Modular Mattress Assembly with Internal Overlap for Compact Packaging
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Solution Overview
Problem
The delivery and installation of mattresses can be burdensome due to their bulkiness and weight, despite efforts to reduce size through compact packaging techniques.
Innovation Solution
A modular mattress design comprising a bottom mattress assembly and a top mattress assembly that can be assembled and disassembled, with an internal overlap that secures the top assembly to the bottom, enhancing tensile strength and facilitating separate packaging and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If compact packaging techniques are used to reduce mattress size, then the volume and ease of delivery are improved, but the weight remains high and structural integrity may be compromised
Solution Approach 1:
The mattress is divided into multiple assemblies (bottom assembly with foundation and bottom cushioning element, top assembly with top cushioning element) that can be packaged separately in compact forms while maintaining individual structural integrity. Each assembly can be compressed independently during packaging yet retains its strength when assembled.
2Ease of operation
If a modular design with separate assemblies is used, then ease of assembly and disassembly is improved, but device complexity increases
Solution Approach 1:
The mattress is segmented into bottom and top assemblies that can be independently packaged and assembled. The bottom assembly includes a foundation and bottom cushioning element, while the top assembly includes a top cushioning element. These segmented components simplify handling and assembly while maintaining overall structural integrity through their coordinated design.
Solution Approach 2:
The top assembly is designed to be positioned on top of the bottom assembly, with the top cushioning element resting on the bottom cushioning element. This nested arrangement allows compact packaging of individual assemblies while enabling straightforward assembly by stacking the components in a logical sequence.
Data Source
AI summary
A mattress that includes a bottom mattress assembly and a top mattress assembly that may be assembled with each other. An internal overlap may be associated with the bottom mattress assembly and protrude beyond a top of a bottom core of the bottom mattress assembly to define a receptacle for a base portion of the top mattress assembly. A cover top and a cover bottom may be placed over the assembly and secured to each other at a location vertically below an upper extent of the internal overlap. The mattress may be modular and, thus, include a bottom mattress assembly selectable from a plurality of different configurations of bottom mattress assemblies and/or a top mattress assembly selectable from a plurality of different configurations of top mattress assemblies. Methods for assembling bottom mattress assemblies and top mattress assemblies with one another to provide a complete mattress are also disclosed.