System and method for customizing a mattress
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Solution Overview
Problem
Conventional foam mattresses lack ergonomic support for the human body, particularly in areas with natural arcs and curves, and fail to provide adequate resistance to compression, especially for individuals with extra weight in the hips, waist, and stomach area.
Innovation Solution
A multi-layer mattress design featuring a first layer, a second softer layer, and a third layer with an arch or wavy shape, where the third layer is embedded within both the first and second layers, providing enhanced support and resistance to compression by distributing weight unevenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform thickness and density foam layers are used, then manufacturing is simple, but ergonomic support for body contours is poor
Solution Approach 1:
The mattress incorporates layers with varying density and firmness at different locations. Specifically, the first layer has a first density and the second layer has a second density different from the first, allowing different regions of the mattress to provide different levels of support. This enables the mattress to adapt to the natural contours of the human body while maintaining a relatively simple manufacturing process.
Solution Approach 2:
The mattress is divided into multiple distinct layers, each with specific functional characteristics. The first layer serves as a support layer with higher density, while the second layer provides comfort with lower density. This segmentation allows each layer to perform its specific function optimally, combining to provide both ergonomic support and manufacturing efficiency.
2Device complexity
If uniform density foam is used throughout, then material selection is simple, but resistance to compression in weight-bearing areas is insufficient
Solution Approach 1:
The mattress uses foam material with non-uniform density distribution. The first layer contains foam with a first density optimized for compression resistance in weight-bearing areas, while the second layer contains foam with a second density optimized for comfort. This local variation in material properties enhances compression resistance where needed without requiring complex overall material selection.
3Ease of operation
If the mattress is designed to be soft for comfort, then ease of operation is improved, but support for body contours is reduced
Solution Approach 1:
The mattress is segmented into a first layer and a second layer with different firmness characteristics. The first layer, being denser, provides the necessary support for body contours and weight distribution. The second layer, being softer, provides comfort and ease of operation. This segmentation allows the mattress to simultaneously achieve both comfort and support functions.
Solution Approach 2:
The mattress combines two different foam materials with distinct density and firmness properties. The composite structure of the first layer (higher density) and second layer (lower density) creates a system that delivers both the softness needed for comfort and the strength needed for contour support, resolving the contradiction between ease of operation and support capability.
Data Source
AI summary
A mattress is disclosed. The mattress includes a first layer, a second layer supported on the first layer and arranged abutting the first layer, and a third layer having a substantially arch shape. The third layer includes a first portion embedded inside the first layer and a second portion at least partially embedded inside the second layer.