Zoned Pocket-Spring Core With Channel Depressions for Stiffness Control

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Solution Overview

Problem

Existing methods for producing zoned pocket spring cores require separate manufacturing and manual assembly of pocket spring strands, leading to complex and costly production processes.

Innovation Solution

A zoned pocket spring core design featuring zones of varying stiffness achieved through the defined omission of springs and automated manufacturing using ultrasonic welding, with spring strand sections arranged in a pattern to create channel-like depressions for reduced stiffness zones, allowing for cost-effective and simplified production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate manufacturing and manual assembly of pocket spring strands is used, then zoned pocket spring cores can be produced with different stiffness zones, but production complexity and costs increase significantly

Engineering Contradiction:

Improvezoned stiffness capabilityVSAvoidproduction process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The pocket spring core is divided into multiple zones with different stiffness characteristics by selectively arranging springs of different heights in specific regions. The core is segmented into zones such as head zone, shoulder zone, lumbar zone, and foot zone, each with tailored spring configurations to provide differentiated support for different body parts.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the pocket spring core are assigned different local properties through varying spring heights and densities. The head zone may have taller springs for higher support, while the foot zone has shorter springs for lower support, creating locally optimized stiffness characteristics without requiring separate manual assembly of pre-manufactured strands.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If separate manufacturing and manual assembly of pocket spring strands is used, then zoned pocket spring cores can be produced, but manufacturing costs increase due to production-logistical expenditure and handling effort

Engineering Contradiction:

Improvezoned stiffness capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The manufacturing process merges the production of multiple spring strands into a single automated process. Springs of different heights are produced in the same manufacturing run and directly positioned in their final zones within the pocket spring core, eliminating the need for separate manufacturing of pre-assembled strands and their subsequent manual assembly.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The automated manufacturing system performs both spring production and positioning operations in one integrated process. The system automatically places springs of appropriate heights into designated zones without requiring external manual intervention for assembly, making the manufacturing process self-sufficient and reducing labor costs.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If separate manufacturing of pocket spring strands with different spring heights is used, then zoned stiffness can be achieved, but production time and handling effort increase

Engineering Contradiction:

Improvezoned stiffness capabilityVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The manufacturing process operates continuously by producing springs of different heights in an uninterrupted sequence and directly positioning them in their respective zones within the pocket spring core. This eliminates the discontinuous steps of separate strand manufacturing, quality inspection, packaging, storage, and manual assembly, maintaining continuous productive action throughout the manufacturing cycle.

Inventive Principle:

Principle #20Continuity of useful action

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 solution enables the cost-effective and automated production of zoned pocket spring cores with optimized support for body regions, reducing manufacturing complexity and costs while providing enhanced support and comfort during sleep.

Implementation Method 1

automated manufacturing using ultrasonic welding

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS11633048B2Pocket-spring core and method for producing the pocket-spring core

Publication Date: 2023.04.25 AGRO HLDG

AI summary

A pocket-spring core having at least one first zone and at least one second zone, wherein the first zone has at least two rows of a first spring portion and at least one of the second zones has at least one row or line of a second spring portion, wherein the second spring portion has at least two layers which are located vertically one above the other and comprise in each case a plurality of helically wound first compression springs, in a first, upper layer, and second compression springs, in a second, lower layer, and at least one row of a third spring portion, is distinguished in that at least one of the second zones of the pocket-spring core has at least one channel-like depression.