Mattress assembly

Solution Overview

Problem

Conventional mattress assemblies are costly and heavy due to multiple foam layers, and their firmness and comfort can vary significantly, making them difficult to manufacture and adjust for different user preferences.

Innovation Solution

A mattress assembly comprising a viscoelastic foam layer for body conformance, a non-viscoelastic foam layer for support, and embedded static spring elements to enhance firmness, allowing for adjustable comfort and reduced production costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If multiple foam layers are used to adjust firmness and comfort, then comfort and support are improved, but manufacturing cost and weight increase

Engineering Contradiction:

Improvecomfort and supportVSAvoidmattress weight

Core Design Contradiction:

Ease of operationVSWeight of stationary object

Solution Approach 1:

The patent combines viscoelastic foam and non-viscoelastic foam in a layered composite structure to achieve different functional properties in each layer, optimizing both comfort and support while controlling weight

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different foam layers are assigned different firmness characteristics - the viscoelastic layer provides softer comfort for body contact while the non-viscoelastic layer provides firmer support, creating local quality variations throughout the mattress

Inventive Principle:

Principle #3Local quality

2Ease of operation

If multiple foam layers are used to adjust firmness and comfort, then comfort and support are improved, but manufacturing cost increases

Engineering Contradiction:

Improvecomfort and supportVSAvoidmanufacturing cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent combines viscoelastic foam and non-viscoelastic foam in a layered composite structure to achieve different functional properties in each layer, optimizing both comfort and support while controlling weight

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different foam layers are assigned different firmness characteristics - the viscoelastic layer provides softer comfort for body contact while the non-viscoelastic layer provides firmer support, creating local quality variations throughout the mattress

Inventive Principle:

Principle #3Local quality

3Strength

If static spring elements are added to enhance firmness, then firmness and support are improved, but device complexity increases

Engineering Contradiction:

ImprovefirmnessVSAvoidmattress structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The mattress is divided into distinct functional layers (viscoelastic foam layer, non-viscoelastic foam layer, and spring element layer), with each layer performing a specific function. This segmentation allows for independent optimization of each component while maintaining overall system simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines viscoelastic foam and non-viscoelastic foam in a layered composite structure to achieve different functional properties in each layer, optimizing both comfort and support while controlling weight

Inventive Principle:

Principle #40Composite materials

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 mattress assembly provides a cost-effective, lightweight solution with adjustable firmness and comfort, enabling tailored support for different body regions while maintaining durability and comfort characteristics.

Implementation Method 1

a first layer of viscoelastic foam defining an upper surface

Methodology Applied

Scientific EffectViscoelasticity: Viscoelasticity

Implementation Method 2

a plurality of static spring elements positioned beneath the upper surface for enhancing a firmness of the combined first and second layers

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9848711B2Mattress assembly

Publication Date: 2017.12.26 TEMPUR WORLD LLC

AI summary

A mattress assembly includes a first layer of viscoelastic foam defining an upper surface, and a second layer of non-viscoelasiic foam supporting the first layer. The mattress assembly also includes a plurality of static spring elements positioned beneath the upper surface for enhancing a firmness of the combined first and second layers.