Angled Slat Mattress Foundation to Reduce Mattress Dip
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Solution Overview
Problem
Traditional mattress foundations often result in 'mattress dip' due to factors like spring position, size, slat size, spacing, sleeper weight, and habits, leading to decreased sleeping comfort and mattress life.
Innovation Solution
A mattress foundation kit with non-perpendicular slats and a unique rail configuration, including side rails, end rails, and center rails, where slats are angled between 25° to 35° and connected by flexible lines to maintain spacing and order, creating a more supportive structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional perpendicular slats are used in mattress foundations, then the structure is simple and easy to manufacture, but mattress dip occurs between slats reducing support quality
Solution Approach 1:
The patent applies asymmetry by positioning slats at non-perpendicular angles (e.g., 45 degrees) relative to the side rails, creating an asymmetric slat configuration that eliminates gaps between slats and prevents mattress dip, thereby improving mattress support quality while accepting increased structural complexity
Solution Approach 2:
The patent introduces a new dimensional aspect by using slats of varying lengths (A slats, B slats, C slats) positioned at different angles and locations, transforming the traditional uniform perpendicular slat arrangement into a multi-dimensional configuration that provides continuous support across the mattress surface
2Reliability
If slats are positioned at non-perpendicular angles (25° to 35°), then mattress support is improved and dip is reduced, but assembly complexity and shipping space requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling the slats at their operational angles (25° to 35°) and pre-positioning them on the rails before shipping, so that when the foundation is assembled at the destination, the slats are already in their correct angular positions, reducing on-site assembly complexity while maintaining improved mattress support
Solution Approach 2:
The patent segments the foundation into modular components (side rails, end rails, center rails, A slats, B slats, C slats) that can be independently manufactured and shipped, allowing the complex angled slat configuration to be assembled from simpler individual parts rather than requiring complex pre-assembly
3Reliability
If uniform slat spacing is used, then manufacturing is simple, but weight distribution is uneven causing mattress dip in high-traffic areas
Solution Approach 1:
The patent applies local quality by using different slat lengths (A slats for edge areas, B slats for intermediate areas, C slats for center areas) positioned according to their specific location's support requirements, providing locally optimized weight distribution that prevents mattress dip in high-traffic areas while maintaining simple manufacturing through standardized slat types
Data Source
AI summary
Mattress foundations and kits include a first side rail, a second side rail, a first end rail, a second end rail, and at least one center rail. The foundations and kits further include a plurality of slats of varying lengths. The invention may further include a method of assembling a foundation kit.