Foam Perimeter Structure for Mattress Edge Support
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Solution Overview
Problem
Conventional mattress foundations provide inadequate reflexive vertical support at the perimeter region, leading to a 'roll-off' tendency and insufficient support when the edge of the mattress is used as a seat, due to the lack of direct support for the border wire, which results in high perimeter loads and increased manufacturing costs when attempting to address this issue.
Innovation Solution
A mattress foundation with an integral perimeter structure made of foam components that extend from the frame to the border wire, providing structural rigidity, flexure, and resilience to enhance support and reduce the 'roll-off' tendency, which can be either a single molded structure or assembled from multiple foam pieces, interacting with the springs and grid to distribute loads effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If perimeter spring elements are added to provide direct vertical support to the border wire, then vertical support at the perimeter region is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the perimeter support function with the existing spring grid structure by positioning springs at perimeter intersections where they simultaneously support both the border wire and the grid, eliminating the need for separate perimeter spring elements
Solution Approach 2:
The springs located at perimeter intersections serve multiple functions: they provide vertical support to the border wire, support the grid structure, and contribute to the overall resilience of the foundation, thereby achieving perimeter support without additional components
2Strength
If the border wire is made of heavier gauge to increase strength, then load-bearing capacity is improved, but the flexibility and reflexive support at the perimeter is reduced
Solution Approach 1:
The patent applies different support characteristics to different regions of the border wire by using the flexible spring elements at perimeter intersections, allowing the heavier gauge border wire to maintain strength while the spring-supported sections provide the necessary flexibility and reflexive support
3Strength
If a dense distribution of springs is used to support the weight of the mattress, then load-bearing capacity is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent provides adequate support by positioning springs at key perimeter intersections and select internal points rather than distributing springs uniformly across the entire foundation, achieving sufficient load-bearing capacity with fewer total springs
Solution Approach 2:
The foundation is divided into distinct support zones with springs strategically positioned at perimeter intersections and internal points, creating an optimized support network that reduces the total number of springs needed while maintaining adequate load-bearing capacity
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 foam perimeter structure improves vertical support at the perimeter region, reducing the 'roll-off' tendency and enhancing the overall load-bearing capacity of the mattress foundation while maintaining flexibility and reducing manufacturing costs by eliminating the need for additional perimeter spring elements.
Implementation Method 1
The foam components of the perimeter structure have at least some attributes of structural rigidity, flexure and resilience which cooperates with movement or deflection of the border wire and/or the grid
Data Source
AI summary
A mattress foundation with a perimeter structure has a frame, springs mounted upon the frame, and a grid supported by the springs, and perimeter structure at a perimeter of the frame which extends from the frame to the grid, forming an exterior wall which extends from the frame to a border wire of the grid. When the perimeter structure is made of structural and reflexive material such as closed-cell foam, it co-acts with the grid and springs and provides additional support to the perimeter region of the grid and foundation. The exterior wall of the perimeter structure forms a solid surface over which padding or upholstery is placed.