Adjustable Foam Mattress With Removable Inserts for Custom Support

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Solution Overview

Problem

Existing mattresses, whether spring-based, foam, or air-filled, face challenges in terms of manufacturing complexity, durability, and user-adjustability, with air-type mattresses being difficult and expensive to manufacture and requiring maintenance, while foam mattresses lack adjustability.

Innovation Solution

An adjustable foam mattress with user-accessible openings for removable inserts that allow for customizable support without the need for pumps or complex parts, featuring multiple layers with varying mechanical characteristics and low-friction surfaces for easy insert placement and removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If air-filled chambers with pumps are used to provide adjustable support, then the mattress becomes adjustable in firmness, but the manufacturing complexity and cost increase significantly

Engineering Contradiction:

Improveadjustability of supportVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mattress is divided into multiple independent foam layers, each capable of being adjusted separately by inserting or removing wedge-shaped blocks. This segmentation allows the mattress to provide adjustable support without requiring complex integrated systems like air chambers and pumps.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses simple, inexpensive foam materials and wedge-shaped blocks that can be easily inserted and removed. These simple components replace expensive, complex air-filled chambers and electric pumps, achieving adjustability through low-cost, maintenance-free elements.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Adaptability or versatility

If air-filled chambers with pumps are used to provide adjustable support, then the mattress becomes adjustable in firmness, but the durability decreases due to moving parts

Engineering Contradiction:

Improveadjustability of supportVSAvoiddurability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The invention extracts and eliminates the problematic moving parts (pumps, air chambers, electrical components) from the mattress system. Adjustability is achieved through static foam layers and simple wedge blocks that have no moving parts, thereby significantly improving durability and reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The foam layers and wedge blocks are designed to be self-adjusting through simple insertion and removal without requiring external power sources, motors, or pumps. This self-service mechanism eliminates components that could fail, enhancing the mattress's reliability.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If openings extend through the top or bottom of the mattress body, then user access to inserts is improved, but the risk of user error and damage to the mattress increases

Engineering Contradiction:

Improveuser access to insertsVSAvoidrisk of user error and damage

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The openings are positioned locally at the sides of the mattress rather than extending through the top or bottom. This localized placement provides sufficient user access while preventing direct contact with the internal foam layers, thereby reducing the risk of accidental damage during insert manipulation.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The wedge-shaped blocks serve as intermediaries that users manipulate from the side openings. These wedges provide a safe interface between the user's hands and the internal mattress structure, allowing adjustment without direct access to vulnerable internal components.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Adaptability or versatility

If multiple foam layers with different mechanical characteristics are used, then customizable support at different locations is achieved, but the manufacturing complexity increases

Engineering Contradiction:

Improvecustomizable support locationVSAvoidmanufacturing simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The mattress uses multiple foam layers with different densities and firmness levels that can be independently configured. Users can dynamically adjust the mattress characteristics by inserting or removing wedge blocks from different locations, allowing customization without requiring complex manufacturing processes.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10104983B1Adjustable mattress using inserted wands

Publication Date: 2018.10.23 BROBARD LLC

AI summary

Embodiments of a mattress and methods of manufacturing the same, wherein the mattress includes a body having one or more openings for removable inserts that a user can position within the openings to adjust the mechanical characteristics of the mattress, including the amount and location of support provided by the mattress to the user. Some embodiments of the mattress include one or more covers, such as a fire-retardant cover, that can encompass the mattress body while still allowing a user to access the openings of mattress body.