Pocket Coil Spring Assembly With Foam for Comfort and Motion Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional pocket coil spring assemblies lack enhanced support and comfort, as they do not effectively integrate flexible foam to improve the unique feel and motion isolation provided by individual coil movement.
Innovation Solution
Incorporating flexible foam into the interior cavity of pocket coil spring assemblies, with its top surface extending above the coil spring, and connecting the fabric pocket's top and bottom areas to create a recess for the foam, allowing it to bond and provide pre-compression, stability, and stretchability, while maintaining individual coil movement and motion isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flexible foam is added to the interior cavity of pocket coil spring assemblies, then comfort and support are enhanced, but device complexity increases
Solution Approach 1:
The flexible foam is nested within the interior cavity of the pocket coil spring assembly, with the foam positioned inside the fabric pocket that already encases the coil spring. This nested configuration allows the foam to be integrated into the existing structure without requiring separate housing or additional external components, thereby enhancing comfort while minimizing the increase in overall device complexity.
Solution Approach 2:
The invention merges the flexible foam with the fabric pocket and coil spring assembly into a unified support structure. The foam is bonded to the fabric pocket, creating a combined element that provides both the mechanical support of the spring and the comfort contouring of the foam, effectively merging multiple functions into a single integrated component.
2Ease of operation
If flexible foam is positioned in the interior cavity with top surface extending above the coil spring, then body contouring is improved, but manufacturing precision requirements increase
Solution Approach 1:
The invention allows the flexible foam to extend above the coil spring to a controlled degree, creating a specific geometric parameter (foam extension height) that enhances body contouring. By defining this parameter range and controlling the foam dispensing process, the system achieves improved contouring while maintaining manufacturability through standardized foam application procedures.
3Stability of the object's composition
If fabric pocket top and bottom areas are connected within the interior cavity to create a recess, then pre-compression and stability are provided, but device complexity increases
Solution Approach 1:
The fabric pocket is pre-configured with connections between its top and bottom areas within the interior cavity, creating a recess structure before the foam is inserted. This preliminary configuration of the fabric pocket establishes the desired pre-compression and stability characteristics, allowing the foam to be subsequently positioned and bonded into the pre-formed recess without requiring complex post-assembly adjustments.
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 integration of flexible foam enhances comfort and support by allowing the foam to react with the fabric pocket, providing a luxurious feel and improved body contouring without disturbing adjacent users, while maintaining the durability and support of the coil spring.
Implementation Method 1
the flexible foam can be directly dispensed and allowed to react and bond to the fabric pocket
Implementation Method 2
each discrete coil is capable of moving independently to support the body of a user
Implementation Method 3
pocket coil spring assemblies, which are also known as wrapped coils, encased coils, encased springs, or Marshall coils
Implementation Method 4
a fabric pocket that encases the coil spring, with a top area that covers the upper portion of the coil spring and a bottom area that covers the lower portion of the coil spring
Implementation Method 5
providing a desired level of pre-compression, stability, and/or stretchability to the pocket coil spring assembly
Data Source
AI summary
A pocket coil spring assembly is provided that includes a coil spring having an upper portion and a lower portion collectively defining an interior cavity of the coil spring. The pocket coil spring assembly further includes a fabric pocket encasing the coil spring with a top area covering the upper portion of the coil spring and a bottom area covering the lower portion of the coil spring. An amount of flexible foam is positioned in the interior cavity of the coil spring such that a top surface of the flexible foam extends above the coil spring. A mattress assembly is further provided that includes a plurality of the pocket coil spring assemblies.