Artificial intelligence customized ergonomic mattress manufacturing process and products

Abstract

A process for manufacturing an AI-powered customized ergonomic mattress includes: a consumer lying supine on a pressure-sensitive mattress to obtain unadjusted supine pressure distribution data; inputting the unadjusted supine pressure distribution data into an AI calculation model to obtain mattress support force distribution data that should be adjusted; and manufacturing an AI-powered customized ergonomic mattress based on the adjusted mattress support force distribution data. After obtaining the consumer's body pressure distribution data on the mattress, this invention uses an AI calculation model to calculate the mattress support force distribution data that achieves pressure balance in the user's sleeping posture. The factory can then produce a customized AI-powered customized ergonomic mattress based on this adjusted mattress support force distribution data, allowing consumers to achieve maximum pressure relief and balance in their sleeping posture at a lower cost. This invention can also simultaneously include pressure distribution data for supine and side sleeping, creating an AI-powered customized ergonomic mattress with both supine and side sleeping sections.

Description

Artificial intelligence customized ergonomic mattress manufacturing process and products This invention relates to an artificial intelligence customized ergonomic mattress manufacturing process and its products, particularly an artificial intelligence customized ergonomic mattress manufacturing process and its products that calculates the mattress firmness distribution using an artificial intelligence calculation model after measuring the pressure distribution data of the consumer's sleeping posture. In today's fast-paced and busy society, people often lack sufficient sleep due to work and life pressures. Therefore, people are increasingly focusing on sleep quality, hoping to achieve the best sleep results in a shorter time. Mattresses play a significant role in sleep quality, but choosing the right mattress can be very difficult for consumers. Although some manufacturers have introduced equipment to measure body pressure to determine which commercially available mattress is most suitable, the variety of mattresses on the market is limited, making it difficult to accommodate consumers of various body shapes and sleeping positions. Consequently, consumers still find it difficult to achieve the best sleep results—that is, a mattress that allows the body to achieve pressure relief and balanced sleeping posture. Furthermore, although there are mattresses on the market that use computer control to automatically adjust the air pressure in the mattress to achieve real-time matching for different body shapes and sleeping positions, they are expensive and have complex structures, resulting in lower consumer acceptance. In view of this, the inventor has devoted himself to research, design and manufacturing, with the aim of providing an artificial intelligence-based customized ergonomic mattress manufacturing process and its products that can be conveniently designed for individual consumers. This is the inventive motivation for the present invention. The main objective of this invention is to provide an artificial intelligence-customized ergonomic mattress manufacturing process and its products. After measuring the pressure distribution data of the consumer's sleeping posture, the data is input into an artificial intelligence calculation model to calculate the support force distribution required by the mattress when a pressure-reducing and balanced sleeping posture is achieved. Based on this data, the most suitable mattress for the consumer can be customized. The process of manufacturing an AI-customized ergonomic mattress according to the present invention includes: a consumer lying supine on a pressure-sensitive mattress to obtain unadjusted supine pressure distribution data; inputting the unadjusted supine pressure distribution data into an AI calculation model to obtain mattress support force distribution data that should be adjusted; and manufacturing an AI-customized ergonomic mattress based on the mattress support force distribution data that should be adjusted. The above embodiments only include measurements of supine sleeping posture. To include measurements of side sleeping posture, the embodiments may include the consumer lying supine on a pressure-sensitive mat to obtain unadjusted supine pressure distribution data; the consumer lying on their side on a pressure-sensitive mat to obtain unadjusted side pressure distribution data; inputting the unadjusted supine pressure distribution data and the unadjusted side pressure distribution data into an artificial intelligence calculation model to obtain mattress support force distribution data that should be adjusted; and manufacturing an artificial intelligence customized ergonomic mattress based on the mattress support force distribution data that should be adjusted. In accordance with the natural curves of the human body, the product of this invention includes a head area, chest area, back area, waist area, hip area, and foot area. To achieve pressure relief and balanced sleeping posture, the product of this invention needs to have different support force variations in the chest, back, waist, and