Pocket spring core
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2023-05-05
- Publication Date
- 2026-03-11
AI Technical Summary
Existing pocket spring core technologies face challenges in efficiently creating areas with different suspension behaviors while maintaining uniform height and increasing production costs due to complex arrangements of springs with varying diameters and orientations.
A pocket spring core design featuring rows of larger and smaller diameter springs, where the smaller springs are arranged in integer multiples perpendicular to the longitudinal direction, forming sections with varying spring densities to achieve different stiffness zones, and optionally pre-tensioned for adjustable stiffness, with smaller springs providing edge reinforcement and surrounding larger springs in a frame shape.
This design effectively creates areas with distinct suspension behaviors, reduces production costs by simplifying spring arrangement, and allows for customizable stiffness through varying spring densities and orientations, enhancing the overall performance and adaptability of the pocket spring core.
Smart Images
Figure EP2023061953_14112024_PF_FP_ABST
Abstract
Description
[0001] Pocket spring core
[0002] The present invention relates to a pocket spring core having a plurality of springs arranged in rows, each of which is arranged in pockets made of a textile material, and in at least one row of larger springs having a larger diameter and smaller springs having a smaller diameter are arranged.
[0003] DE 10 2017 117 833 A1 discloses a pocket spring core comprising a plurality of springs arranged in rows, each of which is housed in a pocket made of textile material. Springs with the same spring behavior are grouped into partial spring strands, and such partial spring strands can be arranged one behind the other in a row. This method of manufacturing a pocket spring core has proven itself to be effective in providing zones with different spring behavior within a pocket spring core.
[0004] US Pat. No. 10,477,979 B2 shows a pocket spring core in which the pocketed springs exhibit different spring behaviors and are pre-tensioned to varying degrees to ensure the pocket spring core has a uniform height. Furthermore, the springs can have different diameters.
[0005] EP 3 858 784 A1 discloses a method for producing a pocket spring core in which an inner region with larger springs is enclosed by a frame of smaller springs. The smaller springs are arranged in strands of textile material, and on at least two sides, the strands of smaller springs are arranged perpendicular to the longitudinal direction of the strands of larger springs, resulting in increased production costs.
[0006] It is therefore an object of the present invention to create a pocket spring core that effectively enables the provision of zones with different spring behavior. This object is achieved with a pocket spring core having the features of claim 1.
[0007] The pocket spring core according to the invention comprises a plurality of springs arranged in rows, each of which is arranged in pockets made of a textile material. In at least one row, larger springs with a larger diameter and smaller springs with a smaller diameter are arranged. The larger diameter of the larger springs corresponds to an integer multiple of the diameter of the smaller springs, and in at least one row perpendicular to the longitudinal direction, a number of smaller springs that is an integer multiple is provided. Thus, in this row of springs, one section can be formed by springs with a larger diameter, and in another section with smaller springs, not just one spring is provided in this row, but two, three, four, or five springs arranged side by side as seen perpendicular to the longitudinal direction of the row.This means that, when viewed from above, the pocket spring core can be extended by a spring with a large diameter, while several springs with a small diameter are arranged within this row. Where one spring with a large diameter is provided, four, nine, or sixteen springs with a smaller diameter can be positioned. The terms "larger diameter" and "smaller diameter" refer to the diameter of the springs at their thickest point, and the smaller springs have a smaller diameter than the larger springs. The springs can be cylindrical or barrel springs.
[0008] A row of springs refers to a strip-like arrangement that can run either longitudinally or perpendicularly to the cuboid-shaped pocket spring core.
[0009] Preferably, in the at least one row with larger springs and smaller springs, the smaller spring is arranged at least at opposite end sections of the row. The smaller springs at the opposite end sections then form an edge reinforcement in the pocket spring core, since they are arranged on the outer edge of the pocket spring core. The stiffness of the smaller springs can be higher than the stiffness of the larger springs relative to the same area. Preferably, the smaller springs surround at least one section of larger springs in a frame-like manner, so that smaller springs are arranged all the way around the outer circumference of the pocket spring core. Optionally, the pocket spring core can have several sections with larger springs that are surrounded by smaller springs in a frame-like manner in order to provide different firmness zones. The smaller and larger springs preferably have the same length in the pocket spring core.Optionally, the springs can be pre-tensioned in the pockets to adjust the stiffness behavior accordingly.
