Mattress Flange Construction for Secure Border Assembly Attachment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mattress construction methods fail to securely attach the border assembly to the sidewalls, leading to potential shifting and misalignment of layers over time, which compromises the evenness and stability of the mattress edges.
Innovation Solution
A flange construction using a non-woven polyester fiber or fabric material is affixed along the perimeter of the mattress, with a flap material adhered to it to secure the border assembly, providing additional center support and anchoring the border assembly to the sidewalls through sewing or gluing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional attachment methods are used to attach the border assembly to the sidewalls, then the manufacturing process is simple, but the border assembly becomes loose and layers become misaligned over time
Solution Approach 1:
The attachment system is divided into multiple functional components: a flange construction with adhesive layer for initial attachment, a border assembly with flap portion for reinforcement, and a separate sewing operation for mechanical fastening. This segmentation allows each component to perform its specific function optimally, ensuring long-term durability while maintaining reasonable manufacturing complexity through modular assembly
Solution Approach 2:
The flange construction with adhesive is applied to the sidewalls before the border assembly is attached. This preliminary action creates a pre-prepared attachment surface that ensures proper positioning and initial bonding, preventing misalignment and ensuring that the border assembly is securely anchored before final sewing reinforcement is applied
2Stability of the object's composition
If the border assembly is securely attached using flange construction with adhesive and sewing, then layer alignment is maintained, but the manufacturing process becomes more complex
Solution Approach 1:
The flange construction acts as an intermediary element between the sidewall and the border assembly. It provides a dedicated adhesive attachment surface that simplifies the bonding process and ensures consistent alignment. The flange serves as a mediator that distributes adhesive evenly and maintains proper positioning during assembly, making the overall process more manageable despite the multiple steps involved
Solution Approach 2:
The flange construction is specifically positioned at the critical interface between the sidewall and border assembly, providing localized reinforcement and alignment features. This local quality enhancement ensures that the most important attachment points have superior bonding characteristics, maintaining layer alignment where it matters most without requiring complex features throughout the entire structure
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
The flange construction effectively secures the border assembly to the mattress sidewalls, preventing layer misalignment and maintaining the mattress's evenness and stability over extended use, outperforming traditional attachment methods by ensuring a durable and long-lasting attachment.
Implementation Method 1
The flap material may be adhered to the flange construction using a substance such as a glue
Data Source
AI summary
A mattress having a flange construction for securing a border assembly is disclosed. The flange construction is formed of a material that is affixed along the perimeter of an upper surface of the mattress. The border assembly includes a flap material for binding the border assembly to the flange construction. The flap material may be adhered to the flange construction, thereby allowing the flange construction to anchor and secure the border assembly to the mattress.