hip areas. Therefore, the unadjusted supine pressure distribution data includes unadjusted supine chest pressure, unadjusted supine back pressure, unadjusted supine waist pressure, and unadjusted supine hip pressure. The unadjusted side-lying pressure distribution data includes unadjusted side-lying chest pressure, and unadjusted... Adjusting the back pressure when lying on one side, the lumbar pressure when lying on one side without adjustment, and the hip pressure when lying on one side without adjustment, the mattress support distribution data should be adjusted to include adjusting the chest support when lying on one's back, the lumbar support when lying on one's back, the hip support when lying on one's back, the hip support when lying on one's back, the side support when lying on one's back, the lumbar support when lying on one's back, and the hip support when lying on one's back. This allows the product of the present invention to be customized to provide different levels of support in the chest area, back area, lumbar area, and hip area. The artificial intelligence calculation model of this invention can, based on the unadjusted supine pressure distribution data and the unadjusted side-lying pressure distribution data, reduce the mattress support force distribution data corresponding to the higher portions of the unadjusted supine and side-lying pressure distribution data, and increase the mattress support force distribution data corresponding to the lower portions of the unadjusted supine and side-lying pressure distribution data. In other words, it compensates for the higher pressure areas of the consumer's chest, back, waist, and hips with lower support, and compensates for the lower pressure areas with higher support. It calculates the mattress support force distribution data that reduces pressure on the higher pressure areas of the consumer's chest, back, waist, and hips, and supports the lower pressure areas. In this way, the parts of the consumer's body under high pressure can be reduced by pressing down on the product of this invention, while the parts of the consumer's body under low pressure are strengthened to distribute more pressure. During the calculation process, the calculation steps of the artificial intelligence calculation model may include: changing the adjustment of the lumbar support force when lying on the back so that the pressure on the consumer's waist is the average of the pressure on the chest, back and buttocks; and changing the adjustment of the chest support force, the back support force and the buttock support force when lying on the back so as to minimize the standard deviation of the pressure on the consumer's chest, back and buttocks. In other words, the AI ​​calculation model of this invention treats the human torso as a body lever, with the chest, back, waist, and buttocks as four force application points. The AI ​​calculation model of this invention uses the waist as the fulcrum of the body lever. After actively supporting the waist, it can use the mechanical principle of lever to calculate the pressure changes of the remaining parts, and then adjust the chest support force, back support force, and buttock support force when lying supine, redistributing the pressure on the chest, back, and buttocks to minimize the standard deviation of the pressure on the chest, back, and buttocks, so that the pressure on both sides of the body lever is balanced (the upper and lower sides of the waist). Since the waist has been adjusted to the average value of the chest, back, and buttocks, as long as the standard deviation of the pressure on the chest, back, and buttocks is minimized, it can ensure that the pressure on the chest, back, waist, and buttocks reaches a consistent balance. The factory can then produce customized ergonomic mattresses based on the data on the distribution of mattress support. When a consumer lies on the product of this invention, the pressure on the chest, back, waist, and hips is balanced, reducing the pressure that is usually concentrated on the shoulders, back, and pelvis. Appropriate chest support can improve thoracic posterior tilt; waist support stabilizes the natural curve of the spine, preventing spinal curvature and increasing the chance of cell damage; the hips and pelvis are supported back to their correct position; and the unsupported pressure from the body's unsupported parts is reduced, minimizing the burden on the body and allowing for full relaxation. This allows consumers to achieve maximum pressure relief and balance in their sleeping posture at a lower cost. When the user's lumbar spine is too deep, simply adjusting the mattress support may not provide sufficient support. To achieve adequate support, a lumbar support pad can be added to the lumbar region of the product of this invention to actively support the user's lumbar spine. The lumbar support pad can be customized in various shapes, angles, and firmnesses, and can be placed above, below, or within the layers of the product of this invention. Adjusting the side-lying chest support, side-lying back support, side-lying lumbar support, and side-lying hip support can further divide the chest, back, lumbar, and hip areas into a central supine sleeping area and side sleeping areas on either side of the supine sleeping area; or, specifically, adjust the support for the shoulders, meaning there is only a central supine sleeping area in the chest area, with side sleeping areas on either side of the supine sleeping area, and the back, lumbar, and hip areas are no longer divided, because most consumers do not completely move their bodies to the side of the mattress when sleeping on their side; most of the time, only the upper body turns to the side, so no additional support adjustment is needed. The advantages of this invention are: 1. Pressure distribution measurement: Pressure distribution data is recorded when the user is lying on their back and side. 2. AI calculation model: The "mattress support distribution data to be adjusted" is calculated based on the pressure distribution data to achieve pressure balance. 