Pocket Spring String Structure to Prevent Sagging and Noise
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Solution Overview
Problem
Existing pocket spring suspensions for bedding mattresses suffer from ineffective maintenance of helical barrel springs within pockets under load, leading to sagging and noise, compromising comfort.
Innovation Solution
The design features helical springs housed in individual retaining pockets formed from elongated flexible fabric, with transverse and longitudinal heat-sealing lines that create a closed contour and recesses to securely hold spring parts, preventing oblique arrangement and noise generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If helical barrel springs are housed in pockets formed by heat-sealable fabric strips, then the suspension structure is simple and manufacturable, but the springs are not effectively maintained in the pockets under load, causing sagging and noise
Solution Approach 1:
The transverse heat-sealing line is divided into two separate parallel lines, creating a gap between them. This segmentation allows the spring to be positioned within the gap, preventing it from shifting obliquely while maintaining the simplicity of heat-sealed pocket construction.
Solution Approach 2:
The gap between the two transverse heat-sealing lines acts as an intermediary structure that holds the spring in place. This intermediate space prevents direct contact between the spring and the sealed edges, eliminating the spring's ability to hook with adjacent springs while maintaining secure positioning.
2Manufacturing precision
If transverse heat-sealing lines are located at determined distances to define pocket width, then pocket dimensions are controlled, but springs can still arrange obliquely and hook with adjacent springs under load
Solution Approach 1:
The transverse heat-sealing line is segmented into two parallel lines with a gap between them. This segmentation creates a restraining structure that prevents the spring from moving obliquely or hooking with adjacent springs, while still allowing precise control of pocket width through the spacing of the two lines.
Solution Approach 2:
The local structure of the transverse sealing line is changed from a continuous line to two separated lines, creating a specific local quality (the gap) that provides spring restraint. This local modification maintains overall pocket width control while adding the stability function.
3Ease of manufacture
If adhesive strips are used to fix pockets to adjacent strings, then string connection is achieved, but the springs within pockets still sag and generate noise under load
Solution Approach 1:
The transverse heat-sealing line is divided into two parallel lines, creating a gap structure that restrains the spring. This segmentation prevents the spring from moving and generating noise or sagging, while the overall assembly process remains simple and adhesive-free for string connection.
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
This configuration effectively maintains spring parts within pockets during compression, reducing sagging and noise, enhancing mattress comfort and independence, while allowing for adjustable stiffness and flexibility.
Implementation Method 1
formed between two folded sections one above the other of an elongated strip of flexible fabric and are delimited by heat sealing lines 9 transverse to the strip 8
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention relates to a string of pocket springs, a suspension for a bedding mattress comprising a plurality of such strings, and a mattress having such a suspension. According to the invention, the string is mainly characterized in that each transverse connecting line (9) is divided, in a region located half-way up between two adjacent pockets (6) of the string and in the region of a smallest-diameter coil (14), into two parts that are connected together by two connecting lines (17) that are substantially spaced apart from one another so as to define a closed and elongate contour parallel to the transverse connecting line (9), and an approximately oval gap (18) is formed by removing fabric material between the two substantially curved connecting lines (17). The invention is used in the field of bedding.