Mattress Core Crush Section for Compression Shipping
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Solution Overview
Problem
The challenge is to transport multiple mattresses in shipping containers without causing deformation, which makes them unsaleable or unusable due to over-packing, as existing methods fail to balance the need for maximizing container space with the integrity of the mattresses.
Innovation Solution
A mattress core design featuring a resiliently compressible crush section made of high-density foam, which reduces the end-to-end, side-to-side, and top-to-bottom dimensions for transportation, using side and end members coupled by adhesives or fasteners, allowing for efficient packing and decompression without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mattresses are over-packed into shipping containers to maximize the number of mattresses transported, then transport costs are reduced, but the mattresses become irreparably deformed and unsaleable
Solution Approach 1:
The mattress is divided into two distinct sections: an inner spring section and an outer crush section. The crush section is specifically designed to be compressible and sacrificial, absorbing the compression forces during transport while protecting the inner spring section from damage. This segmentation allows the mattress to be compressed for shipping without compromising the integrity of the functional components.
Solution Approach 2:
The outer crush section acts as a pre-designed cushioning layer that protects the inner spring section before any harmful compression occurs during transport. This crush section is intentionally made more vulnerable to deformation so that it absorbs the impact and compression forces, preventing damage to the critical inner spring components.
2Volume of moving object
If mattresses are compressed to fit more in shipping containers, then transport efficiency is improved, but the mattresses suffer structural damage
Solution Approach 1:
Different sections of the mattress are given different mechanical properties. The outer crush section is designed with lower strength and higher compressibility to facilitate volume reduction during transport, while the inner spring section maintains high structural integrity to ensure the mattress remains functional after compression. This local differentiation of material properties allows simultaneous achievement of compact packaging and structural protection.
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
This design enables the safe and efficient transportation of multiple mattress cores by compressing them to fit more in shipping containers while maintaining their structural integrity and original shape, reducing transport costs and preventing damage during shipping.
Implementation Method 1
the crush section is resiliently compressible so as to reduce an end to end length of the mattress core and/or a side to side width of the mattress core for transportation
Implementation Method 2
the fasteners are adhesives
Data Source
AI summary
A mattress core, including an inner spring section; and a crush section overlying side sections and end sections of the inner spring section, wherein the crush section is resiliently compressible so as to reduce an end to end length of the mattress core and/or a side to side width of the mattress core for transportation.