Pocket Coil Assembly With Flexible Foam for Pressure Distribution
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Solution Overview
Problem
Traditional pocket coil spring assemblies lack enhanced support and comfort, as they do not effectively distribute pressure and contour to the body, leading to a suboptimal sleeping experience.
Innovation Solution
Incorporating flexible foam either on top of or between the coil springs in a mattress assembly, using a two-part polyurethane foam with adjustable density and hardness, to provide additional support and comfort while maintaining the independent movement of each coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flexible foam is added to the pocket coil spring assembly, then pressure distribution and body contouring are improved, but device complexity increases
Solution Approach 1:
The flexible foam is positioned within the interior cavity of the fabric pocket that already encases the coil spring, creating a nested structure where the foam is contained within the existing pocket assembly. This allows the foam to be integrated without requiring a completely separate assembly process, thereby improving pressure distribution while limiting the increase in device complexity.
Solution Approach 2:
The flexible foam and coil spring are combined within the same fabric pocket enclosure, creating a unified support system. The foam and spring work together to provide both contouring and support functions, improving overall comfort while using a single pocket structure rather than separate components.
2Ease of operation
If flexible foam is positioned on top of coil springs, then comfort and support are enhanced, but manufacturing complexity increases
Solution Approach 1:
The flexible foam is positioned within the fabric pocket during the manufacturing process before the final assembly is completed. This preliminary placement allows the foam to be integrated into the pocket structure in advance, simplifying the overall manufacturing process by avoiding the need for separate foam installation steps after assembly.
3Ease of operation
If flexible foam is used to provide support, then pressure distribution improves, but the independent movement of coils may be restricted
Solution Approach 1:
The flexible foam is positioned specifically within the interior cavity of each individual fabric pocket, allowing each coil to move independently within its own enclosed space. This localized placement ensures that the foam provides pressure distribution benefits without creating restrictions that would prevent the independent movement of adjacent coils, as each pocket acts as an independent unit.
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 flexible foam enhances pressure distribution and body contouring, offering improved comfort and support without transferring motion, resulting in a more luxurious and desirable mattress feel.
Implementation Method 1
an amount of flexible foam positioned either on top of the coil springs or in areas between rows of coil springs
Implementation Method 2
using a two-part polyurethane foam with adjustable density and hardness
Implementation Method 3
The flexible foam enhances pressure distribution and body contouring, offering improved comfort and support without transferring motion
Data Source
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AI summary
A pocket coil spring assembly (10) is provided that includes a coil spring (20) having an upper portion (22) and a lower portion (24) collectively defining an interior cavity of the coil spring. The pocket coil spring assembly further includes a fabric pocket (30) encasing the coil spring with a top area (32) covering the upper portion of the coil spring and a bottom area (34) covering the lower portion of the coil spring. A discrete amount of flexible foam (40) is poured on the top of the fabric pocket such that a top surface (42) of the flexible foam extends above the coil spring. A mattress assembly (200, 300, 400) is further provided that includes the flexible foam dispensed in continuous or discrete amounts between rows of pocket coil springs.