Layered Composite Cushioning System to Reduce Manufacturing Cost
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Solution Overview
Problem
Existing composite cushioning systems combining spring coils, foam, and gel materials are expensive to manufacture, making them inaccessible to a wide market, despite offering user-friendly and aesthetically pleasing support.
Innovation Solution
A composite cushioning system comprising a base layer with coil springs, a lower and upper foam layer, and a topper layer with an elastomeric layer, enclosed by an outer cover, which can include various configurations such as tufted or quilted fabric, to provide cost-effective and user-friendly support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If composite cushioning systems combine spring coils, foam, and gel materials, then user comfort and support performance are improved, but manufacturing cost increases making them inaccessible to much of the market
Solution Approach 1:
The cushioning system is divided into distinct functional layers: a coil spring base layer for structural support, foam layers for cushioning, and an elastomeric topper for comfort. This segmentation allows each component to be manufactured separately using cost-effective processes and then assembled, reducing overall manufacturing cost while maintaining the performance benefits of composite materials.
Solution Approach 2:
The patent uses composite material construction by combining different cushioning materials (coils, foam, elastomeric) in a layered structure. This approach provides the advantages of each material type while enabling cost optimization through selective material placement and simplified manufacturing processes compared to traditional multi-material composites.
2Strength
If coil springs are used for strong structural support, then support performance is improved, but comfort and aesthetics deteriorate due to skin contact and visibility
Solution Approach 1:
The coil spring base layer is nested within and surrounded by foam layers and an outer cover. This nested structure allows the coils to provide structural support internally while being completely enclosed by comfort-providing foam and fabric layers, eliminating direct skin contact and improving aesthetics without compromising support performance.
Solution Approach 2:
Different layers of the cushioning system have different local qualities optimized for their specific functions: the coil layer provides structural support, the foam layers provide cushioning and comfort, and the outer cover provides aesthetic appearance. This local quality differentiation resolves the contradiction between support strength and comfort.
3Ease of operation
If foam is used for soft cushioning support, then comfort is improved, but weight increases making it difficult to reposition
Solution Approach 1:
The cushioning system segments the support function across multiple lightweight components: coil springs for structural support, thin foam layers for cushioning, and an elastomeric topper for comfort. This segmentation achieves comfortable support with reduced overall weight compared to using thick, dense foam alone.
Solution Approach 2:
The patent substitutes heavy, dense foam with a lighter mechanical system combining coils and elastomeric materials to provide equivalent or superior support and comfort. This replacement reduces weight while maintaining or improving the cushioning performance.
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 system offers a cost-effective solution that combines the benefits of individual coil spring, foam, and gel cushion systems, providing improved performance and accessibility to a broader market.
Implementation Method 1
The topper layer may have an elastomeric layer coupled to a foam layer
Implementation Method 2
Foam has special durability due to its quality of returning to a decompressed state after a user provided pressure is removed
Data Source
AI summary
A composite cushioning system including a coil spring layer, a topper layer, and a cover surrounding all of it. The topper is provided in one of several embodiments. A first embodiment has an elastomeric layer disposed between a lower foam layer and an upper fabric layer, all held together in a tufted appearance using a plurality of buttons. A second embodiment includes a smaller area elastomeric layer within a foam border and covered by a fabric-foam layer. A third embodiment includes an elastomeric layer enclosed in a fabric cover. A fourth embodiment includes an elastomeric layer melt fused to a lower foam layer bordered by a support structure. A fifth embodiment includes upper and lower elastomeric layers formed around an intervening fabric layer, wherein the fabric layer extends from edge of the elastomeric layers, with the excess fabric layer being held between corresponding upper and lower foam borders.