Mattress with Overlapping Edge Segments for Adjustable Bed Flexibility
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Solution Overview
Problem
Rigid edge support systems in mattresses, particularly those with thermally-welded polyethylene side walls, are not well-suited for adjustable bed bases as they do not flex effectively with the changing shape of the bed, leading to issues like 'roll-out' and loss of edge support when the mattress is bent.
Innovation Solution
A flexible mattress design featuring overlapping edge segments with resilient anchors that can articulate and adjust to accommodate the shape changes of an adjustable bed base, ensuring continuous edge support and a flat surface without bulging or rolling out.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid edge support systems with thermally-welded polyethylene side walls are used, then edge support durability and resistance to roll-out are improved, but the mattress cannot effectively flex with changing bed base shapes
Solution Approach 1:
The edge support system is divided into multiple discrete edge segments that can move independently relative to each other. Each segment is anchored to the mattress support but can articulate at its leading edge, allowing the segmented structure to flex and adapt to changing bed base shapes while maintaining overall edge support integrity.
Solution Approach 2:
The edge segments are designed with dynamic characteristics, featuring resilient anchors and tapered leading edges that allow controlled movement and articulation. This dynamic design enables the edge support system to adapt its configuration in response to bed base shape changes, transitioning from a static rigid structure to a dynamic adaptive one.
2Ease of manufacture
If traditional rigid edge support systems are used on adjustable bed bases, then manufacturing simplicity is maintained, but the mattress develops bulging and roll-out issues when bent
Solution Approach 1:
By segmenting the edge support into multiple independent units with standardized anchors and configurations, the design maintains manufacturing efficiency through modular assembly while eliminating the bulging and roll-out problems associated with continuous rigid structures when bent.
3Adaptability or versatility
If overlapping edge segments with resilient anchors are used, then adaptability to bed base shape changes is improved, but device complexity increases
Solution Approach 1:
The edge segments utilize resilient anchors that function as flexible connection elements, allowing articulation without requiring complex mechanical joints or moving parts. This approach achieves high adaptability through material-level flexibility rather than mechanical complexity.
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 flexible edge support system maintains firm support and a flat surface in both flat and bent configurations, securely anchoring the side and end walls to the spring unit, even during bending, thus addressing the limitations of traditional rigid edge support systems.
Implementation Method 1
The head portion comprises at least one barb. Preferably the head portion comprises two barbs. Preferably the head portion comprises two opposed barbs.
Implementation Method 2
One fairly unique way of providing edge support comprises thermally-welded polyethylene side walls to a polyethylene base to form a single integrated base and edge support system.
Data Source
AI summary
A mattress 10 that provides an edge support feature that remains firmly supportive throughout bending of the mattress on an adjustable foundation, while also providing a flat, tailored finish for the side of the mattress. The mattress has a base, an upper surface, and two side walls extending between two end walls such that the base, upper surface, side walls, and end walls define a cavity comprising a mattress support, such as a spring unit, that supports the upper surface above the base. The side walls and/or end walls comprise an edge support system having a plurality of overlapping edge segments.