Dual Mesh Mattress Foundation for Airflow and Custom Support
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Solution Overview
Problem
Standard mattress designs, including both spring-based and foam core mattresses, face limitations in providing consistent comfort and support, particularly in temperature management and firmness, while conventional box springs are large, heavy, and lack flexibility.
Innovation Solution
A mattress and foundation assembly featuring dual suspension layers with upper and lower flexible mesh layers supported by pivotably coupled u-shaped carriers, allowing for independent adjustment and improved airflow, temperature management, and customizable support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional box springs are used, then structural support is provided, but the foundation becomes large, heavy, and inflexible
Solution Approach 1:
The foundation is divided into multiple independent suspension layers (upper and lower mesh layers) that can move independently, replacing the monolithic box spring structure. Each layer is supported by discrete carriers that pivot independently, distributing weight and enabling flexibility while maintaining support.
Solution Approach 2:
The patent uses flexible mesh materials for both upper and lower suspension layers, replacing rigid wooden frames and wire grids. These flexible membranes provide structural support while allowing movement and adapting to mattress contours, significantly reducing weight compared to traditional box springs.
2Reliability
If foam mattresses are used, then comfort and support are improved, but temperature management and firmness customization become problematic
Solution Approach 1:
The foundation is segmented into upper and lower suspension layers with carriers positioned at discrete points, creating gaps and channels that allow air circulation. This segmented structure enables temperature management by facilitating airflow beneath and between mattress layers.
Solution Approach 2:
The flexible mesh suspension layers function as porous structures that permit air passage while providing support. The mesh configuration creates continuous airflow paths that help dissipate heat and manage temperature, addressing the thermal retention issue common in foam mattresses.
3Adaptability or versatility
If dual suspension layers with independent carriers are used, then flexibility and temperature management are improved, but device complexity increases
Solution Approach 1:
The use of flexible mesh materials simplifies the overall structure compared to rigid assemblies. The mesh layers can conform and move without requiring complex joints or fasteners, reducing assembly complexity while maintaining high adaptability and flexibility.
Solution Approach 2:
The pivotably coupled carriers are designed to move automatically in response to applied loads without requiring external control mechanisms. The system self-adjusts to mattress contours and user position through passive mechanical movement, eliminating the need for motors, sensors, or control systems.
Data Source
AI summary
Mattress and foundation assemblies generally include a mattress; and a mattress foundation for supporting the mattress, the mattress foundation including a frame configured to elevate the mattress relative to ground; and upper and lower flexible mesh suspension layers spaced apart from one another, each independently supported by a plurality of carriers at discrete points about the surface of the suspension layers, wherein the carriers are pivotably coupled to the frame.