3. Support adjustment logic: Using the lumbar spine as a lever fulcrum, the lumbar support is first adjusted so that its pressure equals the average pressure of the chest, back, and buttocks. Then, the support forces of the chest, back, and buttocks are further adjusted to minimize the standard deviation of pressure, thus achieving pressure balance. 4. Personalized mattress manufacturing: The factory produces customized mattresses that meet the user's needs based on the calculation results. 5. Adaptability to different sleeping positions: Corresponding support adjustment mechanisms are designed for back and side sleeping, and may include lumbar support pads for further lumbar support. This design effectively solves the problem of limited mattress specifications and difficulty in adapting to different body shapes and sleeping positions on the market. It is also more cost-effective than instant-adjustment airbag mattresses, and has great market potential. To further understand the features, characteristics, and technical content of this invention, please refer to the following detailed description of this invention. Please refer to Figure 1, which illustrates an embodiment of the present invention. The figure describes a manufacturing process for an AI-powered customized ergonomic mattress, comprising: a consumer lying supine on a pressure-sensing pad to obtain unadjusted supine pressure distribution data (S1); inputting this unadjusted supine pressure distribution data into an AI calculation model to obtain adjustable mattress support distribution data; and manufacturing an AI-powered customized ergonomic mattress 1 based on this adjustable mattress support distribution data (S4). This embodiment further includes side-sleeping data, thus including: a consumer lying supine on a pressure-sensing pad to obtain unadjusted supine pressure distribution data (S1); a consumer lying on their side on a pressure-sensing pad to obtain unadjusted side-sleeping pressure distribution data (S2); inputting the unadjusted supine pressure distribution data and the unadjusted side-sleeping pressure distribution data into an AI calculation model to obtain adjustable mattress support distribution data (S3); and manufacturing an AI-powered customized ergonomic mattress 1 based on this adjustable mattress support distribution data (S4). As shown in Figures 2 through 6, in accordance with the natural curves of the human body, the artificial intelligence customized ergonomic mattress 1 of this invention includes a head area 11, a chest area 12, a back area 13, a waist area 14, a hip area 15, and a foot area 16. To achieve pressure relief and balanced sleeping posture, this invention requires different support variations in the chest area 12, back area 13, waist area 14, and hip area 15. The head area 11 is partially adjustable by the consumer using a pillow, while the pressure in the foot area 16 is typically low and has minimal impact. Therefore, in this embodiment, the unadjusted supine pressure distribution data includes unadjusted supine chest pressure, unadjusted supine back pressure, unadjusted supine waist pressure, and unadjusted... The adjustment of supine hip pressure data includes unadjusted side-lying chest pressure, unadjusted side-lying back pressure, unadjusted side-lying lumbar pressure, and unadjusted side-lying hip pressure. The adjustment of mattress support distribution data includes adjusted supine chest support, adjusted supine back support, adjusted supine lumbar support, adjusted supine hip support, adjusted side-lying chest support, adjusted side-lying back support, adjusted side-lying lumbar support, and adjusted side-lying hip support. This allows the product of the present invention to customize different support levels in the chest, back, lumbar, and hip areas, while simultaneously accommodating both supine and side-lying sleeping positions. The second image shows the body pressure adjustment results obtained by the artificial intelligence calculation model (I). The calculation was performed based on the pressure distribution data when lying on the back without adjustment. The graph on the left is the darker area where the pressure is concentrated in the chest and buttocks of the consumer before the mattress firmness was adjusted, which increases the burden on the body muscles during sleep. The artificial intelligence calculation model of this invention can, based on the unadjusted supine and unadjusted side-lying pressure distribution data, reduce the mattress support distribution data corresponding to the higher portions of the unadjusted supine and unadjusted side-lying pressure distribution