Mattress Foot Section Hole Layout for Smooth Contraction
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Solution Overview
Problem
Conventional mattresses with adjustable foot sections face issues such as hindered contraction due to uncompressed side parts and potential strength deterioration from corrugation, leading to inefficient force distribution and increased processing steps.
Innovation Solution
A mattress design featuring linear holes inclined relative to the width direction, arranged in a staggered layout with alternating inclinations, allowing efficient shearing stress application without corrugation, maintaining strength and reducing processing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cross-shaped or linear shaped through-holes are punched at regular intervals in a staggered layout to adjust contractibility, then the degree of repulsion can be adjusted, but the side parts of the punched holes cannot be compressed which hinders proper contraction
Solution Approach 1:
The patent changes the hole shape from symmetric cross-shaped or linear holes to asymmetric diamond-shaped holes with inclined sides. The inclined sides at approximately 45 degrees create asymmetric surfaces that can be compressed during contraction, allowing the hole to deform properly and enabling the mattress to contract smoothly without the side parts resisting compression.
Solution Approach 2:
The patent modifies the geometric parameters of the holes by changing their shape and orientation. The diamond-shaped holes are inclined at specific angles (approximately 45 degrees) relative to the longitudinal direction, which changes how the holes respond to compression forces and enables efficient shearing stress application during contraction.
2Length of moving object
If the mattress core is formed with corrugation in the foot section to allow length diminution, then the foot section can contract, but the heels and body may sink into the grooves and hit the bottom
Solution Approach 1:
The patent removes the corrugation structure from the mattress core and replaces it with a flat core containing diamond-shaped holes. This extraction of the harmful corrugation element eliminates the grooves that cause heels and body to sink, while the diamond-shaped holes provide the necessary contraction capability through a different mechanism that does not create harmful surface irregularities.
3Length of moving object
If corrugation is formed to enable contraction, then the foot section can diminish in length, but the mattress core becomes thin which risks strength deterioration
Solution Approach 1:
The patent removes the corrugation structure that thins the mattress core and replaces it with a flat core design. The contraction capability is achieved through the diamond-shaped holes rather than through corrugation, thereby maintaining the core thickness and strength while still enabling the foot section to diminish in length when needed.
Solution Approach 2:
The patent uses a porous structure with diamond-shaped holes distributed throughout the flat mattress core. This porous design allows contraction through the deformation and closing of the holes during compression, providing the necessary length adjustment without requiring the core to be thinned through corrugation, thus maintaining structural strength.
4Force
If the foot fits in the groove of the corrugation, then contraction force acts on the foot, but the contraction of the mattress is hindered
Solution Approach 1:
The patent removes the corrugation grooves that trap the foot and prevent proper contraction. The diamond-shaped holes provide a different mechanism where the foot can apply contraction force without being trapped in grooves, allowing the mattress to contract smoothly as the holes deform and close during compression.
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
Enables easy contraction and uniform deformation of the mattress, preventing strength loss and processing step increases, while ensuring the mattress remains easy to use and maintain.
Implementation Method 1
easy to contract thanks to efficient application of shearing stress to the punched holes of the mattress
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3(a)~3(b)
AI summary
In order to provide a mattress that has punched holes of the same number and the same area as conventional products, is easy to contract thanks to efficient application of shearing stress to the punched holes of the mattress without the need of corrugation forming, and will neither deteriorate in strength nor increase the number of processing steps compared to conventional products, as well as a bed device using the mattress, a mattress 10 has such a structure that the (core of) foot section 18 is formed with a plurality of linear shaped holes 28 that are penetrated at regular intervals in the thickness direction of the foot section with the orientation of the linear-shape inclined relative to the width direction of mattress 10, and the plurality of holes 28 are arranged in the mattress 10 in a staggered layout when viewed from top.