Mattresses including an elastomeric cushioning element and a pocketed coil layer and related methods
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional mattresses with pocketed coil layers face issues such as aesthetic and tactile concerns due to visible springs, and struggle with compression and packaging, particularly for direct-to-consumer mattresses shipped in logs or boxes.
Innovation Solution
A mattress assembly featuring an elastomeric cushioning element comprising 15-32% of the overall thickness, a coil layer with coils encased in multiple polypropylene bags, and a latex-based adhesive for stabilization, along with a polyurethane foam upper layer to enhance comfort and sound dampening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a wire frame is used around the edge of the mattress to provide structure to the cover, then the structure and support are improved, but the metal of the wire frame may be felt through the cover and the device complexity increases
Solution Approach 1:
The patent removes the wire frame entirely from the mattress construction. Instead of using a wire frame to provide edge support, the invention relies on the inherent structural properties of the foam layers and coil system to provide necessary support without requiring a separate wire frame component.
Solution Approach 2:
The patent applies different material properties to different regions of the mattress. The foam layers are formulated with specific densities and firmness ratings that provide localized support where needed, eliminating the need for a wire frame while maintaining structural integrity throughout the mattress surface.
2Ease of manufacture
If conventional foam is used for cushioning, then the manufacturing is simple, but the durability and compression resistance are insufficient
Solution Approach 1:
The patent employs a composite construction combining multiple foam layers with different densities and firmness ratings, along with an integrated coil support system. This composite approach provides both the durability and compression resistance of coil springs while maintaining the manufacturing simplicity and comfort of foam materials.
Solution Approach 2:
The mattress is divided into distinct functional layers: a comfort layer with softer foam for initial contact, a support layer with denser foam for structural integrity, and an integrated coil system for additional support. This segmentation allows each layer to be optimized for its specific function while maintaining overall manufacturing efficiency.
3Ease of operation
If the elastomeric cushioning element thickness is increased to improve comfort, then the comfort and sound dampening are improved, but the overall mattress thickness and volume increase
Solution Approach 1:
The patent optimizes the thickness parameters of the elastomeric cushioning element to achieve the desired balance between comfort and volume. By carefully selecting the thickness within the specified range and adjusting other structural parameters such as foam density and coil configuration, the invention maximizes comfort while controlling overall mattress dimensions.
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 solution provides improved comfort, lateral stability, and reduced sound levels compared to conventional mattresses, while allowing for easier manufacturing and packaging, as the elastomeric cushioning element and polyurethane foam configuration better conforms to weight and reduces the need for laminating the coil layer.
Implementation Method 1
Cushioning materials may be formed of materials that deflect or deform under load, such as polyethylene or polyurethane foams
Implementation Method 2
springs (e.g., coil springs) may be preferable to foam for their durability and ability to withstand compression
Implementation Method 3
a latex-based adhesive for stabilization
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A mattress assembly includes a base layer, a coil layer disposed over the base layer, an upper layer disposed over the coil layer, and an elastomeric cushioning element disposed over the upper layer. The coil layer may include a plurality of pocketed coils. Furthermore, the elastomeric cushioning element may have a thickness within a range of about 2.0 inches (5.08 cm) to about 4.5 inches (11.43 cm). Furthermore, the elastomeric cushioning element may form between about 15.0% and about 32.0% of an overall thickness of the mattress assembly. A method of forming a mattress assembly includes disposing a coil layer over a base layer, disposing an upper layer over the coil layer, disposing an elastomeric cushioning element over the upper layer, and disposing an outer covering over at least the upper layer.