claimed in claim 9, wherein assembling the mattress assembly includes steps of:
providing at least one thermally conductive foam layer 104; and
placing the at least one thermally conductive foam layer 104 above at least one base layer,
wherein
the at least one thermally conductive foam layer104 is configured to spreads heat generated in the mattress in at least two directions (i.e. X direction and Y direction).
11. The method as claimed in claim 9, wherein
the at least one catalytic includes stannous Octoate Catalyst,
the at least one isocyanate group includes toluene diisocyanate; and
the at least one surfactant includes at least one of water, silicone surfactant.