Pocketed Coil Spring Structure With Separate Cushioning Pad Compartments
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Solution Overview
Problem
Existing pocket spring mattresses require additional padding layers that complicate and cost manufacturing, risk deformation, and reduce individual resilience, leading to suboptimal pressure distribution and comfort.
Innovation Solution
Individually pocketed coil springs with a cushioning pad in a separate compartment above the coil spring, maintaining independence and resilience, allowing for simpler and cost-efficient manufacturing without the need for direct connection to the coil spring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If foam or cushioning material is connected directly to the coil spring, then additional padding layer is provided, but the manufacturing becomes complicated and costly, and there is a severe risk that the foam/padding will be deformed or disconnected
Solution Approach 1:
The invention divides the pocket structure into two separate compartments: one for the coil spring and one for the cushioning pad. This segmentation eliminates the need to connect foam directly to the spring, simplifying manufacturing while preventing deformation and disconnection issues. The cushioning pad is placed in its own compartment above the spring, maintaining reliability without complex connections.
Solution Approach 2:
The patent introduces an intermediary structure (the separate compartment/pocket) between the coil spring and the cushioning pad. This intermediary compartment allows the cushioning pad to be positioned above the spring without direct connection, avoiding the manufacturing complications and reliability issues of direct attachment while still providing the desired padding function.
2Ease of operation
If additional padding layer is added on top of the pocket mattress, then sleeping comfort is improved, but the individual resilience of the pocket units is reduced and pressure distribution becomes suboptimal
Solution Approach 1:
By placing the cushioning pad in a separate compartment within each individual pocket rather than adding a continuous layer across the mattress, the invention maintains the individual resilience of each pocket unit. Each pocket independently responds to pressure while providing cushioning comfort, optimizing both comfort and pressure distribution.
3Object-generated harmful factors
If foam/padding is connected to the coil spring, then cushioning effect is achieved, but the appearance and comfort deteriorate when the foam/padding is pushed into the convolutions of the coil spring
Solution Approach 1:
The separate compartment structure prevents the cushioning pad from being pushed into the spring convolutions by providing a distinct space above the spring. This maintains appearance and comfort while keeping the manufacturing process simple, as the pad is simply placed in the compartment rather than being connected to the spring.
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 provides enhanced comfort and pressure distribution, maintains resilience, and prevents cushioning pad displacement, ensuring the mattress's appearance and comfort over time without additional padding layers.
Implementation Method 1
a coil spring having an upper end and a lower end
Implementation Method 2
provides enhanced comfort and pressure distribution
Data Source
AI summary
An individually pocketed coil spring for use in a bedding or seating product, is disclosed, as well as pocket spring mattresses including such pocketed coil springs. The individually pocketed coil spring include: a coil spring having an upper end and a lower end; a casing forming a pocket enclosing said coil spring; and a cushioning pad located above said upper end of the coil spring. The casing provides a first compartment enclosing the coil spring, and a second compartment enclosing the cushioning pad. The first and second compartments are separated from each other.