Adjustable mattress
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Solution Overview
Problem
Conventional adjustable mattresses face reduced adjustability and increased wear and tear due to non-stretchable covers that compress the inner core when bent, altering the comfort and tension of the mattress.
Innovation Solution
An adjustable mattress design featuring a bottom cover made from a blend of stretchable and non-stretchable materials, with the stretchable material comprising a mixture of cotton and spandex, allowing the cover to stretch around the inner core as the mattress bends, reducing force application and enhancing adjustability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If non-stretchable covers are used on the inner core, then the mattress structure is simple and manufacturing is easier, but the covers become tight around bending locations, compressing the inner core and reducing adjustability
Solution Approach 1:
The patent changes the physical parameter of the cover material from non-stretchable to stretchable, allowing the cover to expand and contract with the inner core during bending. This resolves the contradiction by enabling the cover to adapt to position changes while maintaining ease of manufacture through a straightforward material substitution.
Solution Approach 2:
The patent employs composite materials by combining stretchable fabric with the inner core structure. The stretchable cover material provides the necessary flexibility and elasticity to accommodate bending without compressing the inner core, thereby improving adjustability while remaining manufacturable.
2Device complexity
If non-stretchable covers are used on the inner core, then the structure is simpler, but wear and tear increases as the covers become tight and compress the inner core during adjustment
Solution Approach 1:
The patent modifies the mechanical parameter of the cover material to include stretchability, which eliminates the tight compression effect during bending. This reduces stress concentrations and friction that cause wear and tear, thereby improving reliability without increasing structural complexity.
Solution Approach 2:
The stretchable cover material acts as a cushioning element that anticipates and accommodates the bending motion before it occurs. By providing elastic compliance in advance, the cover prevents excessive tension and compression forces that would otherwise accelerate wear on the inner core and cover stitching.
3Ease of manufacture
If non-stretchable covers are used, then manufacturing is easier, but the tension on springs changes as the mattress is adjusted, altering comfort
Solution Approach 1:
The patent changes the elastic parameter of the cover material to match the dynamic requirements of the adjustable mattress. The stretchable cover maintains consistent spring tension during adjustment by expanding and contracting with the inner core, preserving comfort while keeping manufacturing simple.
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 cover reduces wear and tear on the mattress, maintains coil stiffness, and provides greater adjustability by minimizing compression of the inner core during bending, thereby improving the overall comfort and longevity of the mattress.
Implementation Method 1
a bottom cover attached to a bottom surface of the inner core, the bottom cover having at least one section formed of a stretchable material to stretch around the inner core as the adjustable mattress bends
Data Source
AI summary
An adjustable mattress may have an inner spring core between a top and bottom cover. The bottom cover may have at least one section made of a stretchable material that stretches around the mattress as it bends. The stretchable cover reduces the stress on the inner core for the bending when adjusting the mattress. The inner core may be formed from a spring array surrounded by a foam perimeter rail. Sides of the foam perimeter rail may be formed from individual foam coils.