Fully Active Pocket Spring Core With Angled End Turns
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Solution Overview
Problem
Conventional pocket spring cores require a significant amount of wire to achieve desired firmness, increasing manufacturing costs, while traditional spring configurations with flat end turns oriented normal to the axis provide comfort but not firmness, necessitating a balance between wire usage and spring performance.
Innovation Solution
The use of fully active springs with unknotted end turns that have a finite pitch angle, contributing to spring force, reduces the amount of wire needed by incorporating end extensions that bend towards the central spiral portion, allowing for a more aggressive pitch without compromising shape memory.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If springs have flat end turns oriented normal to the spring axis, then comfort and luxury feel are improved, but firmness deteriorates and wire consumption increases
Solution Approach 1:
The patent changes the geometric parameters of the end turns by introducing a pitch angle relative to the spring axis. Instead of being perpendicular to the axis (0° pitch), the end turns are inclined at a specific angle, which allows them to contribute to the spring force while maintaining comfort. This parameter change enables the end turns to actively participate in load-bearing.
Solution Approach 2:
The patent transforms the static end turns (which traditionally only provided support surface) into dynamic elements that actively contribute to spring force. The inclined end turns can now deform and store elastic energy during compression, making the entire spring length fully active in the load-bearing function.
2Strength
If greater wire amount is used to provide firmness, then spring force is improved, but manufacturing cost increases
Solution Approach 1:
The patent ensures that the entire spring length, including the end turns, continuously contributes to the spring force during compression. By eliminating the non-active portion (traditional perpendicular end turns) and making all segments fully active, the spring achieves maximum efficiency in wire utilization, providing required firmness with less material.
3Quantity of substance
If more aggressive pitch is used to reduce wire length, then wire consumption is reduced, but shape memory deteriorates
Solution Approach 1:
The patent applies different pitch angles to different portions of the spring. The central portion can have a more aggressive pitch for wire reduction, while the end turns have a specific inclination angle optimized for both activity and shape retention. This local differentiation allows each segment to perform its function optimally without compromising overall shape memory.
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
This approach reduces the amount of wire required for pocket spring cores while maintaining or exceeding the firmness of conventional designs, thereby lowering manufacturing costs and mitigating wear on pocket material.
Implementation Method 1
Each fully active spring respectively has a central spiral portion with at least one turn, an unknotted first end turn, and an unknotted second end turn... the first end turn and the second end turn contribute to a spring force of the fully active spring
Data Source
AI summary
A pocket spring core for a bedding or seating cushion comprises an array of pocket springs. The array of pocket springs comprises fully active springs (10) respectively enclosed in an associated pocket (35) of fabric. Each fully active spring (10) respectively has a central spiral portion (20) with at least one turn and defining a spring axis (13), an unknotted first end turn (21) defining a first end of the fully active spring (10), and an unknotted second end turn (22) defining an opposing second end of the fully active spring (10). Each fully active spring (10) has a rest shape in which the first end turn (21) and the second end turn (22) have a finite pitch angle, so that the first end turn (21) and the second end turn (22) contribute to a spring force of the fully active spring (10).