Pocket Spring Assembly with Segmented Edge Stiffening Webs
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Solution Overview
Problem
Existing pocket spring assemblies face challenges in achieving stiffened edges without complex and costly modifications to production lines, which affect edge stability and require significant changes to existing machinery.
Innovation Solution
A pocket spring assembly design featuring a core formed by interconnected first pocket springs webs, with second pocket springs webs attached to the lateral surfaces and extending perpendicularly, and third pocket springs webs at the longitudinal ends, all with different stiffness characteristics, is used to create a stiffened edge. This design includes textile strips attached to the second and third pocket springs webs and the textile layers, ensuring the edges are reinforced without extending beyond the core surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If springs with different stiffness characteristics are used at the edges compared to the core, then edge stability is improved, but device complexity increases due to multiple spring types and attachment steps
Solution Approach 1:
The pocket spring assembly is divided into distinct functional zones: a core region with first pocket spring webs and edge regions with second pocket spring webs having different stiffness characteristics. This segmentation allows the edge areas to be independently optimized for stability while the core provides general support, resolving the contradiction by spatially separating different functional requirements.
Solution Approach 2:
Different stiffness characteristics are applied locally at the edges versus the core of the mattress. The second pocket spring webs at the edges have different spring characteristics (e.g., higher stiffness) compared to the first pocket spring webs in the core, allowing edge stability to be enhanced without compromising the overall comfort and support properties of the mattress interior.
2Strength
If additional pocket spring webs are attached to lateral surfaces to stiffen edges, then edge support is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The second pocket spring webs are pre-formed with the required stiffness characteristics before attachment to the core. This preliminary preparation allows for standardized manufacturing of edge components that can be efficiently attached to the core assembly, reducing on-site manufacturing complexity while ensuring consistent edge support quality.
Solution Approach 2:
The mattress employs a composite structure combining first pocket spring webs (core) with second pocket spring webs (edge), where each component is optimized for its specific function. This composite approach allows each material type to be manufactured separately using optimized processes, then combined to achieve superior overall performance without requiring complex integrated manufacturing.
3Stability of the object's composition
If the core is terminated at longitudinal ends with different spring characteristics to stiffen edges, then corner stability is improved, but the assembly complexity increases
Solution Approach 1:
The longitudinal ends of the core are segmented with third pocket spring webs that have different spring characteristics from the core webs. This segmentation creates stiffened corner regions that provide enhanced stability at the longitudinal ends, while the majority of the core maintains its original simpler structure for ease of manufacture.
Solution Approach 2:
Different spring characteristics are applied specifically at the longitudinal ends (corners) of the mattress where enhanced stability is needed, while the central core region maintains uniform spring characteristics for simplicity. This localized differentiation achieves corner stability without requiring complex variations throughout the entire assembly.
Data Source
AI summary
A pocket spring assembly 1 has a core 1′ of a pocket spring assembly formed by a plurality of first, adjacent and interconnected pocket spring webs 2 and at least one second pocket spring web 4 connected to the core. Additional strips are provided connecting the at least one pocket spring web 2 with the first and second layers of textile material, respectively, provided on the core 1′. A mattress has a pocket spring assembly and a method is for manufacturing such an assembly.