Configurable Foam Spring Mattress for Body-Zone Firmness Tuning
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Solution Overview
Problem
Current mattresses fail to provide adequate comfort and support as they lack the ability to adjust firmness to individual user needs, leading to inadequate relief for specific discomfort areas such as back, neck, and joint issues.
Innovation Solution
A mattress system utilizing foam barrels of varying firmness, which can be configured to create different firmness zones, allowing users to select and adjust firmness settings through user interfaces, and incorporating health benefits like activated carbon, tourmaline, and magnets, with the option to reconfigure based on changing health conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional mattresses use uniform foam or spring construction, then manufacturing is simple and cost-effective, but they cannot provide customized firmness for different body regions or user preferences
Solution Approach 1:
The mattress is divided into multiple independent zones, each containing foam springs with specific firmness properties. These zones can be independently configured to address different body regions (head, shoulders, back, hips, legs) or user preferences, allowing customized firmness distribution without requiring complete redesign of the entire mattress structure
Solution Approach 2:
Different firmness levels are applied to specific locations within the mattress rather than using uniform construction throughout. Firmer foam springs are placed in areas requiring more support (e.g., lower back, hips) while softer foam springs are used in areas needing more cushioning (e.g., shoulders, head), creating localized quality variations that optimize comfort and support
2Reliability
If mattresses are designed with adjustable firmness zones for different body regions, then comfort and support are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The foam spring units serve multiple functions: they provide structural support, enable firmness customization, and can be configured for different zone patterns (symmetrical, asymmetrical, diagonal). The same basic foam spring component can be used across different mattress configurations and firmness levels, simplifying manufacturing while maintaining versatility
Solution Approach 2:
Foam springs are pre-configured into complete zone patterns during manufacturing (e.g., symmetrical zones for both sides, or diagonal patterns for single users). This preliminary configuration allows the complex zoning to be established once during production, rather than requiring complex assembly or adjustment by the end user, thereby simplifying the overall manufacturing process
3Ease of operation
If foam springs are used to provide targeted support in specific regions, then relief for discomfort areas is improved, but the mattress structure becomes more complex
Solution Approach 1:
The firmness parameter of foam springs is varied across different zones to provide targeted support. By changing the firmness parameter (density, ILD rating) of foam springs in specific regions, the mattress can be optimized for different body areas without adding mechanical complexity. The foam springs themselves are simply replaced with different firmness ratings rather than adding complex adjustment mechanisms
Data Source
AI summary
An aspect of the present invention relates to a method and system of receiving information of a user's support facility comfort requirements; using a software application to determine a proper support facility firmness configuration to match the user's requirement; selecting foam springs with the proper user required firmness as determined by the software application; and configuring the selected foam springs within the support facility to match the user's firmness requirements.