Modular mattress system and method
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Solution Overview
Problem
Existing mattresses fail to accommodate individual differences in body shape and preferences, requiring sleep partners to compromise on comfort, and consumers often need to purchase entirely new mattresses to experience improved features.
Innovation Solution
A modular mattress system with customizable layers, allowing for personalized configurations based on individual needs and preferences, including dual-zip technology for varying firmness and material composition, and a metric system for evaluating performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional non-modular mattress is used, then the structure is simple and manufacturing is easier, but the adaptability to individual preferences and body shapes is poor
Solution Approach 1:
The mattress is divided into multiple independent modules, each representing a different firmness level or material composition. These modules can be individually selected and arranged to create a customized mattress that adapts to individual preferences and body shapes, resolving the contradiction between adaptability and structural simplicity.
Solution Approach 2:
Different regions of the mattress can have different firmness levels and material compositions tailored to specific body zones (e.g., softer for shoulders, firmer for hips). This local customization allows the mattress to adapt to individual anatomical differences and preferences without requiring complete structural complexity throughout the entire mattress.
2Reliability
If new materials and technologies are introduced into mattresses, then comfort and performance are improved, but the cost of replacement becomes prohibitively high
Solution Approach 1:
The mattress is constructed from multiple independent modules that can be individually replaced. When new materials or technologies are introduced, consumers can replace only the specific modules containing those improvements rather than the entire mattress, significantly reducing replacement costs while still accessing enhanced comfort and performance.
Solution Approach 2:
The modular design allows consumers to discard only the worn or outdated modules and retain the still-functional modules. This selective replacement approach recovers value from existing components while incorporating new materials and technologies where needed, reducing overall replacement expenditure.
3Adaptability or versatility
If a modular mattress system is implemented, then customization and adaptability are enhanced, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The mattress is divided into standardized modules with uniform interfaces and connection mechanisms. This segmentation allows each module to be manufactured independently using standardized processes, and the modules can be easily assembled and disassembled, thereby maintaining manufacturing ease while enabling extensive customization capabilities.
Solution Approach 2:
The modular modules are designed with universal interfaces and standardized dimensions that allow them to be used in various configurations and combinations. This universality simplifies manufacturing by using common components across different mattress models while still providing customization options through different module arrangements and selections.
Data Source
AI summary
As per an embodiment of the disclosure, a minimum of one module is modularized in one of the following mattress layer: comfort, contour, or support. This modularization entails at least one module per side of the mattress. In particular configurations, all modules within a respective layer may have an identical size in length, width, and height. In other configurations, two modules within a respective layer may be larger or smaller than the other modules. For example, in the contour layer, the hip module on both the left and right sides of the mattress may be larger than the head and foot modules.