Mattress with segmented foam core
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Solution Overview
Problem
Adjustable beds cause mattresses to stretch or tear when bending, and fail to conform to the base, resulting in gaps between the mattress and the adjustable base.
Innovation Solution
A mattress structure with a high-density foam support core featuring cranial and caudal flexion channels and stress relief channels, allowing for flexible bending without tearing or compression, and a mattress cover with comfort layers for enhanced support and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the mattress is made from solid high-density foam to provide support, then the support strength is improved, but the mattress cannot flex without stretching or tearing
Solution Approach 1:
The support core is segmented through channels and cuts that divide the solid foam into separate sections. These segments allow the mattress to flex and bend without stretching or tearing the foam material, while the remaining foam sections maintain structural support. The segmentation creates a balance between strength and flexibility by allowing controlled movement through the channels while preserving support in the solid foam regions.
Solution Approach 2:
Different regions of the support core have different properties: areas with channels and cuts provide flexibility and bending capability, while areas with solid foam provide support strength. This local differentiation of material properties allows the mattress to simultaneously achieve both support and flexibility in different locations, resolving the contradiction between these two requirements.
2Stability of the object's composition
If the mattress is made rigid to maintain structure, then the structural stability is improved, but the mattress cannot conform to the adjustable base shape during flexion
Solution Approach 1:
The support core is divided into segments by channels and cuts, allowing the mattress to bend and conform to the adjustable base shape while maintaining structural stability. The segmented structure enables controlled flexion without compromising the overall structural integrity of the mattress.
Solution Approach 2:
The support core transitions from a static rigid structure to a dynamic flexible structure through the addition of channels and cuts. These features allow the mattress to adapt its shape dynamically when the adjustable base is positioned at different angles, while the remaining solid foam maintains structural stability during the transition.
3Adaptability or versatility
If channels and cuts are removed from the support core to enable flexion, then the flexibility is improved, but the support strength is reduced
Solution Approach 1:
Instead of completely removing material from the support core, channels and cuts are created that provide sufficient flexibility while leaving enough solid foam remaining to maintain support strength. The partial removal of material achieves the necessary flexibility without excessive loss of structural support.
Solution Approach 2:
The channels and cuts are strategically positioned in specific locations within the support core to provide flexibility where needed while preserving support strength in other areas. This localized modification allows the mattress to flex without significantly compromising overall support.
Data Source
AI summary
A mattress including a support core formed from a high-density foam, one or more comfort layers, and a mattress cover is disclosed. The support core includes a top face, a bottom face, a first lateral face, and a second lateral face with a cranial flexion channel, a caudal flexion channel, and at least one stress relief channel position on the bottom face. The cranial flexion channel and the caudal flexion channel are each formed from gaps having a width of 0.5 to 2.5 inches and the at least one stress relief channel is formed from a cut in the high-density foam extending between the first lateral face and the second lateral face. The cranial flexion channel, the caudal flexion channel, and the at least one stress relief channel each have a depth leaving a residual thickness of intact high-density foam of 1 inch to 3 inches aligned with each channel.