Pocket Spring Core Zoning With Visible Diameter-Based Deformability
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Solution Overview
Problem
Existing pocket spring cores do not effectively create distinct zones of different deformability to enhance ergonomic comfort for specific body parts, such as the shoulder area, and existing solutions either lack clear differentiation or are not cost-effective in production.
Innovation Solution
A pocket spring core design with at least two zones, where one zone contains a large number of coil springs with a smaller diameter and the other zone contains fewer coil springs with a larger diameter, arranged in strands with a joining process that creates easily accessible joints, allowing for visible differentiation and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If zones with different deformability are created by varying spring parameters (wire thickness, number of coils, heat treatment), then ergonomic comfort for specific body parts is improved, but the deformability zones are not visible from the outside and production complexity increases
Solution Approach 1:
The patent applies local quality by creating zones with different deformability through visible geometric differences in spring diameter. The first zone contains springs with a first diameter while the second zone contains springs with a second diameter, making the deformability zones visually distinguishable. Each zone is optimized for specific body parts: the first zone (smaller diameter) for shoulder area and the second zone (larger diameter) for head area, providing localized ergonomic comfort without increasing production complexity.
Solution Approach 2:
The patent uses visual differentiation (analogous to color changes) by making the deformability zones visible through different spring diameters. The geometric difference in spring size allows consumers to visually identify and understand the functional zones, similar to how color coding indicates different properties. This transparency builds consumer confidence and eliminates the need for complex internal variations that would be invisible.
2Device complexity
If zones with different deformability are created using springs with different basic geometries (e.g., barrel-shaped), then deformability zones become visible, but production cost and complexity increase
Solution Approach 1:
The patent applies parameter changes by varying only the diameter parameter of the cylindrical springs while maintaining the same basic cylindrical geometry. This approach makes the deformability zones visible through the diameter difference between first and second zones, while avoiding the production complexity and cost associated with manufacturing different spring geometries (such as barrel-shaped, conical, or tapered springs). The uniform cylindrical shape simplifies manufacturing while the diameter variation achieves the desired visual and functional differentiation.
3Ease of manufacture
If fewer coil springs with larger diameter are used in one zone, then manufacturing simplicity and cost are reduced, but the number of springs per unit area decreases requiring more accessible joints
Solution Approach 1:
The patent applies segmentation by dividing the pocket spring core into distinct zones (first zone and second zone) with different spring densities and diameters. The second zone contains fewer springs with larger diameters, creating larger spacing between springs and thereby providing more accessible joints for joining operations. This segmentation allows each zone to be optimized independently: the second zone for manufacturing simplicity with fewer, larger springs that are easier to join, while the first zone provides additional support with more, smaller springs.
Data Source
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AI summary
A pocket spring core (1) with at least two zones (2, 3, 4, 5, 6), wherein at least a first zone (3, 5) has a deformability that depends on the deformability of at least one second zone(s) (2, 4 , 6) of the pocket spring core (1) deviates, the at least one first zone (2, 4, 6) having a plurality of first coil springs arranged in strands (7) in pockets (9) and the at least one second zone (3, 5 ) a plurality of second coil springs arranged in strands (8) in pockets (10), the diameter "D" of the first coil springs being larger than the diameter "d" of the second coil springs, one strand (7, 8) being divided by a Joining method on the outer peripheral side of each pocket (9, 10) at a joint (11, 12, 13) in each case connected to an adjacent strand (7, 8), wherein in the at least one first zone (3, 5) and in the at least one second zone (2, 4, 6) the same number of coil springs is provided.