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US-12616313-B2 - System and method for customizing a mattress

US12616313B2US 12616313 B2US12616313 B2US 12616313B2US-12616313-B2

Abstract

A method for customizing a mattress includes acquiring a three dimensional image of a body of a user and preparing, by a processor, a three dimensional model of the body of the user using the three-dimensional image. The method also includes dividing, by the processor, the three dimensional model into a plurality of cylindrical sections arranged parallel to each other and arrayed along a height of the three dimensional model, and determining a downward pressure to be exerted by at least one desired cylindrical section on the mattress. The method further includes determining, by the processor, one or more parameters associated with at least one portion of the mattress adapted to be arranged underneath the at least one desired cylindrical section when person lies on the mattress based on the determined downward pressure.

Inventors

  • Kevin J. Kappenman

Assignees

  • Kevin J. Kappenman

Dates

Publication Date
20260505
Application Date
20220314

Claims (14)

  1. 1 . A method for customizing or selecting a mattress, the method comprising: acquiring, by an image capturing device, a three dimensional (3D) image of a body of a user; preparing, by a processor, a three dimensional (3D) model of the body of the user using the three dimensional image, wherein the 3D image is configured to capture a concavity and a convexity of a front and a rear of the user; dividing, by the processor, the three dimensional model into a plurality of cylindrical sections arrayed along a height of the model of the user, each cylindrical section including a first longitudinal end surface arranged along a first surface of the model corresponding to a front of the body of the user and a second longitudinal end surface arranged along a second surface of the model corresponding to a rear of the body of the user, wherein a central axis of each cylindrical section is substantially perpendicular to a spine of the user, and the sections are arranged parallel to each other in an overlapping configuration; determining, by the processor, a volume of one or more of the plurality of cylindrical sections by determining a shape and a topography of the first longitudinal end surface, the second longitudinal end surface, and a length of the central axis between the first longitudinal end surface and the second longitudinal end surface of the cylindrical section; determining, by the processor, a weight of the one or more of the plurality of cylindrical sections by using the determined volume of the cylindrical section; determining, by the processor, a downward pressure to be exerted by the one or more of the plurality of cylindrical sections on the mattress when the user lies on the mattress by dividing the weight of the one or more of the plurality of cylindrical sections by a surface area of the section determined using the diameter of the associated cylindrical section; determining, by the processor, one or more parameters associated with the mattress, wherein the one or more parameters includes one or more of localized firmness gradients, variable foam density values, and impression load deflection (ILD) values across mattress zones corresponding to the downward pressures exerted by the one or more of the plurality of cylindrical sections; and customizing or selecting the mattress based on the determined one or more parameters such that mattress portion corresponding to the one or more of the plurality of cylindrical sections exhibits a firmness or compliance level corresponding to a downward pressure exerted by the associated body section of the user.
  2. 2 . The method of claim 1 further including determining, by the processor, a weight of the at least one desired cylindrical section based on a determined volume of the at least one respective cylindrical section, wherein the weight is used for determining a downward pressure exerted by the respective section on the mattress.
  3. 3 . The method of claim 2 , wherein the volume of the at least one desired cylindrical section is determined, by the processor, based on a shape and topography of the first longitudinal end surface of the at least one desired cylindrical section, a shape and topography of the second longitudinal end surface of the at least one desired cylindrical section, and a length of a central axis between the first and second longitudinal end surfaces.
  4. 4 . The method of claim 2 , wherein the weight of the at least one desired cylindrical section is determined by using a body mass index of the user.
  5. 5 . The method of claim 1 , wherein the first surface is front surface of the model corresponding to a front of the body of the user, and the second surface is a rear surface of the model corresponding to a rear of the body of the user.
  6. 6 . The method of claim 1 , wherein the mattress includes a support structure having: a foam layer including a first surface and a second surface arranged opposite to the first surface and defining a plurality of slots extending from the first surface to the second surface and arranged in a plurality of rows, and a plurality of hoop assemblies arranged inside the plurality of the slots, each hoop assembly includes a hoop arranged vertically inside the slot and a central axis of the hoop extends substantially horizontally and parallel to the first surface, wherein the hoop is configured to compress under a load, wherein determining the one or more parameters includes determining at least one of a width or a thickness of the hoop of each hoop assembly adapted to be arranged underneath the associated desired cylindrical section.
