Multi-Core Mattress Border Structure for One-Sided Edge Support
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Solution Overview
Problem
Traditional spring mattresses require periodic rotation or flipping to maintain even wear, which is inconvenient and often not followed by users, leading to uneven support and comfort issues.
Innovation Solution
A mattress design featuring multiple cores with a border material extending between and coupling them, providing a single-piece border that simplifies manufacturing and eliminates the need for multiple seams, while allowing for increased firmness, stability, and comfort by supporting the sleeping surface to the edge of the mattress core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional spring mattresses are designed with padding layers on both sides, then comfort is improved, but the mattress requires periodic flipping to maintain even wear which reduces ease of operation
Solution Approach 1:
The mattress is designed with asymmetric construction where the first mattress core has a first padding layer on its first surface and no padding layer on its second surface, while the second mattress core has a second padding layer on its first surface and no padding layer on its second surface. This asymmetric design creates a functional one-sided mattress that eliminates the need for flipping while maintaining comfort on the sleeping surface.
Solution Approach 2:
Instead of making the mattress symmetric with padding on both sides (traditional approach), the invention inverts the approach by concentrating padding layers only on the surfaces that contact the user, while leaving the opposite surfaces without padding. This inversion eliminates the need for flipping while maintaining comfort.
2Ease of manufacture
If multiple pieces of border material are used to encase the mattress cores, then coverage is improved, but manufacturing complexity increases due to taping and sewing multiple pieces
Solution Approach 1:
The border material is configured as a single continuous piece that extends along the outer edges of both the first and second mattress cores. This merging of multiple border pieces into one continuous piece simplifies manufacturing by eliminating the need to tape and sew multiple separate border pieces together, while still providing complete coverage around the mattress cores.
3Area of moving object
If the sleeping surface is extended to the edge of the mattress core, then effective sleeping area is increased, but structural stability may be compromised
Solution Approach 1:
The mattress is segmented into two separate mattress cores (first and second mattress cores) positioned adjacent to each other. This segmentation allows each core to be independently supported by the border material and connection elements, enabling the sleeping surface to extend to the edges while maintaining structural stability through the distributed support system.
Solution Approach 2:
Connection elements and border material serve as intermediaries between the mattress cores and the support surface. These intermediaries provide structural support that allows the sleeping surface to extend to the edges of the mattress cores while maintaining stability, as the connection elements distribute the load and prevent excessive flexing at the edges.
Data Source
AI summary
Mattress systems and methods for their construction are provided. One such mattress includes a first mattress core and a second mattress core positioned on top of the first mattress core. A border material extends along an outer first edge of the first mattress core and along an outer second edge of the second mattress core. The border material has an intermediate portion which extends between the first and second mattress cores and is coupled to at least one of the first and second mattress cores, and in some aspects to both cores.