Air Mattress Pump Manifold for Multi-Zone Configuration
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Solution Overview
Problem
Existing air mattress pump systems require customization for specific numbers of inflatable zones, leading to increased manufacturing costs, inefficiencies, and the need for multiple pump types, which limits market efficiency and convenience.
Innovation Solution
A multiple configuration pump system with a standardized platform and manifold that accommodates varying numbers of air control valves and pump sizes, using interchangeable faceplates and programmable circuit boards to adapt to different mattress configurations, allowing for efficient production and use across multiple mattress models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate pumps are manufactured for each mattress model with different numbers of inflatable chambers, then each pump can be optimized for its specific configuration, but manufacturing costs increase and market efficiency decreases
Solution Approach 1:
The pump system uses a universal manifold design with multiple valve ports that can accommodate different numbers of inflatable chambers. The same basic pump unit can be configured for 1, 2, 3, or 4 chamber mattresses by simply plugging unused ports, eliminating the need to manufacture separate pumps for each mattress model.
Solution Approach 2:
The manifold is divided into multiple independent valve ports, each capable of being independently activated or plugged. This segmentation allows the system to be configured for different numbers of chambers without redesigning the entire pump assembly.
2Adaptability or versatility
If separate pumps are manufactured for each mattress model, then each pump can be precisely matched to its intended use, but the number of different pump types increases and inventory complexity increases
Solution Approach 1:
A single universal pump design serves multiple mattress configurations through configurable valve port plugging, reducing the number of different pump types from potentially dozens down to one or a few base models.
Solution Approach 2:
The system changes its operational parameters by activating or deactivating specific valve ports through plugging, allowing the same physical pump to adapt to different mattress configurations without physical modification to the pump body.
3Manufacturing precision
If customized pumps are created for each mattress style with different numbers of zones, then each pump can control air flow precisely for its specific mattress, but manufacturing time and cost increase
Solution Approach 1:
The universal pump is pre-designed with all necessary valve ports and internal passages to handle any configuration. The specific configuration for each mattress type is determined by which ports are plugged, allowing rapid assembly without custom manufacturing for each model.
Solution Approach 2:
The solution uses inexpensive plastic plugs to configure the pump system for different mattresses. These simple, low-cost components allow rapid reconfiguration without requiring expensive custom tooling or manufacturing processes for each mattress variant.
4Ease of manufacture
If a standardized pump system is used for all mattress configurations, then manufacturing cost and complexity decrease, but the ability to precisely control air flow to specific zones may be compromised
Solution Approach 1:
The universal manifold maintains full air flow control capability for all configurations by providing dedicated valve ports for each potential chamber. When a port is plugged, the system automatically redirects air flow through the remaining active ports, ensuring reliable control for the specific mattress configuration being used.
Solution Approach 2:
The system dynamically adapts its air flow paths based on which valve ports are active versus plugged. The internal manifold design allows air to be redirected through different passages depending on the configuration, maintaining reliable control without requiring a different pump design for each mattress type.
Data Source
AI summary
A multiple configuration air mattress pump system is disclosed. The pump system includes a number of standard components with a few inexpensive varied components to allow for easy and less expensive use of the pump with mattresses having varying numbers of inflatable zones.