Pocketed Coil Mattress With Elastomer Layer for Pressure Relief
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Solution Overview
Problem
Conventional mattresses often fail to provide optimal comfort and pressure relief due to the lack of effective integration of pocketed coils and cushioning materials, leading to inadequate conformity to body shape and increased pressure points.
Innovation Solution
A mattress assembly comprising a base layer, a coil layer with pocketed coils, an optional intermediate cushioning foam layer, and an elastomeric cushioning element that extends over the coil layer, providing enhanced pressure relief and conformity through the combination of pocketed coils and elastomeric materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional mattresses use simple foam or spring layers, then manufacturing is simple, but pressure relief and body conformity are inadequate
Solution Approach 1:
The mattress is divided into multiple functional layers: a base layer, a coil layer with individual pockets, and an elastomeric cushioning layer. Each layer performs a specific function - the coil layer provides structural support while the elastomeric layer conforms to body shape and relieves pressure points. This segmentation allows each component to be optimized independently while working together to solve the pressure relief problem.
Solution Approach 2:
The mattress combines two different materials with complementary properties: coil springs for durability and structural support, and elastomeric material for pressure relief and body conformity. This composite structure leverages the strengths of each material type to achieve both manufacturing feasibility and superior pressure relief performance.
2Object-affected harmful factors
If mattresses use only foam materials, then pressure relief is provided, but durability and compression resistance are insufficient
Solution Approach 1:
The mattress structure separates the pressure relief function (handled by the elastomeric cushioning layer) from the structural support function (handled by the coil layer). This segmentation allows the foam-like elastomeric material to provide pressure relief without bearing the full mechanical load, preserving its durability while achieving the desired comfort.
Solution Approach 2:
The combination of coil springs and elastomeric material creates a composite system where the coils provide long-term structural integrity and compression resistance, while the elastomeric layer provides pressure relief. This composite approach ensures both durability and comfort are achieved simultaneously.
3Strength
If pocketed coils are used without elastomeric cushioning, then structural support is provided, but body conformity and pressure relief are inadequate
Solution Approach 1:
The mattress divides functions between layers: the coil layer handles structural support while the elastomeric cushioning layer handles body conformity and pressure relief. This segmentation allows each layer to be optimized for its specific function without compromising the other.
Solution Approach 2:
The elastomeric cushioning layer acts as an intermediary between the rigid coil structure and the human body. It translates the structural support from the coils into a conforming, pressure-relieving surface that adapts to body shape, thereby bridging the gap between structural integrity and body conformity.
4Object-affected harmful factors
If thick cushioning layers are used for pressure relief, then comfort is improved, but lateral stability decreases
Solution Approach 1:
The mattress separates the cushioning function into a distinct top layer (elastomeric material) from the support function (coil layer). This segmentation allows the thin elastomeric layer to provide pressure relief without compromising the lateral stability provided by the underlying rigid coil structure.
Solution Approach 2:
The elastomeric cushioning layer functions as a thin, flexible film that conforms to body shape for pressure relief while remaining thin enough to maintain lateral stability. The flexibility of this thin layer allows it to adapt to body contours without creating the instability associated with thick cushioning layers.
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 mattress assembly offers improved pressure relief, increased comfort, and enhanced lateral stability by allowing the coils to conform better to body shape, while the elastomeric cushioning element reduces pressure points and enhances airflow, resulting in a more supportive and comfortable sleeping surface.
Implementation Method 1
Cushioning materials may be formed of materials that deflect or deform under load, such as polyethylene or polyurethane foams, vinyl, rubber, springs
Implementation Method 2
an elastomeric cushioning element over the coil layer... providing enhanced pressure relief and conformity
Data Source
AI summary
A mattress assembly includes a base layer, a coil layer over the base layer, and an elastomeric cushioning element over the upper layer. The coil layer includes a plurality of pocketed coils with a coil and a coil topper formed from a compressible, resilient material over the coil. Methods of manufacturing mattresses with elastomeric cushioning elements over pocketed coils that include coil toppers are also disclosed.