[0010] In a first variant, the smaller springs have half the diameter of the larger springs, and in at least one row, two smaller springs are arranged next to each other perpendicular to the longitudinal direction of the row, whereby the number of smaller springs in the longitudinal direction can be chosen arbitrarily, for example two, four or a multiple thereof. In a second variant, the smaller springs have one-third the diameter of the larger springs, and in at least one row, three smaller springs are arranged next to each other perpendicular to the longitudinal direction of the row. Even with three or more springs, any number of springs can be arranged one behind the other in the longitudinal direction.
[0011] In a further embodiment, the springs of the same diameter are connected in a row via the textile material to form a strand. The strands of springs of the same diameter are preferably all aligned parallel in their longitudinal direction. This allows the strands of springs to be processed in the same production direction.
[0012] If a larger spring is positioned adjacent to several smaller springs, the pocket of the larger springs can be connected to a pocket or pockets of the smaller springs by gluing or welding. Optionally, it is also possible to leave the adjacent smaller springs unconnected in a spring string with larger-diameter springs, i.e., to leave the front end of the larger spring unconnected to the adjacent smaller springs. In this case, a connection for positioning the springs is preferably made across adjacent rows, securing the last spring with the larger diameter and the last spring with the smaller diameter.
[0013] In an advantageous embodiment, at least one row is provided which is formed entirely from smaller springs with a small diameter. This row of smaller springs is preferably provided on an outer side of the pocket spring core. The sections with one or more rows of larger springs can preferably be cuboid-shaped with smooth outer edges. Alternatively, it is possible for a plurality of smaller springs with a smaller diameter to be provided in at least one row between two larger springs with a larger diameter, so that one or more larger springs are alternately provided with several smaller springs at one edge in the manner of a toothing. This makes it possible to create several regions of different stiffness.
[0014] Optionally, it is also possible to provide more than two different springs, for example, springs with the same diameter but different spring properties, to create an even finer gradation between ranges of different spring stiffness. The springs can then differ either in diameter, but also in wire thickness or other properties.
[0015] Preferably, the pocket spring core is covered on the top and bottom by one or more cover layers and made into a mattress or upholstery.
[0016] The invention will be explained in more detail below using several exemplary embodiments with reference to the accompanying drawings. They show:
[0017] Figures 1 A and 1 B show two views of a first embodiment of a pocket spring core according to the invention;
[0018] Figure 2 is a perspective view of a portion of the pocket spring core of Figure 1A;
[0019] Figure 3 is a detailed view of a portion of the pocket spring core of Figure 1A, and
[0020] Figure 4 is a perspective view of a modified pocket spring core.
[0021] A pocket spring core 1 comprises larger springs 2, which have a larger diameter than smaller springs 3. The springs 2 and 3 can be wound from a cylindrical or barrel-shaped wire and are each arranged in a pocket made of textile material. The illustration of the springs 2 and 3 is therefore schematic and only shows their arrangement. Figure 1B shows a top view of the pocket spring core 1 of Figure 1A.
[0022] The springs 2 and 3 are arranged in rows 4, wherein the width of the rows 4 is defined by the diameter of a large spring 2, and several springs 2 with a large diameter are arranged one behind the other in the row. In such a row, springs 3 with a smaller diameter are also arranged, wherein in the illustrated embodiment, three springs 3 are arranged next to one another in a row 4. The springs 3 have a diameter that corresponds to approximately one-third of the diameter of the large springs. If the diameter of the largest springs 2 at the thickest point is 9 cm, the diameter of the small springs 3 at the thickest point is approximately 3 cm.
[0023] As a result, row 4 has the same width across the entire extension of the pocket spring core 1. At opposite ends of row 4, several springs 3 with a smaller diameter are provided, forming the edge of the pocket spring core. The stiffness of the smaller-diameter springs 3 can be higher than the stiffness of the larger springs 2 relative to the same area. Two sections with larger-diameter springs 2 are provided, separated by a strip of smaller-diameter springs 3. Optionally, the springs 2 can also extend across the entire central section.
[0024] The springs 2 with a large diameter can be arranged in a continuous row 4, with the springs 2 then being connected to each other via the textile material to form the pockets. The small springs 3 with a smaller diameter can also be connected to each other longitudinally or perpendicularly via the textile material of the pockets.
[0025] In the longitudinal direction of row 4, the last spring 2 with a larger diameter can optionally be connected to the adjacent springs 3 with a smaller diameter by welding or gluing the textile material of the pockets. Alternatively, it is possible to leave the end face in a row 4 between springs 2 and 3 with different diameters unconnected, so that they only rest loosely against one another. In this case, a connection can be made by connecting the springs 2 laterally to the springs 2 of an adjacent row 4, for example by gluing or welding, and also connecting the springs 3 with a smaller diameter in a direction perpendicular to the longitudinal direction of row 4. This can also ensure sufficiently precise positioning of springs 2 and 3.