data, and increase the mattress support distribution data corresponding to the lower portions of the unadjusted supine and unadjusted side-lying pressure distribution data. This compensates for higher pressure areas in the consumer's chest, back, waist, and hips with lower support, while compensating for lower pressure areas with higher support. The calculation results in mattress support distribution data that reduces pressure on areas of the consumer's chest, back, waist, and hips, while providing support to areas of lower pressure. In this way, areas of the consumer's body under high pressure can be compressed by the product of this invention to reduce pressure, while areas of the consumer's body under less pressure are strengthened with enhanced support to distribute more pressure. The graph on the right of the second figure shows the expected pressure distribution when the user lies supine on the product. The number above is the percentage of pressure relief. It can be seen that the product of the present invention, made using the data on the adjustment of mattress support distribution, is expected to reduce the pressure on the consumer's chest by 15% and the pressure on the consumer's buttocks by 28%. During the calculation process, the calculation steps of the artificial intelligence calculation model may include: changing the adjustment of the lumbar support force when lying on the back so that the pressure on the consumer's waist is the average of the pressure on the chest, back and buttocks; and changing the adjustment of the chest support force, the back support force and the buttock support force when lying on the back so as to minimize the standard deviation of the pressure on the consumer's chest, back and buttocks. In other words, the AI ​​calculation model of this invention treats the human torso as a body lever, with the chest, back, waist, and buttocks as four force application points. The AI ​​calculation model of this invention uses the waist as the fulcrum of the body lever. After actively supporting the waist, it can use the mechanical principle of lever to calculate the pressure changes of the remaining parts, and then adjust the chest support force, back support force, and buttock support force when lying on the back, redistributing the pressure on the chest, back, and buttocks to minimize the standard deviation of the pressure on the chest, back, and buttocks, so that the pressure on both sides of the body lever is balanced (the upper and lower sides of the waist). Because the pressure on the waist has been adjusted to the average pressure of the chest, back, and buttocks, as long as the standard deviation of the pressure on the chest, back, and buttocks is minimized, it can ensure that the pressure on the chest, back, waist, and buttocks reaches a consistent balance, achieving the most relaxing and balanced sleeping posture. In the third figure, the four numbers below, from left to right, represent the areas requiring adjustment of chest support, back support, lumbar support, and hip support when lying on your back. In the third figure, these numbers are 3, 5, 8, and 3 from left to right. In this embodiment, numbers 1 to 10 represent support from low to high. Using this data to manufacture the supine sleeping section 121 of the present invention allows consumers to achieve a pressure-reducing and balanced sleeping posture when lying on their backs. The factory can then produce a customized artificial intelligence customized ergonomic mattress 1 based on the data on the distribution of mattress support adjustments. If the artificial intelligence customized ergonomic mattress 1 of the present invention is made of foam, softer foam can be used in areas where support needs to be reduced, or perforated areas can be created in the foam; while firmer foam can be used in areas where support needs to be increased. The fourth figure shows the body pressure adjustment results (II) obtained by the artificial intelligence calculation model. It is calculated based on the pressure distribution data of the side lying position without adjustment. The graph on the left is the darker area of ​​the shoulders and buttocks before the mattress firmness was adjusted, which increases the burden on the body muscles during sleep. The artificial intelligence calculation model of this invention can compensate for the higher pressure areas in the chest, back, waist, and hips of the consumer with lower support based on the unadjusted side-lying pressure distribution data, and compensate for the lower pressure areas with higher support. It calculates the side-lying chest support, side-lying back support, side-lying waist support, and side-lying hip support that should be adjusted and applies them to the side-sleeping part 122. Similarly, the pressure on the consumer's waist can be adjusted to the average value of the chest, back, and hips by first changing the side-lying waist support that should be adjusted. Then, the side-lying chest support, side-lying back support, and side-lying hip support that should be adjusted are adjusted to minimize the standard deviation of the pressure on the consumer's chest, back, and hips, achieving a balanced state of body pressure and the most relaxing balanced sleeping posture. The graph on the right of the fourth figure shows the expected pressure distribution when the user lies on their side