  7. 7 . The method of claim 6 , wherein the mattress includes an alignment structure supported on the support structure and having an alignment layer, wherein the alignment layer includes a first surface and a second surface arranged opposite to the first surface and defines a plurality of cut-outs extending from the first surface of the alignment layer to the second surface of the alignment layer and arranged in a plurality of rows in a staggered arrangement, wherein each cutout of one row partially overlaps with a pair of cutouts arranged in adjacent rows, and the one or more parameters includes number of cut-outs, one or more dimensions of the cut-outs, a density of the cut-outs disposed beneath the at least one desired cylindrical section.
  8. 8 . A system for customizing or selecting a mattress, the system comprising: an image capturing device configured to acquire a three dimensional image of a body of a user; and a processor arranged in communication with the image capturing device and configured to: acquire a three dimensional image of the user from the image capturing device; prepare a three dimensional model of the body of the user using the acquired three dimensional image, wherein the three dimensional image captures concavity and convexity of a front and a rear of the user; divide the three dimensional model into a plurality of cylindrical sections arrayed along a height of the 3D model of the user, each cylindrical section including a first longitudinal end surface corresponding to a front of the body of the user and a second longitudinal end surface corresponding to a rear of the body of the user, wherein a central axis of each cylindrical section is substantially perpendicular to a spine of the user, and the sections are arranged parallel to each other in an overlapping configuration; determine, by the processor, a volume of one or more of the plurality of cylindrical sections by determining a shape and topography of the first and second longitudinal end surfaces and a length of the central axis between the first and second longitudinal end surfaces; determine, by the processor, a weight of the one or more of the plurality of cylindrical sections using the determined volume; determine a downward pressure to be exerted by at least one desired cylindrical section of the plurality of cylindrical sections on the mattress by dividing the weight by a surface area of each cylindrical section determined from its diameter; determine one or more parameters associated with the mattress, wherein the one or more parameters include localized firmness gradients, variable foam-density values, or impression load deflection (ILD) values across mattress zones corresponding to the downward pressures exerted by the one or more of the plurality of cylindrical sections; and customize or select the mattress based on the determined one or more parameters such that mattress portions corresponding to the one or more of the plurality of cylindrical sections exhibit a firmness or compliance level corresponding to a downward pressure exerted by the associated body section of the user.
  9. 9 . The system of claim 8 , wherein the processor determines a weight of the at least one respective cylindrical section based on a determined volume of the at least one desired cylindrical section, wherein the weight is used for determining a downward pressure exerted by the respective section on the mattress.
  10. 10 . The system of claim 9 , wherein the processor determines the volume of the at least one desired cylindrical section based on a shape and topography of the first longitudinal end surface of the at least one desired cylindrical section, a shape and topography of the second longitudinal end surface of the at least one desired cylindrical section, and a length of a central axis between the first and second longitudinal end surfaces.
  11. 11 . The system of claim 9 , wherein the processor determines the weight of the at least one desired cylindrical section by using a body mass index of the user.
  12. 12 . The system of claim 8 , wherein the first surface is front surface of the model corresponding to a front of the body of the user, and the second surface is a rear surface of the model corresponding to a rear of the body of the user.
  13. 13 . The system of claim 8 , wherein the mattress includes a support structure having: a foam layer including a first surface and a second surface arranged opposite to the first surface and defining a plurality of slots extending from the first surface to the second surface and arranged in a plurality of rows, and a plurality of hoop assemblies arranged inside the plurality of the slots, each hoop assembly includes a hoop arranged vertically inside the slot and a central axis of the hoop extends substantially horizontally and parallel to the first surface, wherein the hoop is configured to compress under a load, wherein determining the one or more parameters includes determining at least one of a width or a thickness of the hoop of each of the hoop assembly adapted to be arranged underneath the associated desired cylindrical section.
