Inclined Pocketed Spring Core Layout for Lower Spring Count
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Solution Overview
Problem
The high production costs and low efficiency of traditional pocketed spring mattresses due to the large number of springs used, while maintaining comfort and support performance.
Innovation Solution
An inclined pocketed spring string with partially or entirely inclined springs arranged in a herringbone shape and bonded in a staggered manner, reducing the number of springs and incorporating upright springs at the ends for structural stability and flatness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large number of pocketed springs are used to ensure support performance and comfort, then the support performance and comfort are improved, but the production cost increases and production efficiency decreases
Solution Approach 1:
The spring string is segmented into multiple zones with different spring orientations. The first section has springs perpendicular to the end face, while the second section has springs inclined at an angle. This segmentation allows different regions to fulfill different functional requirements, reducing the total number of springs needed while maintaining support performance.
Solution Approach 2:
Different sections of the spring string are designed with different spring orientations to meet local support requirements. The perpendicular springs provide stable support at the ends, while the inclined springs in the middle section reduce the overall spring count. This local differentiation optimizes both comfort and production efficiency.
2Ease of manufacture
If springs are arranged in inclined configuration to reduce the number of springs, then production cost decreases, but structural stability may be compromised
Solution Approach 1:
The spring string is divided into a first section with perpendicular springs and a second section with inclined springs. The perpendicular springs at the ends provide structural stability and flatness, while the inclined springs in the middle section reduce the total spring count. This segmentation allows the structure to maintain stability while reducing production costs.
Solution Approach 2:
The spring string combines two different spring configurations (perpendicular and inclined) in a composite structure. This composite design leverages the advantages of both orientations: the perpendicular springs ensure stability at the ends, while the inclined springs reduce the overall number of springs needed, achieving both structural integrity and cost reduction.
3Ease of manufacture
If inclined springs are used to reduce spring count, then manufacturing cost is reduced, but the flatness of the bed core surface may be affected
Solution Approach 1:
The spring string is segmented with perpendicular springs at the first and second sections and inclined springs in the middle section. The perpendicular springs at the ends ensure that the bed core surface remains flat in these regions, while the inclined springs in the middle section reduce the overall spring count. This segmentation maintains surface flatness where needed while achieving cost reduction.
Solution Approach 2:
Different sections of the spring string are designed with different spring orientations to meet local requirements. The perpendicular springs at the ends provide flat surface support, while the inclined springs in the middle section reduce the spring count. This local differentiation ensures that the bed core surface remains flat where structural integrity is required while reducing manufacturing costs.
Data Source
AI summary
An inclined pocketed spring string (4) and a pocketed spring bed core (3). The inclined pocketed spring string (4) comprises a plurality of pocketed individual springs (1) connected at intervals. Each pocketed individual spring (1) comprises a fabric (11) and an individual spring (12) packaged in the fabric (11). The individual springs (12) in the pocketed spring string (4) are entirely or partially inclined in the fabrics (11) in an inclined manner. The inclined pocketed spring string (4) and the pocketed spring bed core (3) of the present invention, as compared with the pocketed spring bed core of the same size, can effectively decrease the number of springs used and reduce manufacturing costs.