Mattress Support Structure with Flexing Bars for Lumbar Adaptation
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Solution Overview
Problem
Conventional mattresses fail to optimally support the lumbar region of a person due to uniform thickness and hardness throughout their foam layers, which do not adapt to varying anatomical forms.
Innovation Solution
A mattress design featuring a support structure with a plurality of first bars extending longitudinally and laterally, including at least one second bar that facilitates flexing in convex shapes to support the lumbar region, integrated between a support layer and a comfort layer, with a cover enclosing the bars to provide adjustable support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If uniform thickness and hardness foam layers are used throughout the mattress, then manufacturing simplicity is maintained, but the mattress cannot adapt to varying anatomical forms of persons
Solution Approach 1:
The mattress is divided into multiple foam layers with different thicknesses and hardnesses. The first foam layer has a first thickness and first hardness, while the second foam layer has a second thickness and second hardness. This segmentation allows each layer to perform specific functions - the softer first layer adapts to anatomical contours while the firmer second layer provides structural support, resolving the contradiction between adaptability and structural integrity.
Solution Approach 2:
Different regions of the mattress are designed with different properties. The foam layers have varying thicknesses and hardnesses at different locations to match the anatomical variations of the human body. This local quality approach enables the mattress to provide customized support for different body parts (head, shoulders, hips, legs) while maintaining overall structural coherence.
2Ease of manufacture
If uniform hardness foam layers are used, then ease of manufacture is improved, but lumbar region support is insufficient
Solution Approach 1:
The foam mattress is segmented into multiple layers with different hardness levels. The first foam layer uses a softer hardness (lower ILD value) to conform to the lumbar region and provide comfort, while the second foam layer uses a firmer hardness (higher ILD value) to provide structural support. This segmentation maintains manufacturing simplicity through standard foam production processes while significantly improving lumbar support effectiveness.
Solution Approach 2:
The mattress combines two different foam materials with distinct hardness properties in a layered composite structure. This composite approach allows each material to contribute its optimal properties - the softer foam for comfort and contouring, the firmer foam for support - thereby achieving reliable lumbar support while using commercially available foam materials that are easy to manufacture.
3Adaptability or versatility
If even compression of foam layers is used, then structural simplicity is maintained, but optimal adaptation to body contours is not achieved
Solution Approach 1:
The foam layers are designed with non-uniform thickness and hardness distributed throughout the mattress structure. The first foam layer has varying thickness and softer hardness to allow greater compression and adaptation to body contours in areas like the lumbar region. The second foam layer has different thickness and firmer hardness to provide consistent structural support. This local quality variation enables optimal contour adaptation while maintaining a relatively simple two-layer structure.
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 effectively adapts to the anatomical shape of the user by flexing in an arch shape to provide enhanced support to the lumbar region, improving comfort and support distribution.
Implementation Method 1
The at least one second bar is supported on middle portions of the plurality of the first bars, the middle portions are arranged to flex upwardly relative to ends of the plurality of first bars to support the lumbar region of the person
Data Source
AI summary
A mattress is disclosed. The mattress includes a support layer, a comfort layer arranged supported on the support layer and a support structure sandwiched between the support layer and the comfort layer. The support structure includes a plurality of first bars extending in a longitudinal direction and arrayed in a lateral direction and at least one second bar coupled to the plurality of first bars and supported on the plurality of first bars. The at least one second bar extends in the lateral direction and is configured to facilitate a flexing of the plurality of first bars in convex shapes when a person lies on the mattress to support a lumbar region of the person.