on the pre-designed product. The numbers at the top are the percentage of pressure reduction. It can be seen that the customized mattress made using the mattress support distribution data that should be adjusted can reduce the pressure on the consumer's chest by 20% and the pressure on the consumer's hips by 21% when the user sleeps on their side. In the fifth figure, the four numbers below, from left to right, represent the adjustments needed for chest support, back support, lumbar support, and hip support when lying on one's side. In the fifth figure, these numbers are 1, 5, 8, and 5 from left to right. In this embodiment, numbers 1 to 10 represent support from low to high. Using this data to manufacture the side-sleeping section 122 of the mattress allows consumers to achieve a pressure-reducing and balanced sleeping posture when lying on their side. The factory can then produce customized products of this invention based on the mattress support distribution data. When consumers lie on the product of this invention, the pressure on the chest, back, waist, and buttocks is balanced, reducing the pressure that is usually concentrated on the shoulders, back, and pelvis, and the pressure on all parts of the body tends to be uniform; the chest receives proper support, which can improve thoracic posterior tilt; the waist is supported, stabilizing the natural curve of the spine and avoiding spinal curvature that increases the chance of cell lesions; the buttocks and pelvis are supported to return to the correct position; and the unsupported parts of the body are reduced, resulting in less burden on the body and full relaxation, allowing consumers to achieve the maximum stress relief and balance effect of sleeping posture at a lower cost. As shown in Figure 6, the chest area 12, back area 13, waist area 14, and hip area 15 of the AI-customized ergonomic mattress 1 of this invention can have their support force adjusted according to the mattress support force distribution data. The unadjusted side-lying pressure distribution data can be used to adjust the support force on both sides of the product of this invention. The chest area 12, back area 13, waist area 14, and hip area 15 are further divided into a central supine sleeping area 121 and side sleeping areas 122 on either side of the supine sleeping area 121. The supine sleeping area 121 can be made using the data for adjusting the supine chest support, back support, waist support, and hip support in Figure 3. Each side sleeping area 122 can be made using the data for adjusting the supine chest support, back support, waist support, and hip support in Figure 3. The data in Figure 5 indicating the need to adjust chest support, back support, lumbar support, and hip support when lying on one's side are used to create the mattress. Alternatively, the support may be adjusted specifically for the shoulders, as shown in Figure 7, where there is only a supine sleeping area 121 in the center of the chest area 12, with a side sleeping area 122 on each side of the supine sleeping area 121. The back area 13, lumbar area 14, and hip area 15 are not further subdivided but only the data indicating the need to adjust back support, lumbar support, and hip support when lying on one's side are used. This is because most consumers do not move their bodies completely to the side of the mattress when sleeping on their side; most of the time, only the upper body turns to the side, so no additional support adjustment is needed. As shown in Figure 7, when the user's lumbar spine is too deep, in order to achieve sufficient support, a lumbar pad 17 can be added to the lumbar region 14 of the product of the present invention, so that the product of the present invention forms a protrusion in the lumbar region 14, which actively supports the user's lumbar spine and stabilizes the natural curve of the spine. The lumbar pad 17 can be customized in various shapes, angles and hardness, and can be placed above or below the product of the present invention. In this embodiment, it is placed below, or the product of the present invention can be made into a multi-layer structure and the lumbar pad 17 can be placed between any two layers. The advantages of this invention are: 1. Pressure distribution measurement: Pressure distribution data is recorded when the user is lying on their back and side. 2. AI calculation model: The "mattress support distribution data to be adjusted" is calculated based on the pressure distribution data to achieve pressure balance. 3. Support adjustment logic: Using the lumbar spine as a lever fulcrum, the lumbar support is first adjusted so that its pressure equals the average pressure of the chest, back, and buttocks. Then, the support forces of the chest, back, and buttocks are further adjusted to minimize the standard deviation of pressure, thus achieving pressure balance. 4. Personalized mattress manufacturing: The factory produces customized mattresses that meet the user's needs based on the calculation results. 