Layered Tubular Foam Spring for Nonlinear Mattress Support
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Solution Overview
Problem
Existing foam springs are not suitable for use by individuals of varying weights, as they either compress excessively under heavier individuals or provide inadequate support, and their stiffness affects the comfort and vibration absorption characteristics.
Innovation Solution
A foam spring with a tubular resilient body composed of multiple foam layers of differing physical characteristics, where softer layers compress easily and harder layers resist further compression, achieving a non-linear compression characteristic and strain hardening effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a foam spring is made with low stiffness to be soft, then it is suitable for lighter persons, but it compresses too much for heavier persons causing them to sink into the mattress
Solution Approach 1:
The foam spring is segmented into multiple foam layers with different physical characteristics (different stiffness values). Each layer can be independently designed with specific density and elasticity properties, allowing the spring to provide appropriate support for varying weights without excessive compression.
Solution Approach 2:
The foam spring uses composite foam structure with layers of different foam materials or densities. This composite approach combines the advantages of soft foam (comfort for light persons) and hard foam (support for heavy persons) into a single spring unit, achieving adaptability across different weight ranges.
2Strength
If a foam spring is made with high stiffness to provide firm support, then it is suitable for heavier persons, but it creates a hard contact surface feeling that reduces comfort
Solution Approach 1:
Different foam layers are assigned different local qualities (stiffness values) to perform different functions. The softer top layers provide comfortable contact surface feeling for user comfort, while the harder bottom layers provide firm support capability. Each layer's properties are optimized for its specific location and function within the spring.
3Loss of energy
If a foam spring is designed to be very soft to absorb and damp vibrations, then it provides good vibration damping, but it results in a hard contact surface feeling that reduces user comfort
Solution Approach 1:
The foam spring is divided into functional segments: softer layers positioned to contact the user for comfort, and layers with specific damping properties positioned to absorb vibrations. This segmentation allows independent optimization of comfort and vibration damping characteristics without compromise.
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 spring provides adequate support for varying weights by compressing sufficiently under lighter loads and resisting further compression under heavier loads, while allowing for a comfortable soft or hard contact surface depending on the layer configuration, thus addressing the issue of weight variability and comfort in applications like pillows and mattresses.
Implementation Method 1
a foam spring having a tubular resilient body made of foam with holes extending inwardly from an outside surface to an inside surface
Implementation Method 2
the softest foam layer or layers will compress easily, while it will be more difficult to compress the harder layer or layers
Data Source
AI summary
A foam spring for use in pillows, cushions, mattresses or the like, the foam spring having a tubular resilient body-made of foam with holes extending inwardly from an outside surface to an inside surface, wherein the tubular body-comprises at least one tubular foam layer and at least one reinforcing layer applied to said foam layer over at least a part of the axial length of the spring.