Mattress Package with Segmented Core Rolls to Reduce Volume and Weight

Solution Overview

Problem

Existing spring mattresses are large and heavy, requiring significant space for storage and transportation, leading to high costs and difficulty in handling and assembly, with potential for damage during transit.

Innovation Solution

A mattress package comprising a plurality of core rolls formed by rolling up core segments and a covering roll, packaged in a box, allowing for efficient space utilization and easy assembly by consumers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the mattress is made as a one-piece monolithic component, then the structural integrity is improved, but the volume and weight increase, making storage and transportation costly and difficult

Engineering Contradiction:

Improvestructural integrityVSAvoidpackaging volume

Core Design Contradiction:

Stability of the object's compositionVSVolume of moving object

Solution Approach 1:

The mattress core is divided into multiple independent core blocks that can be separately packaged in compressed states. Each core block maintains its structural integrity independently, but collectively they form the complete mattress structure. This segmentation allows each block to be compacted to a fraction of its expanded volume while preserving the overall mattress functionality when assembled.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If the mattress is made as a one-piece monolithic component, then the structural integrity is improved, but the weight increases, making it difficult for users to carry and assemble

Engineering Contradiction:

Improvestructural integrityVSAvoidmattress weight

Core Design Contradiction:

Stability of the object's compositionVSWeight of moving object

Solution Approach 1:

The mattress core is divided into multiple independent core blocks that can be separately packaged in compressed states. Each core block maintains its structural integrity independently, but collectively they form the complete mattress structure. This segmentation allows each block to be compacted to a fraction of its expanded volume while preserving the overall mattress functionality when assembled.

Inventive Principle:

Principle #1Segmentation

3Volume of moving object

If multiple core blocks are used to assemble the mattress, then the packaging volume is reduced, but the packaging complexity and cost increase

Engineering Contradiction:

Improvepackaging volumeVSAvoidpackaging complexity

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

The mattress cover is designed to contain and organize multiple core blocks within a single packaging structure. The cover acts as a container that holds the compressed core blocks in a nested arrangement, simplifying the packaging process. This nested structure allows multiple components to be packaged together as one unit, reducing packaging complexity while maintaining volume efficiency.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS12384611B2Mattress package and method for packaging a mattress

Publication Date: 2025.08.12 INTER IKEA SYST

AI summary

A mattress package may include a plurality of core rolls, a covering roll, and a box containing the plurality of core rolls and the covering roll. The plurality of core rolls may be defined by a plurality of rolled up core segments. The covering roll may be defined by a rolled up cover material configured to cover a mattress core formed via assembling the plurality of core segments.