5. Adaptability to different sleeping positions: Corresponding support adjustment mechanisms are designed for back and side sleeping, and may include lumbar support pads for further lumbar support. This design effectively solves the problem of limited mattress specifications and difficulty in adapting to different body shapes and sleeping positions on the market. It is also more cost-effective than instant-adjustment airbag mattresses, and has great market potential. However, the above description is only a preferred embodiment of the present invention and should not be used to limit the scope of the present invention. Any changes and modifications that can be obviously made by those skilled in the art should be regarded as not departing from the essence of the present invention. 1: Artificial Intelligence Customized Ergonomic Mattress 11: Head area 12: Chest area 121: Supine Sleeping Section 122: Side sleeping section 13: Back area 14: Waist area 15: Hip area 16: Foot area 17: Lumbar support pad S1~S4: Steps The first figure is a flowchart of the manufacturing process of the AI-powered customized ergonomic mattress of this invention. The second figure is the body pressure adjustment result (I) obtained by the AI ​​calculation model of this invention. The third figure is a schematic diagram of the mattress firmness distribution data to be adjusted, continuing from the second figure. The fourth figure is the body pressure adjustment result (II) obtained by the AI ​​calculation model of this invention. The fifth figure is a schematic diagram of the mattress firmness distribution data to be adjusted, continuing from the fourth figure. The sixth figure is a top view of an embodiment (I) of the AI-powered customized ergonomic mattress of this invention. The seventh figure is a top view of an embodiment (II) of the AI-powered customized ergonomic mattress of this invention. S1~S4: Steps

Claims

1. A process for manufacturing an AI-customized ergonomic mattress includes: a consumer lying supine on a pressure-sensitive mattress to obtain unadjusted supine pressure distribution data, which includes unadjusted supine chest pressure, unadjusted supine back pressure, unadjusted supine lumbar pressure, and unadjusted supine hip pressure; inputting the unadjusted supine pressure distribution data into an AI calculation model to obtain adjustable mattress support distribution data, which includes adjustable supine chest support, adjustable supine back support, adjustable supine lumbar support, and adjustable supine hip support; and manufacturing an AI-customized ergonomic mattress based on the adjustable mattress support distribution data. A process for manufacturing an AI-customized ergonomic mattress includes: a consumer lying supine on a pressure-sensing pad to obtain unadjusted supine pressure distribution data; a consumer lying on their side on a pressure-sensing pad to obtain unadjusted side-lying pressure distribution data; inputting the unadjusted supine pressure distribution data and the unadjusted side-lying pressure distribution data into an AI calculation model to obtain mattress support force distribution data that should be adjusted; and manufacturing an AI-customized ergonomic mattress based on the mattress support force distribution data that should be adjusted. As described in claim 2, the artificial intelligence-customized ergonomic mattress manufacturing process includes unadjusted supine pressure distribution data including unadjusted supine chest pressure, unadjusted supine back pressure, unadjusted supine lumbar pressure, and unadjusted supine hip pressure; unadjusted side-lying pressure distribution data includes unadjusted side-lying chest pressure, unadjusted side-lying back pressure, unadjusted side-lying lumbar pressure, and unadjusted side-lying hip pressure; and adjustable mattress support distribution data includes adjustable supine chest support, adjustable supine back support, adjustable supine lumbar support, adjustable supine hip support, adjustable side-lying chest support, adjustable side-lying back support, adjustable side-lying lumbar support, and adjustable side-lying hip support. As described in claim 1 or 3, the AI-powered customized ergonomic mattress manufacturing process involves the AI ​​calculation model reducing the mattress support distribution data corresponding to the higher portion of the unadjusted supine pressure distribution data, and increasing the mattress support distribution data corresponding to the lower portion of the unadjusted supine pressure distribution data. As described in claim 1 or 3, the AI-powered customized ergonomic mattress manufacturing process includes the following calculation steps in the AI ​​calculation model: changing the lumbar support force to be adjusted so that the pressure on the consumer's lower back is the average of the pressure on the chest, back, and buttocks; and changing the lumbar support force to be adjusted so that the standard deviation of the pressure on the consumer's chest, back, and buttocks is minimized. An artificial intelligence customized ergonomic mattress, which is manufactured by the artificial intelligence customized ergonomic mattress manufacturing process of any one of claims 1 to 5. The AI-customized ergonomic mattress as described in claim 6 includes a head area, a chest area, a back area, a waist area, a hip area, and a foot area. As described in claim 7, the AI-customized ergonomic mattress has a supine sleeping section in the center of the chest area, and a lateral sleeping section on each side of the supine sleeping section. The AI-powered customized ergonomic mattress described in claim 7 has a support pad in the lumbar region.

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