Replaceable Comfort Layer Mattress With Segmented Fire Barriers
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Solution Overview
Problem
The one-sided mattress design reduces the lifespan of mattresses, leading to increased waste and maintenance costs, as consumers cannot easily replace worn-out components, and the traditional design lacks flexibility in fire barrier selection to meet varying flammability requirements.
Innovation Solution
A mattress design featuring a detachable upper comfort layer assembly with a yarn-based knitted fire barrier fabric, allowing users to replace only the upper layer and fire barrier when needed, while maintaining the lower support core structure, and using multiple fire barriers tailored to specific regions to address disparate flammability characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a one-sided mattress design is used to simplify construction and reduce costs, then manufacturing complexity is reduced, but the mattress lifespan is shortened and waste increases
Solution Approach 1:
The mattress is divided into separate functional layers: a permanent support core and a removable comfort layer assembly. This segmentation allows the comfort layer to be replaced independently when worn, extending the overall mattress lifespan while maintaining simplified one-sided construction.
Solution Approach 2:
The comfort layer assembly is designed to be dynamically replaceable through accessible zippers, transforming from a static permanent structure to a dynamic reusable component system. This allows users to refresh the comfort layer without replacing the entire mattress.
2Strength
If traditional mattress construction is used with integrated fire barriers, then structural integrity is maintained, but flexibility in fire barrier selection is reduced
Solution Approach 1:
The fire barrier function is segmented into two independent systems: an internal fire barrier integrated with the support core, and an external fire barrier fabric on the removable comfort layer. This allows selection of different fire barrier materials and configurations to meet varying flammability requirements while maintaining structural integrity.
Solution Approach 2:
Different fire barrier materials and configurations can be applied to different regions and layers of the mattress based on specific flammability requirements. The internal and external barriers can be tailored to address disparate flammability characteristics of different foam types and regions.
3Reliability
If the entire mattress is replaced when the comfort layer wears out, then comfort is restored, but waste increases and cost increases
Solution Approach 1:
The worn comfort layer assembly is extracted and removed from the mattress through accessible zippers, allowing replacement of only the degraded component while retaining the functional support core. This eliminates the need to discard the entire mattress when the comfort layer wears out.
Solution Approach 2:
The design enables selective discarding of only the worn comfort layer while recovering and retaining the support core structure. This partial replacement approach reduces waste and extends the usable life of the mattress by allowing comfort layer refreshment independent of core degradation.
4Ease of operation
If maintenance-free marketing is used for one-sided mattresses, then consumer convenience is improved, but actual maintenance needs are hidden
Solution Approach 1:
The mattress is designed with user-accessible zippers that enable consumers to perform their own comfort layer replacement without professional service. This self-service capability maintains the marketed convenience while actually enabling maintenance to preserve reliability.
Solution Approach 2:
The accessible zipper system is pre-configured to facilitate easy comfort layer removal and replacement. This preliminary design action makes maintenance simple and straightforward, transforming a potentially complex task into a consumer-friendly operation that preserves mattress performance over time.
Data Source
AI summary
A mattress wherein a plurality of independent yarn based fire barrier fabrics encases a plurality of distinct and unattached interior core structures. The plurality of interior core structures include at least a detached and internally flippable upper comfort layer assembly with a plurality of non-homogeneous foams or filling materials encased in a yarn-based fire barrier fabric and a lower, interiorly disposed support core structure with resilient filling materials encased in a yarn-based fire barrier fabric and a fabric cover. The detachable and internally flippable upper comfort layer assembly may be contained in a user accessible compartment that is fashioned into an outer cover assembly.