Molded Mattress with Splicing Blocks for Differential Elastic Support
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Solution Overview
Problem
Traditional mattresses lack differential elastic support and have complex manufacturing processes due to uniform elastic force distribution and layered structures, leading to higher production costs.
Innovation Solution
A customized, spliced and molded mattress design featuring a mattress base layer, supporting layer, and splicing blocks that allow for localized elasticity adjustment, integrated through molding, enabling efficient production and stable structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a layered compound structure with jacket quilting is used, then the mattress provides diverse materials and functions, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple material layers (memory foam, latex, gel, cooling fibers) into a single integrated molded structure. The mattress is formed as one piece through injection molding, eliminating the need for separate layer assembly and jacket quilting processes, thus reducing manufacturing complexity while maintaining material diversity.
Solution Approach 2:
The patent uses composite materials with different properties (memory foam for contouring, latex for support, gel for cooling) integrated within a single molded mattress structure. This allows the mattress to provide multiple functions through material composition rather than through complex layered construction.
2Device complexity
If uniform elastic force distribution is used, then the mattress structure is simple, but the differential supporting need is not met
Solution Approach 1:
The patent implements local quality variations within the molded mattress by incorporating specific material compositions and densities in different zones. The memory foam and latex layers are formulated with varying softness and support characteristics for different body regions, enabling differential supporting while maintaining an overall simple molded structure.
3Reliability
If jacket covering is added for protection, then the internal materials are protected, but the production cycle and cost increase
Solution Approach 1:
The patent merges the protective covering function into the molded mattress structure itself. The outer surface of the molded mattress provides the necessary protection for internal materials, eliminating the need for separate jacket covering steps and thereby improving production efficiency while maintaining material protection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design provides abundant elasticity differences for tailored support, enhancing comfort and reducing production complexity and costs by integrating splicing blocks for differential support, ensuring efficient and reliable manufacturing.
Implementation Method 1
at least one splicing block for changing local elasticity of the supporting area is disposed in the supporting area
Implementation Method 2
the mattress base layer, the supporting layer and the splicing block are integrally formed by molding
Data Source
AI summary
Provided is a customized, spliced and molded mattress, which includes a mattress base layer and a supporting layer, where the supporting layer is disposed on the mattress base layer, at least one supporting area is disposed on the supporting layer, at least one splicing block for changing local elasticity of the supporting area is disposed in the supporting area, and the mattress base layer, the supporting layer and the splicing block are integrally formed by molding. The present disclosure meets the improvement need for elasticity differences in different areas on the mattress by adopting a design that the mattress base layer is integrally formed with the supporting layer with elasticity improvement by molding, so that the mattress has abundant elasticity body feeling. The supporting areas that are formed through the splicing blocks may implement the abundant differential supporting, are applied more skillfully and abundantly, and suitable for customized design and production. A protective covering layer structure formed by once molding is provided, so that the processing and production for the mattress are more efficient, and the whole molded structure is more reliable and stable.(FIG. 1)