Pocketed Microcoil Sleep Layer for Mattress Surface Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional mattresses using spring technology face limitations in providing optimal comfort and support due to the distance of springs from the sleeper, which leads to reduced effectiveness and shorter lifespan, as well as interference from intervening materials that diminish support and comfort.
Innovation Solution
A mattress design featuring a core layer with microcoils placed closer to the surface within a quilted sleep layer, formed by coupling thick comfort fabric with a backing fabric using spot adhesives or welds, eliminating the need for a flame retardant sock and reducing material interference, thereby enhancing support and comfort while extending mattress longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spring technology is used in mattresses, then support for individual sleepers is provided, but the springs are removed from the surface for comfort and enclosed by flame retardant socks and outer ticking layers, which reduces effectiveness and lifespan
Solution Approach 1:
The patent extracts the spring support function from the conventional enclosed mattress structure and places microcoils directly in the sleep layer, removing the need for flame retardant socks and thick bounding fabrics that interfere with support effectiveness
Solution Approach 2:
The mattress is segmented into distinct functional layers: a core layer for primary support and a sleep layer with embedded microcoils for surface comfort, allowing each layer to be optimized independently
2Reliability
If thick fabrics and foams are used as wraps around spring supports, then structural integrity is maintained, but these intervening materials diminish support and comfort
Solution Approach 1:
The patent removes the interfering thick fabric wraps and foam layers that conventionally bound spring supports, placing microcoils directly in the sleep layer where they can provide support without material interference
Solution Approach 2:
The sleep layer uses a composite construction of fabric layers with embedded microcoils, providing both structural integrity and direct support contact without the need for thick intervening materials
3Ease of manufacture
If conventional stitching methods are used to attach comfort layers, then assembly is achieved, but metal needles create holes that reduce comfort and aesthetics
Solution Approach 1:
The patent replaces conventional mechanical needle stitching with ultrasonic welding technology, which joins fabric layers without creating holes or visible stitch marks, thereby maintaining comfort and aesthetic appearance
Solution Approach 2:
Ultrasonic energy serves as an intermediary joining mechanism, transferring vibrational energy to melt and bond fabric layers together without direct mechanical penetration, eliminating needle holes while achieving secure attachment
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 placement of microcoils in the sleep layer improves pressure point alleviation, airflow, and coil density, maintaining support and comfort by reducing material interference and extending the mattress's lifespan.
Implementation Method 1
The sleep layer coupling is formed by spot coupling without using a metal needle to stitch the layers together. In other words, the spot coupling may comprise an adhesive or weld.
Implementation Method 2
For example, if the coupling mechanism is a sonic weld, the backing fabric is generally chosen as one that can be sonically welded to the thick, comfort fabric.
Data Source
AI summary
The present application provides a cushion having a core layer and a quilt support/comfort layer. The core layer may comprise innersprings, foams, air cells, or combinations thereof. The support/comfort layer comprises a sleep layer that simulates a conventional quilted fabric layer. The sleep layer includes a thick, comfort fabric and a backing fabric, which backing fabric may be the same as the thick, comfort fabric. The sleep layer is formed by coupling the thick, comfort fabric to the backing fabric to form a plurality of individual pockets in which micro spring coils are placed. The micro spring coils have less uncompressed height than conventional innerspring coils. The sleep layer coupling is formed by spot coupling without using a metal needle to stitch the layers together. In other words, the spot coupling may comprise an adhesive or weld.