Mattress with a two-layer mattress core and recess zones for hip and shoulder area
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Solution Overview
Problem
Current mattresses lack sufficient variability to accommodate different body shapes, weights, and sleeping habits, as they typically only allow adjustment of hardness or sink zone firmness, failing to provide adequate customization for individual anatomical needs.
Innovation Solution
A mattress design featuring two layers of foam with different spring strengths and integrated sink zones in the hip and shoulder areas, allowing for 8 adjustable hardness combinations by layer rotation and exchange, ensuring the spine maintains its natural shape regardless of sleeping position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a mattress has fixed firmness levels with bonded layers, then manufacturing is simpler, but adaptability to different body types and sleeping habits is insufficient
Solution Approach 1:
The mattress core is divided into separable layers that can be independently positioned. Each layer can be placed in different orientations (flipped) and exchanged with other layers, creating multiple firmness configurations without requiring a completely different mattress structure. This segmentation enables adaptability while maintaining manageable complexity.
Solution Approach 2:
The mattress transitions from a static, fixed-structure design to a dynamic, reconfigurable system. Users can actively adjust the mattress configuration by flipping and exchanging layers according to their specific needs, making the mattress adaptable to changing requirements over time rather than fixed at manufacture.
2Adaptability or versatility
If a mattress offers multiple firmness variations, then adaptability improves, but device complexity and component quantity increase
Solution Approach 1:
Each mattress layer is designed to serve multiple functions: it can be positioned in different orientations (flipped), exchanged with other layers, and used in various combinations. This multi-functionality allows a small set of universal components to generate a large number of firmness variations, avoiding the need for multiple specialized components.
Solution Approach 2:
The mattress achieves multiple firmness variations by changing the arrangement and orientation parameters of existing layers rather than by adding different components. By flipping layers to present different surfaces (top vs. bottom) and exchanging layer positions, the system generates 8 distinct firmness combinations from just two layers, efficiently varying parameters without increasing component count.
3Ease of manufacture
If compression zones are created by removing material, then manufacturing is simpler, but structural integrity and support may be compromised
Solution Approach 1:
Different regions of the mattress layers are designed with locally optimized properties. The top and bottom surfaces of each layer have different characteristics, with the top surface providing compression zone functionality through its specific structure or material properties, while the bottom surface maintains structural integrity. This local quality differentiation allows compression zones to be created without compromising overall strength.
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
This design allows for 8 different overall hardness levels in the sink zones, accommodating various body types and comfort preferences, enabling users to customize their mattress effectively for optimal orthopedic support and adaptability.
Implementation Method 1
a mattress core with at least two layers of foam, for example, cold foam, latex, or viscoelastic foam. These layers have different specific spring strengths and therefore yield differently under an identical load
Implementation Method 2
The compression zones have a reduced spring tension compared to the specific spring tension of the respective layer. These compression zones are orthopedically important so that the spine always maintains its natural shape during the night
Data Source
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AI summary
It is a versatile configurable mattress (100) with a mattress core (10) with at least two superimposed layers (H,W) of foam with different specific spring strengths, in which • two different overall spring strengths of the mattress can be produced solely by exchanging the top and bottom layers; • two different overall firmness levels in the area of the sinking zones can be produced solely by turning the top layer; and • two further different overall firmness levels in the area of the sinking zones can be produced solely by turning the bottom layer.