Polymer Cushion with Voids to Reduce Bunching on Adjustable Bases
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Solution Overview
Problem
Mattresses with adjustable bases often experience bunching and ridges when inclined, leading to discomfort and potential bruising, and folding or rolling results in air pockets that complicate packing and shipping.
Innovation Solution
Incorporating a polymer with a first plurality of voids and grooves on the underside and a second plurality on the upper surface, allowing the mattress to fold and bend without bunching, while also enabling more compact packing and reduced shipping volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the adjustable base is inclined at a large angle, then the mattress can support the user at a desired ergonomic position, but the midpoint or pivot point of the mattress bunches in the mattress material due to folding or compression
Solution Approach 1:
The patent incorporates a plurality of voids within the polymer structure of the mattress. These voids allow the mattress material to compress and fold without creating surface bunching or ridges, enabling the mattress to maintain a smooth surface even when inclined at large angles on an adjustable base.
Solution Approach 2:
The patent modifies the physical structure of the polymer by introducing voids, which changes the compressibility and folding characteristics of the material. This parameter change allows the mattress to accommodate large inclination angles without surface deformation.
2Volume of moving object
If the mattress is folded or rolled for transport, then it can be packed into a box for shipment, but ridges form on the surface and air pockets are created that take up space
Solution Approach 1:
The plurality of voids in the polymer structure allows the mattress to fold and roll without creating air pockets or surface ridges. The voids accommodate the folding process internally, enabling compact packaging while maintaining surface smoothness.
3Reliability
If retainer bar assemblies are secured to prevent mattress movement, then the mattress stays in place on the adjustable base, but compression occurs near the midpoint or pivot point of the mattress
Solution Approach 1:
The voids in the polymer structure reduce compression stress at the midpoint by allowing the material to compress internally without creating surface bunching. This maintains position stability while reducing harmful compression effects.
Data Source
AI summary
Mattresses, cushions, and body-support mats or pads are disclosed. Polymer(s) at least partially define a length, width and depth, the depth extending from an upper surface proximate to where a user rests to a lower surface opposite the upper surface. Voids in the polymer traverse at least a portion of the width. The plurality of voids are located at the lower surface and/or the upper surface and are defined by polymer walls and wall(s) of polymer walls define each polymer foot of polymer feet. A first region of a plurality of lower surface regions includes at least one foot of the plurality of polymer feet that has a first size. A second region of the plurality of lower surface regions includes at least one other foot having a second size. The at least one other foot spans a greater distance along the length than the at least one foot.