System and method for customizing a mattress

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Solution Overview

Problem

Conventional foam mattresses lack the ability to ergonomically support the human form, particularly in areas with natural arcs and curves, such as the hips, waist, and stomach, due to uniform thickness and density throughout the layers.

Innovation Solution

A multi-layer mattress design featuring a third layer with a curved or wavy shape, partially embedded within the base and second layers, incorporating coils, cavities, or thermoplastic sheets, providing differential support and compression based on body contours.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If uniform thickness and density foam layers are used throughout the mattress, then manufacturing is simple and cost-effective, but ergonomic support for natural body arcs and curves is insufficient

Engineering Contradiction:
Improvemanufacturing simplicityVSAvoidergonomic support
Core Design Contradiction:
Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent applies local quality by varying the density and thickness of foam layers at different locations within the mattress. Specifically, the mattress includes foam layers with different densities arranged in a gradient pattern, where softer foam layers are positioned in areas requiring more cushioning (such as the shoulder and hip regions) and firmer foam layers are positioned in areas requiring more support (such as the lumbar region). This localized variation in material properties enables the mattress to adapt to the natural arcs and curves of the human body while maintaining a relatively simple manufacturing process.

Inventive Principle:
Principle #3Local quality

2Stability of the object's composition

If uniform firmness is maintained throughout the mattress, then structural integrity is preserved, but resistance to compression in specific high-weight areas is insufficient

Engineering Contradiction:
Improvestructural integrityVSAvoidresistance to compression
Core Design Contradiction:
Stability of the object's compositionVSStrength

Solution Approach 1:

The patent implements local quality by creating zones of varying firmness within the mattress structure. The mattress includes alternating layers of soft and firm foam materials, where the firmness is locally optimized based on the expected weight distribution of the human body. High-weight bearing areas such as the hips and lumbar region are positioned over firmer foam layers that provide enhanced compression resistance, while lower-weight areas are positioned over softer foam layers that provide better contouring. This localized differentiation of material properties allows the mattress to maintain overall structural integrity while providing targeted compression resistance where needed.

Inventive Principle:
Principle #3Local quality

3Adaptability or versatility

If the mattress is designed to contour to body curves, then ergonomic support is improved, but the ability to provide uniform support across all body areas is reduced

Engineering Contradiction:
Improvecontouring supportVSAvoiduniform support
Core Design Contradiction:
Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The patent applies segmentation by dividing the mattress into multiple distinct foam layers with different density and firmness properties. Rather than using a single uniform foam material, the mattress is segmented into at least two separate foam layers: a softer top layer that conforms to body contours and a firmer bottom layer that provides foundational support. These segmented layers work together to simultaneously achieve contouring support in high-contact areas and uniform support across the entire mattress surface, resolving the contradiction between adaptability and structural stability.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS12616311B2System and method for customizing a mattress
Publication Date: 2026.05.05 BED PATENT HOLDINGS LLC
  • US12616311B2 patent drawing
  • US12616311B2 patent drawing
  • US12616311B2 patent drawing

AI summary

A mattress includes a first layer, a second layer, and a third layer having a substantially arch shape. The third layer includes a first portion extending in a longitudinal direction from a location proximate to a first longitudinal end towards a second longitudinal end and completely embedded, in a vertical direction, inside the first layer. A second portion extending in a longitudinal direction from the first portion towards the second longitudinal end and at least a part of a length of the second portion is completely embedded, in the vertical direction, inside the second layer. The third layer includes one of a plurality of coils arranged in a grid pattern, a plurality of cavities arranged in a grid pattern, a non-woven thermoplastic sheet having heat bonded strands, or a woven thermoplastic sheet having heat bonded strands.