Pocketed Microcoil Sleep Layer for Surface-Level Mattress Support
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Solution Overview
Problem
Conventional mattresses using spring technology face limitations in providing optimal comfort and support due to the distance of springs from the sleeper, which leads to reduced effectiveness and shorter longevity, as well as issues with pressure points and airflow.
Innovation Solution
A mattress design featuring a core layer with microcoils placed closer to the surface within a quilted sleep layer, formed by spot coupling a thick comfort fabric with a backing fabric to create individual pockets, eliminating the need for metallic needles and reducing intervening materials, thus enhancing support and comfort while maintaining the appearance of a conventional quilt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spring technology is used with springs enclosed in thick fabrics and foams, then the springs are protected and enclosed properly, but the springs are removed from the surface of the mattress reducing support effectiveness and comfort
Solution Approach 1:
The mattress is divided into separate functional layers: a support layer with individually pocketed coils providing structural support, and a comfort layer with quilted fabric and batting providing surface comfort. This segmentation allows each layer to perform its specific function optimally without compromising the other.
Solution Approach 2:
The spring support system is moved from a three-dimensional enclosed structure to a two-dimensional surface-level configuration. Individual coils are positioned at the mattress surface within a quilted plane, eliminating the need for deep enclosure while maintaining protection through the quilted fabric structure.
2Ease of operation
If springs are placed closer to the mattress surface for improved support and comfort, then support effectiveness increases, but the springs may cause pressure points and reduce airflow
Solution Approach 1:
The support function is divided into individual coil units rather than a continuous spring system. Each coil independently supports body weight, distributing pressure across multiple contact points rather than concentrating it, which reduces pressure points while maintaining surface proximity for effective support.
Solution Approach 2:
The comfort layer uses a quilted fabric structure with inherent porosity and air channels that allow airflow to pass through. The batting material also provides breathable structure, ensuring that placing coils at the surface does not restrict airflow while maintaining comfort.
3Strength
If conventional stitching with metallic needles is used to assemble mattress layers, then layers are securely joined, but the process is complex and may compromise comfort layer integrity
Solution Approach 1:
Traditional mechanical needle stitching is replaced with adhesive bonding for attaching the comfort layer to the support layer. This substitution eliminates the complexity of needle-based assembly while providing secure, uniform bonding across the entire surface area without puncturing or damaging the comfort fabric.
Solution Approach 2:
The attachment of the comfort layer to the support layer is merged into a single adhesive bonding operation rather than requiring separate stitching steps. This consolidation simplifies the assembly process while ensuring comprehensive coverage and secure bonding throughout the interface.
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 design improves comfort and support by placing microcoils closer to the sleeper, reducing pressure points, enhancing airflow, and extending the mattress's longevity by maintaining consistent hardness and reducing compressive stress on filler materials.
Implementation Method 1
The sleep layer is formed by coupling the thick, comfort fabric to the backing fabric to form a plurality of individual pockets in which spring coils are placed. The sleep layer coupling is formed by spot coupling without using a metal needle to stitch the layers together.
Implementation Method 2
The coils contained in the individual pockets formed in the quilted, ticking layer are micro-coils. Generally, a micro-coil comprises a wire coil having an uncompressed height of less than 2.5 inches.
Data Source
AI summary
The present application provides a cushion having a core layer and a quilt support/comfort layer. The core layer may comprise innersprings, foams, air cells, or combinations thereof. The support/comfort layer comprises a sleep layer that simulates a conventional quilted fabric layer. The sleep layer includes a thick, comfort fabric and a backing fabric, which backing fabric may be the same as the thick, comfort fabric. The sleep layer is formed by coupling the thick, comfort fabric to the backing fabric to form a plurality of individual pockets in which micro spring coils are placed. The micro spring coils have less uncompressed height than conventional innerspring coils. The sleep layer coupling is formed by spot coupling without using a metal needle to stitch the layers together. In other words, the spot coupling may comprise an adhesive or weld.