Upcycled Rebond Foam Mattress Core for Comfort and Spinal Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional spring mattresses fail to achieve a balance between comfort and spinal support, leading to inadequate rest and potential health issues due to improper spinal alignment and circulation problems.
Innovation Solution
A multi-layer foam core mattress design featuring a cushion layer, core, and base layer with carefully defined physical parameters such as density and indentation force deflection (IFD) to provide both comfort and spinal support, using a matrix of rebond foam pieces bonded together with a binder to create a durable and supportive core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spring mattresses use traditional wire spring assemblies or solid latex cores, then structural support is provided, but comfort and spinal alignment are insufficient
Solution Approach 1:
The mattress is divided into multiple functional layers: a comfort layer with soft foam (IFD 6-18, density 1.5-4 lb/ft³) for comfort, a core layer with rebond foam pieces (IFD 21-36) for spinal support, and a base layer (IFD 28-70, density 1.5-2 lb/ft³) for stability. Each layer serves a specific function to balance comfort and support.
Solution Approach 2:
Different regions of the mattress have different material properties optimized for their specific functions. The comfort layer uses lower density foam for softness, while the core uses higher density rebond foam for support, and the base layer uses intermediate properties for stability.
2Reliability
If foam pieces are used to construct the core, then comfort and support balance is achieved, but manufacturing complexity increases
Solution Approach 1:
The core is constructed using foam pieces with specific volume ranges (at least 5% with volumes <0.5 in³, at least 40% with volumes 0.5-2.0 in³, and at least 20% with volumes >2.0 in³) and controlled density (1.5-3.0 lb/ft³) to achieve the desired IFD range of 21-36 while maintaining manufacturability.
3Reliability
If multiple foam layers with specific parameters are used, then spinal alignment and comfort are optimized, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies precise parameter ranges for each layer: comfort layer (IFD 6-18, density 1.5-4 lb/ft³), core layer (IFD 21-36 with specific foam piece volume distribution), and base layer (IFD 28-70, density 1.5-2 lb/ft³). These controlled parameters ensure consistent spinal alignment and comfort performance.
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
The mattress achieves a balance between comfort and spinal support, preventing muscle aches and fatigue while maintaining durability and ease of packaging for shipping, as demonstrated by tests showing minimal firmness and support changes over cycles and human spinal alignment tests.
Implementation Method 1
The core may include a matrix of rebond foam pieces that includes at least 5% foam pieces having volumes of less than about 0.5 in3, at least 40% foam pieces having volumes of between about 0.5 and 2.0 in3, and at least 20% foam pieces having volumes of greater than 2.0 in3
Data Source
AI summary
A foam core mattress including a cushion layer having a foam with an IFD of between about 6 to about 18 and a density of between about 1.5 lb./ft3 to about 4 lb./ft3. The mattress includes a core that is coupled with a bottom surface of the cushion layer. The core includes a matrix of rebond foam pieces that includes at least 5% foam pieces having volumes of less than about 0.5 in3, at least 40% foam pieces having volumes of between about 0.5 and 2.0 in3, and at least 20% foam pieces having volumes of greater than 2.0 in3, wherein the core has an IFD of between about 21 and 36. The mattress includes a base layer coupled with a bottom surface of the core. The base layer has an IFD of between about 28 to about 70 and a density of between 1.5 lb./ft3to about 2 lb./ft3.