Mattress Top Micro-Spring Design for Airflow and Stitching Ease
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Solution Overview
Problem
Existing mattress designs often feature rigid encasements that restrict airflow and obstruct the movement of micro-springs, leading to suboptimal comfort and support.
Innovation Solution
A mattress top design incorporating an upper cushioning section with decorative upholstery and inner resilient foam, paired with a lower micro-spring support section featuring micro-springs in pockets with a peripheral margin for unobstructed stitching, allowing for improved airflow and integration without rigid encasements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid encasements are used to support micro-springs, then structural stability is improved, but airflow is restricted and spring movement is obstructed
Solution Approach 1:
The patent replaces rigid encasements with flexible fabric pockets that contain the micro-springs. These fabric pockets allow airflow to pass through while still providing containment and support for the springs, eliminating the airflow restriction caused by rigid structures.
Solution Approach 2:
The patent uses porous or open-weave fabric materials for the pocket construction that allows air circulation through the mattress layers. This porous structure enables airflow while maintaining the structural integrity needed to support the micro-springs.
2Stability of the object's composition
If rigid encasements are used to support micro-springs, then structural stability is improved, but spring movement is obstructed
Solution Approach 1:
The flexible fabric pockets allow the micro-springs to move and compress freely in response to body weight and movement, without the obstruction caused by rigid encasements. The fabric material flexes with the springs while maintaining containment.
3Area of stationary object
If micro-springs are placed at the edge of the support section, then support coverage is improved, but stitching is obstructed
Solution Approach 1:
The patent creates a peripheral margin by positioning the micro-springs inward from the absolute edge of the fabric pocket before the stitching process. This preliminary arrangement allows sewing needles and threads to access the fabric edges without obstruction from the micro-springs, enabling complete perimeter stitching while maintaining edge support coverage.
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
Enhances comfort and support by allowing air circulation through the micro-springs and facilitating seamless assembly of the mattress components, resulting in a more integrated and functional mattress structure.
Implementation Method 1
allowing for improved airflow and integration without rigid encasements
Implementation Method 2
a lower micro-spring support section featuring micro-springs in pockets
Implementation Method 3
a cushioning system consisting of a plurality of resilient layers of foam
Data Source
AI summary
A mattress top for an innerspring mattress comprising an upper section including an outer decorative fabric layer and an inner foam layer and a lower section including an array of micro-springs to support the upper section wherein the periphery of the upper section and the periphery of the lower section are stitched together to form an unitary mattress top.