Dual-Layer Pillow Core for Support on Soft Mattresses
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Solution Overview
Problem
Existing sleep pillows lack sufficient support when placed on soft mattresses, leading to potential damage to the cervical spine and inadequate comfort during sleep.
Innovation Solution
A pillow design featuring a stacked arrangement of a contact layer and a support layer, where the support layer is integrally formed with a higher hardness than the contact layer, ensuring stability and comfort through a tight connection and differential densities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the pillow is made soft to improve comfort, then the user experience is improved, but the support function deteriorates and the pillow collapses on soft mattresses
Solution Approach 1:
The pillow is divided into two distinct layers: a contact layer and a support layer. The contact layer (softer, 70-90D) provides comfort where the user's head rests, while the support layer (harder, 50-70D) maintains structural integrity and prevents collapse. This segmentation allows each layer to perform its specific function optimally without compromising the other.
Solution Approach 2:
Different regions of the pillow have different hardness characteristics tailored to their specific functions. The contact layer has higher density (70-90D) for comfort, while the support layer has lower density (50-70D) but is positioned to provide structural support. This local differentiation of material properties resolves the contradiction between softness and support.
2Reliability
If the pillow hardness is increased to improve support, then the support function is improved, but the comfort and softness deteriorate
Solution Approach 1:
The pillow structure separates the support function (handled by the support layer) from the comfort function (handled by the contact layer). The support layer can be optimized for structural integrity while the contact layer is optimized for softness, eliminating the need to compromise between these conflicting requirements.
Solution Approach 2:
The pillow applies different material densities to different functional zones: the contact layer uses higher density material (70-90D) for comfort, while the support layer uses lower density material (50-70D) configured to provide adequate support. This local optimization allows both softness and support to coexist in their respective regions.
3Ease of operation
If the pillow is made entirely of soft material to improve comfort, then the comfort is improved, but the pillow loses structural stability and cannot maintain shape
Solution Approach 1:
The pillow is segmented into a contact layer and a support layer with distinct material properties. The support layer acts as a structural backbone that maintains the pillow's shape and stability, while the contact layer provides the soft comfort surface. This segmentation ensures both comfort and structural integrity are achieved simultaneously.
Solution Approach 2:
The pillow uses a composite structure combining two different foam materials with different density ranges (contact layer: 70-90D, support layer: 50-70D). This composite approach allows the pillow to exhibit both soft comfort characteristics and structural stability that neither material could achieve alone.
Data Source
AI summary
A pillow includes a pillow core main body. The pillow core main body includes a contact layer and a support layer. The contact layer and the support layer are stacked and connected. A hardness of the support layer is greater than a hardness of the contact layer. Through the above structure, when the pillow core main body is placed on a soft mattress, due to the high hardness of the support layer, the pillow core main body is provided with good support, and the pillow core main body will not collapse under the support of the support layer. Moreover, due to the good softness of the contact layer, a user can have a comfortable experience when resting on the contact layer. The stacked arrangement of the contact layer and the support layer not only provides sufficient support for the pillow, but also gives the user a comfortable sleeping experience.