Perimeter-Wrapped Mattress Core to Prevent Edge Flattening
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional mattresses with foam encasements suffer from flattening under user weight due to flexibility, leading to uncomfortable pressure points and reduced support, especially at the perimeter edges, and staples tend to pull out when mattresses are adjusted.
Innovation Solution
A non-woven, non-elastic fabric is wrapped around the perimeter of the mattress core structure to compress and hold it in place, preventing flattening and securing staples, thereby maintaining mattress shape and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a foam encasement is used to shape the mattress perimeter, then the mattress corners are shaped and lateral support is provided, but the foam becomes flexible allowing the core structure to spread and flatten under user weight
Solution Approach 1:
The patent changes the material parameter from flexible foam to non-elastic non-woven fabric, fundamentally altering the mechanical properties of the perimeter encasement. This parameter change eliminates the flexibility issue while maintaining the shaping function, preventing the core structure from spreading under load.
Solution Approach 2:
The invention combines the non-woven fabric encasement with the foam core structure and staple assembly to create a composite system. The fabric layer provides structural integrity and prevents spreading, while the foam provides cushioning, and the staples provide secure attachment - together forming a composite solution that addresses all requirements.
2Duration of action of stationary object
If polyurethane foam is used for the encasement, then the mattress perimeter is supported, but the foam breaks down over time becoming softer and failing to provide a sturdy sitting edge
Solution Approach 1:
The patent changes the material from polyurethane foam to non-woven fabric, fundamentally altering the degradation characteristics. Non-woven fabric does not undergo the same softening degradation as foam over time, maintaining its structural properties and providing lasting support for sitting edges.
3Force
If foam encasement is used, then lateral support is provided, but the flexible foam allows the core structure to spread outward pushing the encasement outward and flattening the mattress
Solution Approach 1:
The patent changes the encasement material from flexible foam to non-elastic non-woven fabric, fundamentally altering the force transmission characteristics. The non-elastic fabric provides rigid lateral support that prevents the core structure from spreading outward, maintaining core stability while providing necessary support forces.
4Ease of manufacture
If staples are used to secure flanges to side walls, then the cover is attached, but the staples pull out when the mattress is bent in adjustable beds
Solution Approach 1:
The patent applies the non-woven fabric encasement beforehand to protect and reinforce the staple attachment points. This prior application of the fabric layer prevents staple pullout by distributing the stress and providing a protective barrier, ensuring reliable attachment even when the mattress is bent in adjustable beds.
Data Source
AI summary
A mattress (22) having a core structure (8) wherein side walls (15) are compressed inward and held in place using a preferably non-woven strip of fabric (21) or similar non-elastic or non-stretchable material that is wrapped around the side walls.