Pocket coil spring assembly including flexible foam
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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, and can transfer motion between users.
Innovation Solution
Incorporating flexible foam on top of or between coil springs in a pocket coil spring assembly, which provides additional support and pressure distribution, using materials like polyurethane foam or gel to enhance comfort and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional pocket coil springs are used alone, then the structure is simple and cost-effective, but the pressure distribution and body contouring capability are insufficient
Solution Approach 1:
The patent combines pocket coil springs with flexible foam materials to create a composite support system. The foam layers (including memory foam, latex foam, or gel foam) are positioned between the coil springs and the comfort layers, creating a multi-material construction that enhances pressure distribution and body contouring while maintaining the independent coil movement capability
Solution Approach 2:
The patent merges the mechanical support function of pocket coil springs with the pressure-distributing and contouring properties of flexible foam materials. This combination allows the mattress to achieve both structural support and comfort enhancement in a single integrated system
2Ease of operation
If flexible foam is added to enhance comfort and pressure distribution, then support and comfort are improved, but the device complexity increases
Solution Approach 1:
The patent segments the mattress construction into distinct functional layers: the pocket coil spring layer for mechanical support, intermediate flexible foam layers for pressure distribution and contouring, and comfort layers for surface softness. This segmentation allows each layer to perform its specific function optimally while making the overall assembly more manageable through clear layer differentiation
3Reliability
If pocket coil springs are used, then motion transfer between users is reduced, but additional support and contouring capability is lacking
Solution Approach 1:
The patent introduces flexible foam materials as intermediary elements between the pocket coil springs and the user's body. These foam layers act as mediators that enhance body contouring and pressure distribution while the pocket coil springs continue to provide motion isolation. The foam absorbs and distributes pressure points, preventing direct transmission of motion through the coil springs
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 improves the overall feel and support of the mattress by distributing pressure and reducing motion transfer, offering a more luxurious and comfortable sleeping experience.
Implementation Method 1
provides additional support and pressure distribution
Implementation Method 2
flexible foam in the shape of a hemisphere is then positioned on the top area of the fabric pocket
Implementation Method 3
using materials like polyurethane foam or gel to enhance comfort and durability
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. A discrete amount of flexible foam is poured on the top of the fabric pocket such that a top surface of the flexible foam extends above the coil spring. A mattress assembly is further provided that includes the flexible foam dispensed in continuous or discrete amounts between rows of pocket coil springs.