Mattress core

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Solution Overview

Problem

Traditional spring mattresses face challenges in recycling and disposal due to their complex composition, leading to environmental issues and high recycling costs, while existing foam mattresses struggle to match the performance and consistency of spring mattresses in providing varying densities for comfort.

Innovation Solution

A mattress core manufactured using a single mold with columns of different heights, shapes, and densities, featuring integrated air flow channels and holes, allowing for consistent and efficient production of regions with varying densities without manual assembly or cutting, utilizing higher quality foam to mimic spring mattress comfort without the recycling issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional spring mattresses are used to provide varying densities for comfort, then comfort performance is improved, but recycling and disposal become difficult and expensive

Engineering Contradiction:

Improvecomfort performanceVSAvoidrecycling ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from traditional springs to foam columns with varying densities. By controlling foam density as a continuous parameter during manufacturing, the invention achieves different firmness levels in different mattress regions while using a single material type that is easy to recycle, thus resolving the contradiction between comfort performance and recycling ease

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite foam structures with columns of different densities embedded in a base foam layer. This composite approach allows varying comfort characteristics in different regions while maintaining a unified foam material composition that simplifies recycling compared to multi-material spring mattresses

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If slab stock foam is used to manufacture foam mattresses, then production cost is reduced, but density consistency and quality become poor

Engineering Contradiction:

Improveproduction costVSAvoiddensity consistency

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating columns of foam with specific densities at specific locations within the mattress. The molding process allows different regions to have columns with tailored density characteristics, achieving consistent and controlled density distribution throughout the mattress rather than the random variations found in slab stock foam

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention uses preliminary action by pre-configuring the foam columns within a mold before the final curing process. The columns are positioned and density-adjusted in advance during mold preparation, ensuring consistent density distribution before the foam is poured and cured, thereby achieving manufacturing precision while maintaining cost-effectiveness

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If traditional foam mattresses are manufactured without varying density regions, then manufacturing simplicity is maintained, but comfort performance deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcomfort performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent segments the mattress structure into a base foam layer and multiple columns of varying densities arranged in specific patterns. This segmentation allows different regions to provide different support characteristics, improving comfort performance while the columns are integrated into a single mold, maintaining manufacturing simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The foam columns serve multiple functions: they provide structural support, create varying density regions for comfort, and enable zoned support differentials. By making the columns multi-functional within a single manufacturing process, the invention improves comfort performance without significantly complicating manufacturing

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If pocketed coil mattresses are used to provide zoned support, then comfort performance is improved, but device complexity and disposal difficulty increase

Engineering Contradiction:

Improvezoned support performanceVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the functions of multiple individual spring units into a unified foam column structure. The columns are molded as integral parts of the mattress core, eliminating the need for separate components, fasteners, and assembly steps. This merging reduces structural complexity while maintaining zoned support capabilities through varying column densities

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9706851B2Mattress core

Publication Date: 2017.07.18 MALKIEWICZ JAMES

AI summary

This invention is a mattress core that is manufactured as a single unit. It is made up of individual cones that have different configurations resulting in different densities at different portions of the mattress. There are three main ways to accomplishing this goal: columns of different sizes and shapes, columns with different hole diameters, and columns with different density foam used to create them. A key advantage of this invention is that it is a single mattress made from a single mold, and does not require multiple parts to be put together.