Removable Mattress Massage Modules for Compressed Foam Shipping
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Solution Overview
Problem
Conventional beds with massage functions are complex and expensive, requiring maintenance from service technicians or manufacturer involvement when the massage mechanism is damaged.
Innovation Solution
A mattress design featuring removable massage modules that can be inserted into the mattress after shipping, utilizing a three-layer foam structure with high-density polyurethane foam and visco-elastic polyurethane foam, and connected to a module controller for vibration control, allowing for easy maintenance and replacement of modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If massage motors are built into the mattress structure, then the massage function is integrated and reliable, but the device complexity and maintenance cost increase significantly
Solution Approach 1:
The mattress is divided into functional modules: a base mattress layer and separate removable massage modules. Each massage module contains a massage motor and can be independently inserted into or removed from cavities in the mattress, allowing the massage function to be separated from the main mattress structure.
Solution Approach 2:
The massage motors are extracted from the main mattress structure and placed in separate removable modules. This allows the massage function to be taken out as an independent component that can be easily removed, replaced, or serviced without affecting the mattress itself.
2Volume of stationary object
If the entire mattress is shipped compressed, then shipping space and storage efficiency improve, but the massage modules cannot be installed before delivery
Solution Approach 1:
The massage modules are pre-assembled and packaged separately in small boxes, ready for installation. The base mattress is prepared with cavities during manufacturing, so that when the customer receives the compressed mattress and expands it, the cavities are ready to receive the pre-packaged massage modules.
3Reliability
If service technicians are required for massage mechanism repair, then the massage function reliability is maintained, but the loss of time and maintenance cost increase
Solution Approach 1:
The massage modules are designed as self-service replacement units. When a massage module fails, the customer can simply remove the defective module from the mattress cavity and insert a replacement module without requiring any technical knowledge or service technician intervention.
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
This design reduces maintenance costs and complexity by enabling customers to easily insert and replace massage modules, providing a cost-effective massage function without the need for frequent technician visits or manufacturer involvement, while also allowing for more efficient shipping and storage due to the compressed mattress size.
Implementation Method 1
a mattress with a massage function provided by vibration motors
Implementation Method 2
hot air generated by an electric motor exits holes or slots in a base plate of each massage motor and travels through the cylindrical holes in the foam section to exit out of the bottom of the mattress
Data Source
AI summary
Removable massage modules provide a mattress with a massage function. The mattress is compressed and shipped in a packing box with the massage modules separate from the mattress. The end customer then inserts the massage modules. The mattress has a bottom foam layer with cavities whose walls are perpendicular to the outer surface of the foam layer. Each massage module includes a massage motor encased in molded foam. The molded foam is attached to a foam section with cylindrical holes that pass from an outer side to the molded foam and allow hot air to escape the massage motor. The top and bottom sides of each massage module have the shape formed by the walls of the cavities. The massage modules are connected by power cords to a module controller that receives RF signals from a remote control device. The massage modules can also be inserted into a mattress topper.