Foam Spring Mattress Layout for Replaceable Zoned Firmness
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Solution Overview
Problem
Current mattresses fail to provide customizable firmness to accommodate individual user preferences for comfort, as they often rely on fixed combinations of materials that do not adequately address localized body discomfort or changing comfort requirements over time.
Innovation Solution
A mattress system featuring interchangeable foam springs with a containment facility and attachment devices, allowing users to select and arrange foam springs of varying firmness within a bed to create customized comfort configurations, using methods such as questionnaires or software applications to determine optimal placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed combinations of materials are used in mattresses, then manufacturing simplicity is maintained, but adaptability to individual user preferences and localized comfort needs deteriorates
Solution Approach 1:
The mattress is divided into multiple independent zones, each containing foam springs with different firmness levels. These zones can be independently selected and arranged to create customized firmness patterns across the mattress surface, allowing different body regions to receive appropriate support.
Solution Approach 2:
Different firmness levels are applied to specific locations within the mattress rather than using uniform firmness throughout. This allows localized adjustment of support characteristics to match individual body contours and comfort requirements in different areas.
2Ease of operation
If interchangeable foam springs with attachment devices are implemented, then ease of operation for customization is improved, but device complexity increases
Solution Approach 1:
The mattress structure transitions from a static, fixed configuration to a dynamic, reconfigurable system. Foam springs can be easily attached and detached from the base layers using simple attachment devices, allowing users to change the firmness configuration as needed without complex tools or procedures.
Solution Approach 2:
Attachment devices serve as intermediaries between the foam springs and the mattress base layers. These devices facilitate easy connection and disconnection while maintaining structural integrity, enabling simple reconfiguration without requiring direct complex interactions between components.
3Adaptability or versatility
If foam springs are made replaceable and removable, then adaptability to changing comfort needs is improved, but reliability of mattress structure may deteriorate
Solution Approach 1:
Attachment devices are pre-installed on the foam springs and base layers during manufacturing, ensuring proper alignment and secure connections when components are assembled. This preliminary preparation maintains structural reliability while enabling easy reconfiguration.
Solution Approach 2:
The attachment devices are designed as simple, durable components that can withstand repeated attachment and detachment cycles. While individual foam springs may be replaced, the attachment mechanism itself is built to maintain structural integrity over long-term use through multiple reconfigurations.
Data Source
AI summary
A method includes selecting an arrangement of foam springs, the arrangement that matches user-selected firmness requirements; attaching foam springs to a foam panel in a removable, replaceable manner; and inserting the foam springs and the foam panel into a containment facility. A mattress includes foam springs; a foam panel to which an arrangement of the foam springs is attached in a removable, replaceable manner; a containment facility within which the foam springs and the foam panel are disposed; and a side rail with indentations within which sides of at least some of the foam springs are disposed. The mattress may also include a fabric webbing, attached to the containment facility, within which some of the foam springs are disposed in a removable, replaceable manner; and an attachment device attaching together at least two of the foam springs.