  14. 14 . The system of claim 13 , wherein the mattress includes an alignment structure supported on the support structure and having an alignment layer, wherein the alignment layer has a first surface and a second surface arranged opposite to the first surface and defines a plurality of cut-outs extending from the first surface of the alignment layer to the second surface of the alignment layer and arranged in a plurality of rows in a staggered arrangement, wherein each cutout of one row partially overlaps with a pair of cutouts arranged in adjacent rows, and the one or more parameters includes number of cut-outs, one or more dimensions of the cut-outs, a density of the cut-outs disposed beneath the least one desired cylindrical section.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS The present Application is a continuation-in-part of U.S. application Ser. No. 17/403,228, filed on Aug. 16, 2021, which claims the benefit of U.S. Provisional Patent Application Ser. No. 63/066,991 filed on Aug. 18, 2020, all of which are incorporated herein by reference. FIELD The present invention pertains to a mattress. More particularly, the present invention pertains to a system and method for assisting a customer to customize or select a mattress according to a body profile of a user. BACKGROUND Good sleep is one of the basic necessarily for humans and is desired to provide the human body with adequate rest and repair to the body tissues and brain. Selecting the right mattress becomes essential to provide comfortable and restorative sleep. The right mattress should have anatomical support that is suitable according to the body profile of the user such as body weight, weight distribution, height, BMI, and overall body topography. However, typically mattresses are manufactured based on average body profile of humans that often results in improper postures while sleeping. The improper posture of the user also exaggerates due to the uneven weight distribution of the human body on the mattress. Methods and systems for customizing the mattress for an individual are known in the art. However, the existing methods and systems customize the mattress based on a two dimensional profile of the individual. These systems and methods, therefore, do not consider concave or convex surfaces of the body, or cannot accurately estimates weight distributions or surface pressures of the individual, which is undesirable. SUMMARY According to an aspect of the disclosure, a method for customizing a mattress is disclosed. The method includes acquiring a three dimensional image of a body of a user and preparing, by a processor, a three dimensional model of the body of the user using the three-dimensional image. The method also includes dividing, by the processor, the three dimensional model into a plurality of cylindrical sections arranged parallel to each other and arrayed along a height of the three dimensional model. Each cylindrical section includes a first longitudinal end surface arranged along a first surface of the three dimensional model and a second longitudinal end surface arranged along a second surface of the three dimensional model. The method further includes determining, by the processor, a downward pressure to be exerted by at least one desired cylindrical section of the plurality of cylindrical sections on the mattress. The method further includes determining, by the processor, one or more parameters associated with at least one portion of the mattress adapted to be arranged underneath the at least one desired cylindrical section when person lies on the mattress based on the determined downward pressure. In some embodiments, the method includes determining, by the processor, a weight of the at least one desired cylindrical section based on a volume of the at least one desired cylindrical section. In some embodiments, the volume of the at least one desired cylindrical section is determined, by the processor, based on a shape of the first longitudinal end surface of the at least one desired cylindrical section, a shape of the second longitudinal end surface of the at least one desired cylindrical section, and a length of the at least one desired cylindrical section. In some embodiments, the weight of the at least one desired cylindrical section is determined by using a body mass index of the user. In some embodiments, the first surface is front surface of the model corresponding to a front of the body of the user, and the second surface is a rear surface of the model corresponding to a rear of the body of the user. In some embodiments, the mattress includes a support structure having a foam layer including a first surface and a second surface arranged opposite to the first surface and defining a plurality of slots extending from the first surface to the second surface and arranged in a plurality of rows. The support structure also includes a plurality of hoop assemblies arranged inside the plurality of the slots. Each hoop assembly includes a hoop arranged vertically inside the slot and a central axis of the hoop extends substantially horizontally and parallel to the first surface. The hoop is configured to compress under a load. Further, determining the one or more parameters includes determining at least one of a width or a thickness of the hoop of each hoop assembly adapted to be arranged underneath the at least one cylindrical section. In some embodiments, the mattress includes an alignment structure supported on the support structure and having an alignment layer having a first surface and a second surface arranged opposite to the first surface and defining a plurality of cut-outs extending from the first surface to the second surface and arranged in a plurality of ro