Mattress Foam Layer With Large Cleaving for Lateral Creep Support
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Solution Overview
Problem
Conventional flexible foam mattresses lack sufficient elongatability and elastic performance to provide effective anatomical support, particularly in the lateral direction, which limits their ability to accommodate the human form comfortably without the need for complex shaping or contouring.
Innovation Solution
A mattress design featuring a specialized layer with large diameter, through-and-through cloven holes or channels that increase elongatability and elastic performance, allowing the foam to 'creep' laterally under compression, mimicking fluid-like behavior and providing enhanced anatomical support without the need for shaping or contouring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional flexible foam mattresses use progressively layered foam layers of various softness degrees, then anatomical support is achieved, but the elongatability and elastic performance in the lateral direction are insufficient
Solution Approach 1:
The patent introduces a foam layer with large diameter through-holes (cleaved channels) creating a porous structure. This porous configuration allows the foam to elongate and deform laterally when compressed, providing fluid-like adaptability while maintaining support. The holes enable material to shift and redistribute, enhancing elastic performance without compromising anatomical support capability.
Solution Approach 2:
The patent modifies the physical structure of the foam layer by creating large diameter holes (over 1/2 inch) throughout the layer. This structural parameter change transforms the foam from a conventional dense structure to one with significant void space, enabling lateral creep and fluid-like behavior while maintaining the support function through the remaining foam material.
2Strength
If foam layers are shaped and contoured to create defined support areas, then anatomical support zones are achieved, but the device complexity increases
Solution Approach 1:
The patent uses the through-holes to segment the foam layer into distinct regions that naturally form support zones. The holes create a patterned structure where foam material is distributed in a way that provides different levels of support across the mattress surface, eliminating the need for complex shaping and contouring operations while achieving anatomical support zones.
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 mattress achieves enhanced anatomical support by allowing the foam to bulge or swell in areas under less compression, providing soft vertical support and enhanced support for key body regions like the shoulders, hips, neck, ribs, and upper thigh, while maintaining perimeter fastening for increased fluid-like performance.
Implementation Method 1
causing the specialized foam layer to essentially creep laterally when placed under compression, mimicking the performance of fluid
Implementation Method 2
The cloven holes increase the elongatability and the elastic performance of the specialized foam layer
Data Source
AI summary
A layered mattress including a first layer having a first support surface facing substantially externally and a second support surface opposite the first support surface; a specialized layer having a top support surface adjacent the second support surface of the first layer, a bottom support surface, and a plurality of holes defined to extend through the specialized layer; a second layer having a third support surface adjacent the bottom support surface of the specialized layer and a fourth support surface opposite the third support surface; and a pad having a fifth support surface adjacent the fourth support surface of the second layer and a sixth support surface opposite the fifth support surface.