Pocketed Spring Comfort Layer With Airflow-Controlled Compression
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Solution Overview
Problem
Existing comfort layers in seating and bedding products, such as those made of visco-elastic foam, retain heat and create a noise issue due to fabric expansion, while lacking the luxury feel of slow-compression and recovery characteristics without using foam.
Innovation Solution
A comfort layer comprising individually pocketed springs within semi-impermeable or impermeable fabric pockets, where the fabric's airflow control retards compression and recovery rates, mimicking the feel of visco-elastic foam without heat retention, achieved through controlled seam gaps and fabric permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visco-elastic foam or latex foam pads are used to provide luxury feel with slow compression and recovery, then comfort and luxury feel are improved, but heat retention increases and body heat dissipation slows down
Solution Approach 1:
The patent uses air as a medium within sealed pockets containing coil springs. The air pressure and volume changes during compression and recovery provide the slow-acting luxury feel without the heat retention of foam. The pneumatic system allows heat to pass through while maintaining the desired comfort characteristics.
Solution Approach 2:
The fabric pockets are designed with specific porosity to control air flow. The material allows air to move in and out of the pockets during compression cycles, providing cooling while maintaining the slow compression characteristic. The porosity is optimized to balance comfort and heat dissipation.
2Ease of operation
If fabric pockets are made impermeable to airflow to control compression rate, then slow compression and recovery are achieved, but noise is generated due to fabric expansion
Solution Approach 1:
The fabric pockets incorporate local variations in permeability. Certain areas have higher permeability to allow air escape during expansion, reducing noise, while other areas maintain lower permeability to control the compression rate. This localized quality differentiation solves both requirements simultaneously.
Solution Approach 2:
The fabric material parameters are adjusted to achieve the desired balance. The permeability, thickness, and elasticity of the fabric are specifically selected to control air flow rates during compression and expansion, minimizing noise while maintaining slow compression characteristics.
3Ease of operation
If semi-impermeable fabric material is used to retard compression rate, then luxury feel is achieved, but manufacturing complexity increases
Solution Approach 1:
The comfort layer is divided into multiple independent pockets, each containing a coil spring. This segmentation allows for standardized manufacturing of individual pocket units that can be assembled efficiently. The semi-impermeable fabric is cut and sewn in standard patterns, reducing overall manufacturing complexity despite the specialized material requirements.
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 comfort layer provides a luxurious feel with slow compression and recovery, enhanced cooling due to airflow, and reduced noise, all without the heat retention issues of traditional foam layers, at a cost-effective manufacturing process.
Implementation Method 1
The fabric pocketing material within which the springs are contained may be semi-impermeable to airflow through the fabric material... air may pass through such a semi-impermeable material, but at a reduced rate
Implementation Method 2
individually pocketed springs, each spring being contained within a fabric pocket
Data Source
AI summary
A comfort layer for a bedding or seating product has slow-acting pockets characterized by the individual springs of the comfort layer being pocketed with either semi-impermeable or impermeable fabric. Each seam joining opposed plies of fabric around each of the coil springs of the comfort layer may be segmented, allowing air to flow between the segments, thereby increasing the luxury “feel” of the comfort layer. The method of making the comfort layer includes compressing the springs and creating pockets with a welding horn and an anvil.