Modular Mattress Assembly with Pivotable Chassis for Ground Shipping
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Solution Overview
Problem
Most mattresses exceed size limits for ground delivery, leading to higher shipping costs due to the need for freight shipping, which increases the cost of purchasing a mattress.
Innovation Solution
A modular mattress assembly with a chassis comprising pivotable sections and a spring assembly that can be shipped in compact boxes, allowing for easy assembly and customization of firmness by combining different spring packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a mattress is shipped as freight due to size limits, then the mattress can be delivered to destination, but the shipping cost increases significantly
Solution Approach 1:
The mattress is divided into multiple sections (head section, foot section, and intermediate sections) that can be folded relative to each other. This segmentation allows the mattress to be collapsed into a compact configuration for shipping while maintaining full size when assembled, thereby enabling cost-effective ground delivery instead of expensive freight shipping
Solution Approach 2:
The mattress incorporates movable joints and folding mechanisms that allow it to dynamically change between a compact folded state for shipping and a fully extended usable state. This dynamic capability enables the mattress to adapt its form factor based on whether it is being transported or used, resolving the contradiction between size and shipping cost
2Volume of moving object
If a mattress is made modular with pivotable sections, then the mattress can be shipped compactly, but the device complexity increases
Solution Approach 1:
The mattress is divided into modular sections connected by folding joints, allowing each section to be independently positioned. This segmentation enables compact folding for shipping while using simple, standardized connection mechanisms that minimize overall structural complexity
Solution Approach 2:
The mattress sections are designed to nest together when folded, with intermediate sections collapsing between the head and foot sections. This nesting arrangement maximizes compactness while using simple hinge-based connections rather than complex mechanical assemblies, thereby reducing device complexity
3Adaptability or versatility
If spring assemblies are made removable and interchangeable, then firmness can be customized, but the ease of operation decreases
Solution Approach 1:
The spring assembly is divided into multiple removable packs that can be independently installed or removed. Each spring pack is designed as a discrete module that interfaces with the mattress structure through simple connection points, allowing users to customize firmness by selecting different spring pack combinations without requiring complex assembly procedures
Solution Approach 2:
The mattress structure incorporates universal mounting interfaces and standardized connection mechanisms that work with different spring pack configurations. This universality allows the same basic structure to accommodate various firmness preferences through simple spring pack selection and installation, maintaining ease of operation while enabling customization
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.