Adjustable Foam Core Firmness With Vacuum Pressure Feedback
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Solution Overview
Problem
Conventional foam mattresses are factory preset and cannot be modified by users to achieve custom levels of firmness, softness, or contour, failing to accommodate individual variations in size, shape, and body type, leading to suboptimal comfort and support.
Innovation Solution
A system with a vacuum pressure control and feedback mechanism that uses a hermetically sealed foam core, a vacuum pump, and pneumatic valves to adjust firmness and softness, along with a remote control and pressure sensors for precise user adjustments and real-time feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a vacuum pump is employed to adjust the level of vacuum pressure in a foam core, then the desired density and firmness/softness is achieved, but achieving a precise, custom level of firmness, softness or contour for the individual user has been impossible
Solution Approach 1:
The patent implements a feedback control system where pressure sensors continuously monitor the internal pressure of the foam core and transmit this information to a microprocessor. The microprocessor compares the measured pressure with the desired target pressure and automatically adjusts the vacuum pump operation to maintain the precise custom firmness level, resolving the contradiction between adaptability and complexity by automating the control process
Solution Approach 2:
The system enables users to program their custom firmness preferences once, and the automated feedback control system handles all subsequent adjustments independently. The microprocessor continuously monitors pressure and controls the vacuum pump without requiring manual intervention, allowing the system to serve itself and maintain optimal comfort levels automatically
2Ease of operation
If the foam core is made softer by removing air, then contour and comfort are improved, but the support firmness is reduced
Solution Approach 1:
The patent transforms the static foam core into a dynamic system where the firmness can be continuously adjusted by controlling the internal pressure. The vacuum pump can remove air to soften the foam for better contouring, or air can be reintroduced to increase firmness for better support, allowing the same foam core to adapt to different support requirements
Solution Approach 2:
The system changes the physical parameter of internal pressure to control foam properties. By precisely controlling the vacuum level (pressure parameter), the system can achieve the optimal balance between softness for contour comfort and firmness for support, with the pressure range allowing transition from very soft to very firm states
3Ease of manufacture
If conventional foam beds are factory preset at a density and IFD value, then manufacturing is simplified, but the user cannot modify the firmness to meet individual comfort needs
Solution Approach 1:
The system performs preliminary action by factory-installing the vacuum pump, pressure sensors, and control system within the foam bed. This preliminary configuration enables post-manufacturing adaptability without complicating the core foam production process, as the adjustable firmness mechanism is added as an integrated system rather than modifying the foam manufacturing itself
Solution Approach 2:
The patent creates a universal solution where a single foam bed design with integrated vacuum control can serve multiple firmness requirements. The same basic foam core structure works for different users by adjusting the vacuum level, making the product universally adaptable rather than requiring multiple factory-preset variants
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
Enables users to achieve custom comfort and support levels by dynamically adjusting the foam core's pressure, providing immediate and effective feedback for quick adjustments, ensuring optimal firmness, softness, and contour based on user preferences.
Implementation Method 1
a vacuum pump unit in pneumatic communication with the foam core for drawing air from the foam core and creating a vacuum
Implementation Method 2
One or more pressure sensors in pneumatic communication with the core sense the pneumatic pressure and corresponding firmness of the core and generate feedback signals indicative thereof
Data Source
AI summary
A pressure control and feedback system for an adjustable foam support includes a vacuum pump for drawing air from a hermetically sealed foam core to reduce the firmness of the core. A valve opens to permit and closes to block the passage of air into and out of the core. A remotely operated controller generates control signals to selectively start and stop operation of the pump, and selectively open and close the valve, which provides a selected level of pneumatic pressure and corresponding firmness in the core. A pressure sensor detects the pressure and firmness of the core and generates representative feedback signals. An indicator device responsive to the feedback signals indicates the sensed firmness of the core. Software calibrates the system and provides the system with intelligent operation.