Multiple zone mattress core element with multiple coil configurations
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Solution Overview
Problem
Conventional mattresses lack the ability to provide customizable support and firmness across different body zones, leading to inadequate comfort and support for users with varying preferences.
Innovation Solution
A mattress core with multiple zones, each comprising wire coil springs of varying sizes and heights, enclosed in fabric pouches, allowing for specific support characteristics in side, end, head, foot, and trunk areas, enabling users to select firmness levels by combining different coil configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional mattresses use uniform coil configurations throughout, then manufacturing is simple and cost-effective, but they cannot provide customized support and firmness for different body zones
Solution Approach 1:
The mattress core is divided into multiple zones (head, foot, side, center) with each zone containing coils of specific characteristics. This segmentation allows different body zones to receive tailored support while maintaining a manageable manufacturing process through modular assembly.
Solution Approach 2:
Different coil characteristics (gauge, diameter, height) are assigned to specific mattress zones based on local support requirements. For example, heavier gauge coils are used in the center for maximum support, while lighter coils are used at the head and foot where less support is needed.
2Adaptability or versatility
If wire coil springs of different sizes and gauges are used in various zones, then tailored support for specific body areas is achieved, but manufacturing complexity and production time increase
Solution Approach 1:
The mattress is constructed from modular units or zones that can be manufactured separately and then assembled together, allowing parallel production of different coil configurations to improve overall manufacturing efficiency.
Solution Approach 2:
Coils are pre-sorted and pre-positioned in their respective zones before final assembly, and fabric pouches are prepared in advance to contain the coils during manufacturing, streamlining the production process.
3Adaptability or versatility
If multiple fabric pouches containing different coil configurations are assembled, then customized firmness and support are achieved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
Multiple fabric pouches containing different coil configurations are merged together in a systematic arrangement to form the complete mattress core, creating a unified structure that provides zoned support while maintaining assembly efficiency.
Solution Approach 2:
The fabric pouch design and assembly methodology serve multiple functions: containing coils, providing structural organization, enabling modular assembly, and facilitating quality control, thereby simplifying the overall assembly process despite the complexity of multiple coil types.
Data Source
AI summary
This disclosure addresses mattresses. The mattress includes a core made up of multiple zones. Each of the zones includes a plurality of core elements, the core elements being formed from at least one wire coil spring at least partially contained in a fabric pouch. The core elements are typically joined in linear chains. The zones vary in support firmness according to the selection of a user. The core elements include wire coil springs formed from wires of at least two different sizes, and of at least two different heights.