Slatted Bed Base Foam Support Structure for Zoned Comfort
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Solution Overview
Problem
Existing bed frames and insert frames fail to provide optimal lying comfort, particularly in adjusting different regions like the shoulder and pelvic zones, and do not allow for easy customization to individual comfort needs.
Innovation Solution
The use of foam bodies with structured surfaces featuring longitudinal and transverse grooves to form nubs, which can be manufactured in various hardnesses, colors, and surface structures, and designed to fit seamlessly with spring slats, allowing for adjustable support configurations, including T-shaped receiving grooves and varying heights and depths to accommodate different sleeping positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional foam bodies with smooth surfaces are used, then the structure is simple and easy to manufacture, but the lying comfort and adaptability to different body zones cannot be optimized
Solution Approach 1:
The foam body surface is provided with grooves and nubs that create different local regions with varying properties. The nubs provide localized pressure points while the grooves create valleys for body contouring, allowing different areas of the foam body to adapt to different body zones (shoulder, back, pelvic regions) with specific support requirements.
2Adaptability or versatility
If the foam body is designed with complex structured surfaces including grooves and nubs, then lying comfort and customization for different sleeping positions is improved, but the manufacturing complexity increases
Solution Approach 1:
The foam body is pre-formed during manufacturing with the groove and nub structure already integrated into the foam material itself. This preliminary structuring allows the complex surface geometry to be achieved without requiring post-manufacturing assembly of multiple components, as the structural elements are created as a single integrated piece.
3Reliability
If the foam body completely encloses the spring strip, then support and comfort are improved, but the assembly process becomes more difficult
Solution Approach 1:
The foam body is divided into functional segments: an enclosed region that completely surrounds the spring strip for maximum support, and open regions with grooves that allow spring strip ends to extend outward. The T-shaped receiving grooves further segment the structure to facilitate alignment and insertion of spring strips during assembly.
4Ease of operation
If T-shaped receiving grooves are added to the foam body, then assembly with spring slats is facilitated, but the manufacturing complexity increases
Solution Approach 1:
The T-shaped receiving grooves are pre-formed as integral features of the foam body during the foam molding process. This preliminary creation of receiving structures eliminates the need for separate assembly steps to create mounting features, allowing the grooves to be formed simultaneously with the foam body itself.
Data Source
Figure 1
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AI summary
The frame has various zones such as shoulder and pelvic zones, which are adjustable in inclination and/or height. Multiple spring units are received in clip connectors (2). The spring units are formed as fixed foam bodies (3) on or at the connectors. The foam bodies are provided with receiving sections for encompassing or overlapping the connectors, where foam bodies can be produced in different hardness, colors and surface textures.