Foam Core Mattress Reserve Region for Multi-Body-Type Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current foam mattresses are expensive to produce due to the need for multiple variations to accommodate different sleep types and body build types, as they often require compromises in vertebral column support.
Innovation Solution
A foam core with a supporting layer featuring upper and lower parts, where the lower part has a reserve region that only deforms above a predetermined limit pressure, allowing optimal adaptation to various body types and sleep positions without compromising support for side and back sleepers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple mattress variations are produced to accommodate different body build types and sleep types, then the suitability for different customers is improved, but the manufacturing cost increases
Solution Approach 1:
The foam core is designed with a reserve region that can serve multiple functions: it provides additional support capacity for heavier individuals (body types E and H) while remaining inactive for lighter individuals (body types A and I). This allows a single mattress design to accommodate multiple body build types and sleep positions without requiring separate product lines, thereby reducing manufacturing complexity and cost while maintaining high adaptability
Solution Approach 2:
The reserve region is designed with a specific density and thickness that allows it to activate only when a certain load threshold is exceeded. By carefully selecting the parameters of the reserve region (density between 30-50 kg/m³, thickness between 5-15 cm), the mattress automatically adapts to different weight categories, eliminating the need for multiple product variations
2Ease of manufacture
If compromises are made in vertebral column support to accommodate multiple body types, then the manufacturing complexity is reduced, but the support quality deteriorates
Solution Approach 1:
The supporting layer is divided into two distinct regions: a first region with optimized support characteristics for lighter individuals and a second reserve region with higher density for additional support. This segmentation allows each region to be optimized for its specific function while working together to provide appropriate support for various body types, maintaining high support quality without compromising manufacturing simplicity
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
This design enables a single foam core or mattress to support multiple body types and sleep positions, reducing production costs and increasing economies of scale by maintaining optimal vertebral column support across a broad range of customers.
Implementation Method 1
The foam core is formed such that the reserve region is not substantially deformed in case of a load on the upper part above the reserve region if the load is below a predetermined limit pressure, and that in case of a load above the predetermined limit pressure, the reserve region is deformed
Data Source
AI summary
A foam core for a mattress including a supporting layer for supporting the vertebral column, the supporting layer including an upper part and a lower part. Different body support regions are provided in the upper part along the longitudinal direction of the foam core, a plurality of the body support regions having at least one recess in the material of the foam core. At least one reserve region is provided in the lower part and has at least one recess in the material of the foam core. The foam core is formed such that the reserve region is not substantially deformed in case of a load on the upper part above the reserve region if the load is below a predetermined limit pressure, and that in case of a load above the predetermined limit pressure, the reserve region is deformed. A mattress having such a foam core is furthermore shown.