Hybrid Mattress Side Rail Laminate for Edge Support and Comfort
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Solution Overview
Problem
Current side rail assemblies in mattress assemblies, primarily made of foam or foam and coils, fail to provide adequate edge support and user comfort, leading to roll-off issues and insufficient peripheral support.
Innovation Solution
Hybrid side rail assemblies featuring a laminate structure of one or more foam layers and one or more fiber layers in a stacked arrangement, which are peripherally disposed around the mattress inner core to provide enhanced edge support and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional foam or coil side rail assemblies are used, then the structure is simple and easy to manufacture, but the edge support and user comfort are insufficient
Solution Approach 1:
The side rail assembly uses a composite structure combining foam material and fiber material layers. The foam layer provides foundational support while the fiber layer enhances edge support and comfort, creating a hybrid material system that outperforms traditional single-material constructions.
Solution Approach 2:
The side rail assembly is divided into multiple discrete layers including a foam layer and a fiber layer, each with specific functions. This segmentation allows optimization of each layer's properties independently while maintaining overall structural integrity and performance.
2Ease of operation
If traditional foam side rail assemblies are used, then the manufacturing process is simple, but the tactile response and comfort are inadequate
Solution Approach 1:
The combination of foam and fiber materials creates superior tactile response and comfort characteristics that neither material could achieve alone, while the layered composite structure can be manufactured using standard assembly processes.
Solution Approach 2:
The fiber layer is specifically positioned in the side rail assembly where enhanced tactile response and comfort are most needed, providing localized quality improvement without requiring changes to the entire mattress structure.
Data Source
AI summary
A side rail assembly and a mattress assembly including the side rail assembly about at least a portion of a perimeter of the mattress assembly. The side rail assembly includes a laminate structure including one or more foam layers and one or more fiber layers in a stacked arrangement. The fiber layer can be a non-woven layer.