Bedding components including a convoluted foam layer
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Solution Overview
Problem
Conventional mattresses with metal coil springs do not adequately provide pressure point relief, and existing convoluted foams are primarily designed for feel rather than functional benefits.
Innovation Solution
A mattress topper with a convoluted foam layer featuring a geometrically patterned surface, including hexagonal depressions with a circular inner wall, provides increased pressure relief and a larger contact surface area for adhesion, enhancing sleeper comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional metal coil springs are used in mattresses, then structural support is provided, but pressure point relief is insufficient
Solution Approach 1:
The foam layer is segmented into multiple convoluted surfaces with numerous individual depressions, each acting as an independent pressure relief element. This segmentation allows the mattress to provide pressure point relief across multiple locations simultaneously without requiring complex mechanical structures
Solution Approach 2:
The invention combines foam material with a convoluted surface structure to create a composite system that provides both support and pressure relief. The foam layer integrates the structural function with the pressure relief function, eliminating the need for separate complex mechanisms
2Ease of operation
If existing convoluted foams are used, then aesthetic feel is improved, but functional pressure relief benefits are limited
Solution Approach 1:
The convoluted surface features depressions with specific geometric characteristics (hexagonal outer walls, circular inner walls, defined depths) that are optimized for pressure relief functionality. Each depression is designed with specific dimensional relationships to maximize its pressure distribution effectiveness while maintaining aesthetic appearance
Solution Approach 2:
The invention specifies precise parameter ranges for the convoluted depressions including depth (0.25-6 inches), spacing (0.25-4 inches), and dimensional relationships between outer and inner walls. These parameter optimizations transform the foam from merely aesthetic to functionally effective for pressure relief
3Strength
If foam layers are adhered together, then structural integrity is maintained, but contact surface area for adhesion is insufficient
Solution Approach 1:
The convoluted surface introduces a third dimension to the foam layer interface by creating depressions that extend vertically into the foam. This dimensional change increases the effective contact surface area between layers by incorporating both the top surface and the lateral surfaces of the depressions, thereby enhancing adhesion strength without increasing the footprint area
Data Source
AI summary
Mattress toppers for mattress assemblies and pillowtop mattress assemblies generally includes a convoluted foam layer including a convoluted upper surface and a bottom planar surface. The convoluted foam layer includes a convoluted upper surface and a bottom planar surface. The convoluted upper surface comprising repeating geometric depressions defined by an outer geometric-shaped outer wall and a concentric shaped inner wall. The geometric depression can be defined by a geometric outer wall, e.g., hexagonally shaped, and a concentric inner wall, e.g., circular shaped.