Modular Mattress Assembly with Pivotable Chassis for Compact Shipping
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Solution Overview
Problem
Conventional mattresses are often too large for ground delivery, leading to higher shipping costs due to the need for freight shipping, which increases the overall cost of purchasing a mattress.
Innovation Solution
A modular mattress assembly with a chassis comprising pivotable sections and a spring assembly, allowing the mattress to be shipped in compact boxes and assembled upon delivery, featuring a tambor and removable spring packs for customizable firmness and a topper for enhanced comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If mattresses are shipped as freight due to their size, then delivery is possible, but shipping costs increase significantly
Solution Approach 1:
The mattress is divided into multiple compressible sections that can be folded or rolled into a compact configuration for shipping, then expanded to full size for use. This segmentation allows the mattress to fit within standard ground delivery size limits while maintaining full functionality when assembled.
2Loss of energy
If mattresses are made compact for ground delivery, then shipping costs decrease, but assembly complexity increases
Solution Approach 1:
The mattress sections are pre-connected through hinges or connection mechanisms during manufacturing, so that upon delivery the consumer only needs to perform simple unfolding or unrolling actions rather than complex assembly. The connection structures are pre-positioned to guide the expansion process.
Solution Approach 2:
The mattress incorporates movable connection elements such as hinges or telescopic sections that allow easy transition between compact and expanded states. These dynamic connection mechanisms enable simple assembly operations while maintaining structural integrity.
Data Source
AI summary
A mattress assembly includes a chassis having top and bottom walls and first and second sidewalls that each extend from the top wall to the bottom wall. Inner surfaces of the walls and the sidewalls define an interior cavity. The top and bottom walls each include a first section that is connected to the first sidewall and a second section that is connected to the second sidewall such that the first sections are pivotable relative to the first sidewall and the second sections are pivotable relative to the second sidewall. The first section of the top wall is pivotable relative to the second section of the top wall and the first section of the bottom wall is pivotable relative to the second section of the bottom wall. A spring assembly is configured to be positioned within the interior cavity.