[0026] The sections of springs 2 with a larger diameter, formed from several rows 4, are linear on three sides. On the right side in Figure 1B, a sawtooth-shaped structure is shown in a row 5, in which one spring 2 with a larger diameter alternates with an array of nine springs 3 with a smaller diameter. This creates a transition in the row 5 between the area with the larger springs 2 and the smaller springs 3. This transition is formed by only one row 5, but can also be formed by multiple rows 5.
[0027] Figure 2 shows a section of this area of a row 5, in which a larger spring 2 and an array of nine smaller springs 3 are provided alternately. A spring 21 and a spring 22 are separated by nine smaller springs 3, each of which is arranged in rows of three springs 3. Seen in plan view, the square area occupied by a spring 21 or 22 is approximately the same size as the area made up of nine smaller springs 3. The area made up of the nine springs 3 is surrounded on three sides by the springs 20, 21 and 22 and connected on the fourth side to further springs 3 of smaller diameter.
[0028] Figure 3 shows a section of the pocket spring core 1, in which the springs 2 with a larger diameter are arranged in a cuboid shape and are surrounded on three sides by springs 3 with a smaller diameter.
[0029] Figure 4 shows a modified embodiment of a pocket spring core T, which is formed from springs 2 with a larger diameter and springs 7 with a smaller diameter, the diameter of springs 7 being approximately half the diameter of springs 2. Thus, a row 4 contains springs 2 and 7 with different diameters, with one spring 2 with a larger diameter being arranged in each row 4 and two springs 7 with a smaller diameter being arranged perpendicular to the longitudinal direction of row 4. In a field in which one spring 2 is arranged, there are four springs 7 in a field of the same size.
[0030] 1 , 1 ' pocket spring core
[0031] 2 spring 3 spring
[0032] 4 row
[0033] 5 row
[0034] 6 row
[0035] 7 springs 20 springs
[0036] 21 spring
[0037] 22 spring
Claims
Claims 1. Pocket spring core (1, T) with a plurality of springs (2, 3, 7) arranged in rows, each of which is arranged in pockets made of a textile material, and in at least one row (4) larger springs (2) with a larger diameter and smaller springs (3, 7) with a smaller diameter are arranged, characterized in that the larger diameter of the larger springs (2) corresponds to an integer multiple of the diameter of the smaller springs (3, 7) and in the at least one row (4) perpendicular to the longitudinal direction the number of smaller springs (7) that is an integer multiple is provided.
2. Pocket spring core according to claim 1, characterized in that in the at least one row (4) with larger springs (2) and smaller springs (3, 7), the smaller springs (3, 7) are arranged at least at opposite end sections of the row (4).
3. Pocket spring core according to claim 1 or 2, characterized in that the smaller springs (3, 7) surround at least one section with larger springs (2) in a frame-like manner.
4. Pocket spring core according to one of the preceding claims, characterized in that the smaller springs (7) have half the diameter of the larger springs (2) and in the at least one row (4) two smaller springs (7) are arranged next to one another perpendicular to the longitudinal direction of the row (4).
5. Pocket spring core according to one of claims 1 to 3, characterized in that the smaller springs (3) have a third of the diameter of the larger springs and in the at least one row (4) three smaller springs (3) are arranged next to one another perpendicular to the longitudinal direction of the row (4).
6. Pocket spring core according to one of the preceding claims, characterized in that the springs (2, 3, 4) with the same diameter are connected to one another in a row (4) via the textile material to form a strand.
7. Pocket spring core according to claim 6, characterized in that the strands of springs (2, 3, 4) are all aligned parallel in their longitudinal direction.
8. Pocket spring core according to one of the preceding claims, characterized in that at least one row (6) is provided which is formed entirely from smaller springs (3, 7) with a smaller diameter.
9. Pocket spring core according to one of the preceding claims, characterized in that in at least one row (5) between two larger springs (2) a plurality of smaller springs (3, 7) with a smaller diameter are provided.
10. Pocket spring core according to one of the preceding claims, characterized in that the larger springs (2) adjacent to several smaller springs (3, 7) are connected to the pockets of the smaller springs (3, 7) by gluing or welding the pockets.
11. Pocket spring core according to one of claims 1 to 9, characterized in that in the longitudinal direction of the at least one row (4) there is no direct connection between springs (2, 3, 7) with different diameters and these are only connected to springs (2, 3, 7) from adjacent rows (4).
12. Mattress or cushion with a pocket spring core according to one of the preceding claims.