Pocketed Mattress String Layout for Thin Independent Spring Support
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Solution Overview
Problem
Existing spring mattresses, particularly those using the pocket technique, are expensive to manufacture and struggle to provide individual resilience and thinness, making them unsuitable for applications like bed mattresses and seat cushions without compromising comfort.
Innovation Solution
A spring mattress design featuring interconnected strings with coil springs and slots between them, allowing for increased individual resilience and reduced spring count, combined with biased casing portions to maintain separation and enhance comfort, using thicker wire for cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If springs are enclosed in pockets using the traditional pocket technique, then individual resilience and comfort are improved, but manufacturing cost increases significantly
Solution Approach 1:
The mattress is divided into multiple independent strings, each containing multiple springs enclosed in continuous casings. This segmentation allows each spring to function independently while simplifying the overall manufacturing process compared to traditional individual pocket construction
Solution Approach 2:
Multiple springs are combined into continuous strings with continuous casings, reducing the number of separate components and assembly steps. This merging approach maintains individual spring resilience while significantly simplifying manufacturing compared to traditional individual pocket construction
2Length of moving object
If spring length is reduced to make thinner mattresses, then mattress thickness decreases, but spring stability deteriorates and comfort decreases
Solution Approach 1:
The problem of spring stability in thin mattresses is solved by moving from a two-dimensional planar arrangement to a three-dimensional configuration where casing portions extend beyond spring ends. This dimensional change allows shorter springs to remain stable without compromising comfort
3Volume of moving object
If end portions of casings are moved towards each other to create compact mattresses, then mattress compactness improves, but individual resilience of springs deteriorates
Solution Approach 1:
The casing is segmented into multiple portions along its length, with specific portions extending beyond spring ends. This segmentation allows the mattress to be compact while maintaining spring independence and individual resilience through the extended casing portions
4Ease of manufacture
If thicker wire is used for springs, then manufacturing cost decreases, but mattress comfort and flexibility worsen
Solution Approach 1:
The relationship between wire thickness and comfort is optimized by changing other parameters - specifically the casing configuration with portions extending beyond spring ends. This allows the use of thicker, more cost-effective wire while maintaining comfort through the mechanical design of the casing-spring interaction
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 design results in a cost-effective, comfortable, and resilient mattress that can be easily manufactured with fewer springs, offering improved comfort and flexibility, suitable for various applications, including thinner options.
Implementation Method 1
the springs will be relatively individually resilient so that they can flex individually without affecting the neighboring springs
Data Source
AI summary
A spring mattress is described, including a plurality of strings interconnected side by side. Each string includes a plurality of continuous casings and, enclosed therein, coil springs. Moreover, between at least some of the springs in at least one of the strings a slot is arranged which opens towards the upper or lower side of the mattress. It is preferred for the springs between which the slot is arranged to be separated with an intermediate separation distance, which separation distance exceeds about 10% of the diameter of the largest turn of the adjoining springs. In addition, it is preferred for the casing portions to be arranged at the ends of the spring to be moved towards each other, through the spring, and connected to each other by at least one connecting device.