Comfort layer having repeating pattern of pocketed mini coil springs of different heights
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Solution Overview
Problem
Existing pocketed spring comfort layers in bedding and seating products lack the ability to provide posturized support without the need for additional foam or fiber layers, which increases costs and complexity.
Innovation Solution
A comfort layer comprising a matrix of individually pocketed mini coil springs with varying heights, arranged in specific patterns and configurations to provide different firmness regions without the need for additional layers, using fabric pockets with weld seams to contain the springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform height mini coil springs are used throughout the comfort layer, then manufacturing is simple and cost-effective, but posturized support cannot be achieved
Solution Approach 1:
The patent applies local quality by varying the height of mini coil springs in different regions of the comfort layer. Specifically, the lumbar region contains taller mini coil springs (first height) while other regions contain shorter mini coil springs (second height). This creates different firmness levels in different areas, enabling posturized support to accommodate the natural curvature of the spine while maintaining a unified manufacturing process.
2Adaptability or versatility
If additional foam or fiber layers are placed above the pocketed spring comfort layer, then posturized support can be achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent merges the functions of multiple layers into a single comfort layer by integrating varied height mini coil springs directly into the pocketed spring assembly. This eliminates the need for separate foam or fiber layers that would otherwise be required to provide posturized support. The different height springs themselves create the necessary support zones, reducing overall product complexity while maintaining the desired functionality.
3Adaptability or versatility
If additional foam or fiber layers are placed above the pocketed spring comfort layer, then posturized support can be achieved, but production cost increases
Solution Approach 1:
The patent changes the physical parameter of spring height within the existing comfort layer structure to achieve posturized support. By varying the height parameter of mini coil springs in different regions (taller in lumbar area, shorter elsewhere), the patent creates differentiated support zones without adding additional material layers. This reduces both material quantity and production cost while maintaining the adaptability needed for posturized support.
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 solution allows for posturized support in bedding and seating products by varying the firmness of the comfort layer, reducing the need for additional foam or fiber layers, thereby lowering production costs and enhancing support without increasing thickness.
Implementation Method 1
Comfort layers comprising mini pocketed coil springs have heretofore been a uniform firmness throughout
Implementation Method 2
a comfort layer made of pocketed springs
Implementation Method 3
U.S. Pat. Nos. 9,968,202 and 9,943,173 each disclose a comfort layer made of pocketed mini coil springs configured to overlay a spring core
Data Source
AI summary
A posturized comfort layer for a bedding or seating product has different sections of different firmness due to different pocketed mini coil springs within the sections. The springs may be individually pocketed between two sheets of non-woven polypropylene fabric joined with circular or rectangular weld seams. Regardless of the shape of the weld seams, the different firmness of the different sections of the comfort layer may be due to different mini coil springs contained in the pockets. In some embodiments, all pockets may have the same spring and the springs contained in different size weld seams to create pockets of different heights.