Cushions including one or more zones of different materials and related methods of manufacture for improved yield
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Solution Overview
Problem
The existing methods for manufacturing cushioning elements, such as mattresses and seat cushions, are inefficient due to the high cost and waste of molds required for producing multiple sizes, leading to significant labor expenses and reduced yield.
Innovation Solution
A method of forming a king-size elastomeric cushion with intersecting buckling walls, which is then separated into four equal-sized cushioning elements, allowing for the selection and use of smaller elements to create cushions of various sizes, thereby reducing material waste and labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manufacturers purchase the largest mold needed (e.g., king size) and use it to form all different sizes, then the number of molds is reduced, but material waste increases significantly
Solution Approach 1:
The king-size cushioning element is divided into multiple smaller cushioning elements of different sizes (queen, full, twin) by making cuts along predetermined lines. This segmentation allows a single king-size mold to produce multiple smaller cushions, reducing material waste while avoiding the need for multiple specialized molds for each size.
2Device complexity
If the largest mold is used to produce smaller sizes, then mold inventory cost is reduced, but labor costs for trimming and handling excess material increase
Solution Approach 1:
The cushioning element is pre-formed in the king-size mold with internal structures (walls, voids, columns) already configured to accommodate multiple smaller cushion sizes. The predetermined cut lines are established during the molding process, so that subsequent separation requires minimal additional processing. This preliminary configuration reduces the labor and time required for trimming and handling excess material compared to forming each size separately.
3Productivity
If a single king-size cushion is formed and then separated into four equal-sized elements, then yield and efficiency increase, but the ability to produce different cushion sizes is limited
Solution Approach 1:
The king-size cushioning element contains asymmetrically positioned walls, voids, and columns that create regions of different dimensions and characteristics. When cuts are made along predetermined lines, these asymmetric features naturally produce smaller cushioning elements with different sizes and properties (e.g., queen, full, twin sizes) from a single king-size form, thus achieving both high productivity and size variety.
Data Source
AI summary
A method of forming a cushioning element including forming a large cushioning element, and then dividing the large cushioning element into four equal smaller cushioning elements. The four smaller cushioning elements may be substantially the same size. Each of the smaller cushioning elements may be used as separate cushioning elements.