Pocketed Spring Comfort Layer With Airflow-Controlled Seams
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Solution Overview
Problem
Existing comfort layers in seating and bedding products, such as those using visco-elastic or latex foam, retain heat due to their closed cell structure, leading to discomfort and noise issues associated with fabric expansion from coil springs.
Innovation Solution
A pocketed spring comfort layer with strategically designed airflow through the seams between mini coil springs, allowing air to flow between and around the springs, mimicking the luxury feel of visco-elastic or latex foam without heat retention, achieved by using ultrasonic welding to create gaps in the weld segments of the fabric seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visco-elastic or latex foam pads are used to cover spring cores, then a luxury feel with slow compression and recovery is achieved, but heat retention increases due to closed cell structure
Solution Approach 1:
The patent replaces closed-cell foam materials with a porous structure consisting of individually pocketed coil springs enclosed in fabric pockets. This porous construction allows air circulation and heat dissipation while maintaining the slow compression and recovery characteristics that provide the luxury feel, thereby resolving the heat retention issue without sacrificing comfort.
Solution Approach 2:
The invention creates a composite structure combining fabric material and coil springs to form pocketed assemblies. This composite approach replicates the functional properties of foam (slow compression, luxury feel) while eliminating the harmful heat retention characteristic, achieving both comfort and thermal regulation.
2Strength
If fabric material is used to enclose coil springs in pocketed spring cores, then structural support is provided, but noise is generated due to fabric expansion during load removal
Solution Approach 1:
The patent applies different fabric materials to different regions or pockets based on their specific requirements. By selecting fabrics with appropriate acoustic properties for specific locations, the design provides structural support where needed while minimizing noise generation in areas prone to fabric expansion, thus locally optimizing both strength and noise reduction.
3Stability of the object's composition
If airflow is restricted through fabric material in pocketed spring cores, then structural integrity is maintained, but heat dissipation is reduced
Solution Approach 1:
The use of porous fabric materials in the pocketed spring construction allows airflow through the structure while maintaining structural integrity. The porous nature of the fabric provides both mechanical strength and thermal regulation by enabling heat dissipation through air circulation, resolving the contradiction between structural stability and heat management.
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 improved airflow, reducing heat retention and noise, while maintaining the slow compression and recovery characteristics of luxury foams, thus enhancing user comfort without the need for foam materials, making it cost-effective.
Implementation Method 1
achieved by using ultrasonic welding to create gaps in the weld segments of the fabric seams
Implementation Method 2
the coil spring's upwardly directed force on the fabric
Implementation Method 3
the same or a similar slow-to-compress and slow-to-recover to its original height luxury feel as memory foam
Implementation Method 4
The comfort layer of the present invention, whether incorporated inside a bedding or seating product, or manufactured and sold as a separate product, provides an additional cooling effect to the product due to airflow through the comfort layer
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
A comfort layer (16, 16a, 50, 56, 56a, 56b, 132, 140) for a bedding or seating product (10) has slow-acting pockets (44, 44a, 84, 84a) characterized by the individual springs (28) of the comfort layer (16, 16a, 50, 56, 56a, 56b, 132, 140) being pocketed with either semi-impermeable or impermeable fabric. Each seam (30, 70) joining opposed plies (22, 23, 24, 25, 64, 65, 66, 67) of fabric around each of the coil springs (28) of the comfort layer (16, 16a, 50, 56, 56a, 56b, 132, 140) may be segmented, allowing air to flow between the segments (26, 68), thereby increasing the luxury "feel" of the comfort layer (16, 16a, 50, 56, 56a, 56b, 132, 140). The method of making the comfort layer (16, 16a, 50, 56, 56a, 56b, 132, 140) includes compressing the springs (28) and creating pockets (44, 44a, 84, 84a) with a welding horn (32, 32a, 72, 72a) and an anvil (42, 42a, 74, 74a).