Motorized Spring Module Design for Adjustable Mattress Firmness
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Solution Overview
Problem
Current sleeping systems fail to provide adequate user comfort and flexibility in adjusting firmness and support, which can be influenced by factors such as snoring, central apnea, obstructive apnea, and restless leg syndrome, and are limited by the rigidity of the sleeping surface and position.
Innovation Solution
An adjustable sleeping system comprising a plurality of spring modules coupled to a bed frame, where each spring module includes adjustable spring assemblies that can change the weight or force carried to accommodate various firmness settings, controlled by a bed controller that communicates with each spring module to adjust the load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mattress uses combinations of closed- and open-cell foams to reduce high force areas, then user comfort is improved, but the system lacks flexibility in adjusting firmness and support
Solution Approach 1:
The mattress is divided into multiple independently controllable zones with adjustable spring assemblies, allowing different firmness levels in different regions. Each zone can be adjusted separately to provide customized support while maintaining overall comfort.
Solution Approach 2:
The mattress incorporates dynamically adjustable spring assemblies that can change their firmness characteristics in real-time based on user needs. The spring constants and pre-loads can be modified to transition between soft and firm support levels, providing adaptability that static foam structures cannot achieve.
2Adaptability or versatility
If air bladders are used to create individual pockets of support with changeable air pressure, then adaptability is improved, but device complexity increases
Solution Approach 1:
The mattress uses air-filled bladders within spring assemblies to provide adjustable support. By controlling air pressure in these bladders, the firmness and support characteristics can be modified without requiring completely different mechanical structures, thus achieving adaptability with moderate complexity.
Solution Approach 2:
The support characteristics are adjusted by changing physical parameters such as air pressure within the bladders and spring pre-loads. This allows continuous adjustment of firmness levels without mechanical reconfiguration, simplifying the control system while maintaining high adaptability.
3Reliability
If the sleeping surface is made rigid for structural stability, then reliability is improved, but user comfort and ability to accommodate different positions deteriorates
Solution Approach 1:
The mattress structure implements local quality by providing rigid structural support through the frame and spring assemblies where needed for stability, while incorporating compliant foam layers and adjustable elements at the sleeping surface to accommodate different body positions and provide comfort. Each region has properties optimized for its specific function.
Data Source
AI summary
Spring modules for an adjustable sleeping system. At least some of the example embodiments are spring modules comprising: a spring rail, and a plurality of adjustable spring assemblies spaced along the length of the spring rail. Each adjustable spring assembly may comprise: a motor with a stator coupled to the spring rail, a lead screw coupled to the rotor of the motor, and the lead screw extending above an upper surface of the spring rail, a spring plate coupled to the lead screw, and a main spring coupled to the spring plate. Thus, the weight or force carried by each adjustable spring assembly along the spring rail is separately adjustable by a bed controller.