Suspended Flexible Matrix Support Structure With Foam Frame
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Solution Overview
Problem
Conventional mattress and foundation designs rely on outdated materials and complex assembly processes, leading to increased costs and failure to leverage modern materials' advantageous properties for flexible support structures.
Innovation Solution
A suspended flexible matrix support system utilizing a foam frame with compressible and resilient properties, combined with flexible members arranged longitudinally and transversely, which can be configured to varying heights and materials, including engineered plastics, to provide reflexive support and accommodate additional components like sensors or electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional wire spring innersprings and wood/steel frame constructions are used, then structural support is provided, but manufacturing complexity and assembly costs increase significantly
Solution Approach 1:
The patent combines the frame structure and support function into a single integrated foam foundation unit. The foam material provides both structural support and reflexive support properties, eliminating the need for separate wire springs and wood/steel frame assemblies. This merging reduces manufacturing complexity while maintaining structural integrity.
Solution Approach 2:
The foam foundation serves multiple functions simultaneously: it acts as the structural frame, provides reflexive support, elevates the sleeping surface, and can be integrated with adjustable base mechanisms. This multi-functionality eliminates the need for separate components, reducing assembly complexity while providing comprehensive support.
2Reliability
If traditional wire spring innersprings and multiple padding layers are used, then support and comfort are provided, but manufacturing costs increase due to large number of components
Solution Approach 1:
The patent merges multiple traditional components (wire springs, padding layers, frame structure) into a single foam foundation unit. The foam material inherently provides both support and comfort properties, eliminating the need for separate wire spring innersprings and multiple padding layers, thereby reducing manufacturing costs while maintaining support performance.
Solution Approach 2:
The patent uses foam material as a composite structure that integrates the functions previously requiring separate materials (springs for support, padding for comfort). The foam's cellular structure provides both structural integrity and cushioning properties, reducing the number of components needed while maintaining or improving support performance.
3Stability of the object's composition
If conventional fixed-height frame structures are used, then structural stability is provided, but adaptability to different configurations and additional components is limited
Solution Approach 1:
The patent employs an adjustable base mechanism that allows the foam foundation to be positioned at various heights and angles. This dynamic adjustment capability enables the structure to adapt to different configurations (flat, inclined, elevated) while the foam material itself maintains structural stability through its inherent strength and rigidity.
Solution Approach 2:
The foam foundation is designed to accommodate multiple functions and configurations: it can serve as a flat base, an inclined surface, or an elevated platform. The universal design allows integration with various adjustable mechanisms and accommodates different mattress types, providing both stability and adaptability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces costs by simplifying assembly and leveraging modern materials for improved flexibility and support, while allowing for customizable designs and integration of additional features like sensors or electronics within the support structure.
Implementation Method 1
the frame is constructed of compressible and resilient foam material, the frame provides reflexive support
Implementation Method 2
the frame is constructed of compressible and resilient foam material, the frame provides reflexive support
Data Source
AI summary
A suspended matrix support structure has a perimeter frame which supports a flexible matrix formed with intersecting flexible members, the ends of which are supported by the perimeter frame. Edges of the flexible members are held within channels which form a frame about the flexible matrix. In one embodiment, the perimeter frame is constructed of foam with contoured features which support the frame of the flexible matrix. The flexible members of the flexible matrix extend across the expanse within the perimeter frame to provide a flexible support structure which can be used as a mattress, mattress foundation or both in combination.