Configurable foam comfort system
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Solution Overview
Problem
Conventional mattresses lack configurability, comfort, and durability, leading to varying quality issues and limited customization options for users.
Innovation Solution
A modular foam comfort system featuring hexagonal or 'M' shaped cells with different firmness levels that can be stacked and rearranged to create customized support configurations, with form-fit walls and triangular grooves for stability and easy reconfiguration, allowing for personalized comfort and extended mattress life through replaceable components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional mattresses use uniform materials and construction methods, then manufacturing is simplified, but configurability and comfort customization are limited
Solution Approach 1:
The mattress is divided into multiple independent foam cells with different firmness levels (soft, medium, firm) that can be individually selected and arranged. Each cell functions as an independent module, allowing users to create customized comfort configurations by stacking and arranging cells in desired patterns, thereby achieving high adaptability without requiring completely different mattress designs for each configuration.
Solution Approach 2:
The foam cells are designed with universal features including standardized connection mechanisms (form-fit walls, triangular grooves) that allow the same basic cell design to serve multiple functions and positions within the mattress. The cells can be arranged in various configurations and stacked in different orientations, enabling a single cell type to fulfill multiple comfort and support roles throughout the mattress structure.
2Ease of repair
If conventional mattresses are designed as single integrated units, then structural stability is maintained, but repairability and component replacement are difficult
Solution Approach 1:
The mattress is constructed from discrete, separable foam cells rather than a single integrated foam block. Each cell can be independently removed and replaced without affecting the structural integrity of the remaining mattress. The connection mechanisms (form-fit walls and triangular grooves) are designed to maintain stable assembly when cells are properly connected, while allowing easy disassembly for replacement of worn or damaged cells.
3Adaptability or versatility
If conventional mattresses use fixed firmness levels throughout, then manufacturing is simpler, but comfort customization for different body regions is limited
Solution Approach 1:
Different firmness levels (soft, medium, firm) are assigned to specific foam cells based on the support needs of different body regions. For example, softer cells can be placed in areas requiring pressure relief (hips, shoulders) while firmer cells provide support in areas needing stability (lower back, legs). This localized differentiation of firmness properties allows comprehensive comfort customization while using standardized cell designs that can be manufactured efficiently.
Data Source
AI summary
A configurable foam mattress comfort system includes a firm foam mattress foundation including an upper surface having a triangular grooves disposed across a width thereof, and foam elongate cells configured to fit partially within corresponding triangular grooves from among the triangular grooves disposed across the width thereof. A length of each of the foam elongate cells is substantially equal to the width of the firm foam mattress foundation. The foam elongate cells are configured to be custom-stacked on each other and on the firm foam mattress foundation in accordance with a user's desired comfort configuration.