A mattress spring core comprising at least one corner spring pocket for increasing mattress shape stability
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Solution Overview
Problem
Existing mattress spring core designs with steel or foam frames are costly, require manual handling, and cannot be vacuum pressed or rolled for storage and transport without damage, while also posing challenges for recycling and sustainability.
Innovation Solution
A mattress spring core design featuring spring pockets arranged in longitudinal columns and transverse rows with corner pockets projecting from adjacent columns, allowing for a rectangular shape and stability, and using adhesive attachment for size stability, enabling automated production and sustainable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a steel frame or foam box construction is used to reinforce the edges of the mattress, then shape stability is improved, but production cost increases and manual handling is required
Solution Approach 1:
The invention extracts the reinforcement function from separate steel frames or foam box constructions and integrates it directly into the spring core structure itself. The corner spring pockets project longitudinally beyond the adjacent column end spring pockets, creating built-in corner reinforcement that eliminates the need for separate frame components, thereby reducing production cost while maintaining shape stability.
Solution Approach 2:
The invention merges the corner reinforcement function with the spring core structure by making the corner spring pockets an integral part of the spring array. This consolidation combines what were previously separate components (spring core and corner reinforcement) into a unified structure, reducing the number of parts and simplifying manufacturing.
2Stability of the object's composition
If a steel frame construction is used to reinforce the edges of the mattress, then shape stability is improved, but the mattress cannot be vacuum pressed and rolled for storage
Solution Approach 1:
The invention creates a dynamic corner reinforcement structure where the corner spring pockets can compress and deform under vacuum pressure, unlike rigid steel frames. The spring pockets are formed from flexible material that allows the mattress to be vacuum pressed and rolled, while still providing shape stability when the mattress is in use and uncompressed.
3Ease of manufacture
If traditional spring core designs are used, then production is simpler, but shape stability and corner definition are insufficient
Solution Approach 1:
The invention applies local quality by creating corner spring pockets with different geometric properties than the regular spring pockets. The corner spring pockets project longitudinally beyond the adjacent column end spring pockets, providing enhanced corner definition and shape stability only where needed, while maintaining the simplicity of the overall spring core construction.
Data Source
AI summary
A mattress spring core including a plurality of spring pockets arranged in longitudinal columns and transverse rows, wherein at least one corner spring pocket projects longitudinally from an adjacent column end spring pocket.