Mattress Assembly with Segmented Border Wires for Modular Portability
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Solution Overview
Problem
Conventional mattresses are large, heavy, and inflexible, making them difficult to move and transport, and they often require uniform firmness, which can be a drawback for shared sleeping arrangements.
Innovation Solution
A mattress assembly featuring segmented border wires joined by releasable connectors, allowing for customization and easy assembly/disassembly, enabling two mattresses to be joined together for a larger surface, and compatible with both foam and spring cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional mattresses are manufactured as single large units, then structural integrity and support are maintained, but portability and ease of transportation deteriorate
Solution Approach 1:
The mattress is divided into multiple separable sections with standardized connection interfaces. Each section can be independently handled and transported, then reconnected to form the complete mattress structure, resolving the contradiction between maintaining structural integrity and improving portability.
Solution Approach 2:
The mattress structure transitions from a fixed monolithic form to a dynamic configurable system where sections can be connected or separated based on transportation or usage needs. The connection mechanism allows the mattress to adapt between a unified strong structure and separable portable units.
2Ease of manufacture
If mattresses are made with uniform firmness throughout, then manufacturing simplicity is maintained, but adaptability to different user preferences deteriorates
Solution Approach 1:
The mattress is divided into independent sections that can have different firmness characteristics. Each section can be manufactured with specific foam densities or support properties tailored to user preferences, while maintaining standardized connection interfaces for assembly simplicity.
Solution Approach 2:
Different sections of the mattress can have locally optimized properties such as varying foam densities, firmness levels, or support characteristics. This allows customization for different sleeping positions or user preferences in different zones without complicating the overall manufacturing process.
3Stability of the object's composition
If mattresses are constructed as single integrated units, then structural stability is ensured, but ease of assembly and reconfiguration deteriorates
Solution Approach 1:
The mattress structure is segmented into modular sections with standardized connection interfaces that ensure stable assembly. The interfaces are designed to maintain structural integrity when connected while allowing easy separation and reconfiguration, resolving the contradiction between stability and ease of assembly.
Solution Approach 2:
Connection interfaces are pre-configured on each mattress section during manufacturing, with alignment features and attachment mechanisms prepared in advance. This preliminary preparation enables quick and stable assembly without requiring complex field configuration or specialized tools.
Data Source
AI summary
Disclosed is a mattress assembly having a spring or foam core structure and reduced-sized parts. Spaced along the mattress top and bottom border are a plurality of bands having through-openings. Border wire segments extend through the through-openings and are joined end-to-end by releasable connectors to form a continuous border wire providing edge support. Butterfly springs having tube-like bands for receiving the border wire segments prevent sagging. In spring mattresses, the bands, which may be rings or a similar type part, are carried at the top and bottom of the outer springs. In foam mattresses, the bands are formed by a plurality of loops formed in a continuous folded strip fixed by adhesive or other means to the mattress border walls. Two such mattresses may be joined together by interweaving a flexible cord through the bands of adjoining mattresses. The mattress assembly is completed by encasing in an outer cover.