Mattress structure and production method of the same
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Solution Overview
Problem
Traditional inflatable mattresses are heavy due to their internal fillings, making them difficult to transport and maintain, and they lack the necessary elasticity for comfortable sleep.
Innovation Solution
The mattress structure incorporates a sponge layer with grooves cut using a numerically controlled cutting machine, reducing the sponge's weight and amount used, and is bonded to TPU composite fabric layers with an adhesive, optionally featuring heat insulation and a light reflecting film, allowing for auto-inflation and enhanced comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sponge layer is added to inflatable mattress for better resilience and inflating effect, then mattress comfort and elasticity are improved, but mattress weight increases making it difficult to transport
Solution Approach 1:
The sponge layer is designed with a porous structure containing multiple cavities and grooves. This porous configuration reduces the overall density and weight of the sponge material while maintaining its elastic and resilient properties. The cavities allow air circulation and reduce material usage, achieving weight reduction without sacrificing comfort or support functionality.
Solution Approach 2:
The sponge layer is segmented into multiple sections with grooves dividing it into distinct regions. This segmentation creates multiple smaller cavities throughout the sponge structure, reducing the amount of solid material needed while maintaining structural integrity and elastic performance. The segmented design also facilitates air flow and reduces overall weight.
2Stability of the object's composition
If traditional mattress structure is used, then mattress provides basic support, but mattress becomes bulky and difficult to transport and store
Solution Approach 1:
The mattress utilizes a flexible inflatable structure with thin film-like layers including the sponge layer, top layer, and bottom layer. These flexible layers can be compressed and folded when deflated, dramatically reducing volume for storage and transport. When inflated, they maintain structural integrity and provide necessary support functions.
Solution Approach 2:
The mattress structure is designed to dynamically change between inflated and deflated states. The sponge layer and surrounding structures are configured to provide support when inflated but collapse into a compact form when deflated, enabling easy transport and storage while maintaining functional performance during use.
3Stability of the object's composition
If solid sponge material is used throughout the mattress, then mattress provides uniform support, but manufacturing process becomes time-wasting and material usage is excessive
Solution Approach 1:
Instead of using solid sponge material throughout, the invention employs porous sponge with cavities and grooves. This porous structure achieves uniform support distribution through the air-filled cavities while reducing material usage. The standardized porous pattern can be efficiently manufactured using mold injection or cutting processes, improving production speed and reducing material waste.
Solution Approach 2:
The sponge layer is segmented into standardized modules with grooves creating uniform cavities. This modular segmentation allows for efficient manufacturing through repetitive cutting or molding processes, significantly improving production efficiency. The segmented design also reduces material usage while maintaining uniform support characteristics across the mattress surface.
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 design significantly reduces the overall weight of the mattress, conserves sponge material, and enhances heat insulation and comfort through auto-inflation and massage-like effects, while maintaining resilience and ease of use.
Implementation Method 1
the material of the adhesive layer may be TPU, PVC or EVA, or various other polymer composite materials that can bond the sponge layer to the top layer and to the bottom layer with a hot-melting operation or a high frequency operation
Implementation Method 2
the material of the adhesive layer may be TPU, PVC or EVA, or various other polymer composite materials that can bond the sponge layer to the top layer and to the bottom layer with a hot-melting operation or a high frequency operation
Implementation Method 3
a plurality of first grooves are provided in the sponge layer arranged between the top layer and the bottom layer, which can lighten the weight of the sponge layer and accordingly, the weight of the whole mattress structure
Implementation Method 4
either the top layer or the bottom layer is provided with an air charging nozzle that is in communication with the sponge layer
Data Source
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Figure 11~14
AI summary
Provided are a mattress structure and a production method of the same, relating to the technical field of inflatable beds. The mattress structure includes: a top layer (1), a sponge layer (3) and a bottom layer (2) that are connected successively, wherein a plurality of first grooves (4) are provided in the sponge layer (3). In the mattress structure, a plurality of first grooves (4) are provided in the sponge layer (3) arranged between the top layer (1) and the bottom layer (2), which can lighten the weight of the sponge layer (3) and accordingly, the weight of the whole mattress structure; moreover, not only the weight can be lightened, but also the used amount of sponge can be saved, which means that it has the advantages of convenient use and energy saving etc.