Modular Foam Mattress Topper for Adjustable Cushioning Support

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Solution Overview

Problem

Consumers lack a customizable mattress topper system that allows for varying support characteristics by combining a viscoelastic foam topper with a polyurethane foam topper, which can be arranged in multiple configurations over an existing mattress.

Innovation Solution

A mattress topper system comprising a first viscoelastic foam layer with a shaped top surface and a second foam layer, either conventional polyurethane or viscoelastic, with varying densities, packaged together for consumers to adjust support levels by altering their orientation over a mattress, allowing for a range of hardness from IFD25 of 4 to 25.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a single mattress topper is used, then the structure is simple and easy to install, but the support characteristics cannot be customized or varied

Engineering Contradiction:

Improvecustomizability of support characteristicsVSAvoidnumber of topper components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mattress topper system is divided into multiple separable components (first topper and second topper) that can be independently selected and combined. Each topper has distinct properties (viscoelastic vs. conventional foam, shaped surfaces) that can be mixed and matched to create customized support characteristics, resolving the contradiction between adaptability and complexity by allowing modular assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The topper system is designed to perform multiple functions through different configurations. The same set of toppers can be arranged in various orientations (upright, inverted, combined) to provide different support levels (soft to firm), making the system universally applicable to diverse consumer needs without requiring multiple separate products.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple foam layers with different densities are combined, then support level can be varied from IFD25 of 4 to 25, but the system becomes more complex to package and deliver

Engineering Contradiction:

Improverange of hardness optionsVSAvoidpackaging and delivery of multiple components

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Multiple foam layers with different densities and properties are combined into a single packaged system delivered to the consumer. The first topper (viscoelastic, higher density) and second topper (conventional or viscoelastic, lower density) are packaged together as a coordinated set, simplifying the manufacturing and delivery process while maintaining the ability to create varied hardness options through different arrangements.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If shaped surfaces are used on foam layers, then comfort and body conforming are improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvecomfort and heat retentionVSAvoidprecision of shaped surface formation

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The foam toppers feature shaped surfaces with local variations in geometry (peaks, valleys, contours) that provide enhanced comfort and body conforming in specific areas. These localized shape features are formed through convolute cutting or similar processes that create the desired surface topology while maintaining manufacturing feasibility, balancing comfort improvement with manufacturing precision requirements.

Inventive Principle:

Principle #3Local quality

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 consumers to customize the cushioning support level by providing multiple configurations that increase the support level and hardness of the mattress topper system, offering greater flexibility and comfort options without requiring a new mattress.

Implementation Method 1

Viscoelastic or memory foams exhibit a slower recovery from compression as compared to other foams, such as conventional polyurethane foams. Viscoelastic foams conform to a body reclining thereon

Methodology Applied

Scientific EffectViscoelasticity: Viscoelasticity

Implementation Method 2

conventional polyurethane foams

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS8209804B2Customizable mattress topper system

Publication Date: 2012.07.03 FXI INC

AI summary

A customizable mattress topper system includes a first mattress topper of viscoelastic foam with a shaped top surface and a second foam mattress topper. The viscoelastic foam topper has a higher density than the second topper. The first mattress topper and second mattress topper are packaged and sold together as a system. The first mattress topper may be placed over the second mattress topper, or vice versa, and in various orientations over a bedding mattress as desired by a consumer to customize the level of cushioning support.