Resilient unit with different major surfaces
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Solution Overview
Problem
Existing resilient units, such as pads and mattresses, lack versatility in providing comfort, convenience, and protection due to limited customization of material properties and resilience characteristics, which restricts their application in various environments.
Innovation Solution
A resilient unit comprising a pad with a plurality of encapsulated resilient elements, such as coil springs, between layers of material that differ in characteristics like optical, thermal, tactile, and physical properties, allowing for tailored performance in specific applications, with the layers being bonded or welded to form pockets that optimize spring stability and compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If resilient units use uniform material layers, then manufacturing is simple, but versatility and customization are limited
Solution Approach 1:
The patent applies local quality by using different material layers with specific properties in different locations. The first and second layers have different characteristics (e.g., waterproof, antibacterial, elastic, permeable properties) to provide tailored performance in specific zones of the resilient unit, allowing customization without requiring complete structural redesign.
Solution Approach 2:
The patent employs composite materials by combining multiple layers with different material properties into a single resilient unit. The first layer and second layer are made from different materials with complementary properties, creating a composite structure that achieves versatility and customization while maintaining manufacturing feasibility through established layering techniques.
2Reliability
If resilient elements are encapsulated in pockets formed by bonding layers, then stability and compression are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the resilient unit into discrete pockets, each containing individual resilient elements (springs). The first and second layers are bonded at specific locations to form these segmented pockets, which stabilize the springs and enable controlled compression while maintaining ease of manufacture through modular assembly.
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 enhances comfort, convenience, and protection by providing customizable resilience, reduced noise, and improved stability, making the unit suitable for diverse applications from seating and flooring to protective gear and packaging.
Implementation Method 1
The first and second layers may be welded together, for example ultrasonically or thermally. The weld may form a join that may be wider than it is tall, and is preferably substantially flat.
Implementation Method 2
The first and second layers may be welded together, for example ultrasonically or thermally.
Implementation Method 3
The first and second layers may be welded together, for example ultrasonically or thermally.
Data Source
AI summary
A resilient unit comprises a number of wire coil springs 12, each of which is located within its own discrete pocket 14 formed by first, upper and second, lower layers 14a and 14b of material, preferably of non-woven material. The two layers 14a and 14b have been thermally, or ultrasonically, welded together at points 16 between the adjacent springs to create the pockets. The upper layer of material 14a differs from the lower layer of material 14b in respect of at least one characteristic.