Pocketed spring assembly
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Solution Overview
Problem
Mattress manufacturers face high labor costs and inefficiencies in constructing foam encasements for pocketed spring assemblies, as each size requires a separate process, and there is a need for a cost-effective way to ship and assemble pocketed spring assemblies with built-in edge support without using foam buckets.
Innovation Solution
A pocketed spring assembly with four sides of edge support is designed, featuring parallel strings of springs with exterior and interior strings, where each string is joined to adjacent strings and scrim sheets, providing edge support through barrel-shaped coil springs with varying diameters and heights, allowing for easier shipping and assembly without additional edge support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foam encasements are constructed separately for each pocketed spring assembly size, then edge support is provided, but labor costs and manufacturing complexity increase
Solution Approach 1:
The patent combines the edge support function with the pocketed spring assembly itself by constructing the border using the same fabric and spring string materials as the assembly. This integration eliminates the need for separate foam encasements, reducing manufacturing complexity while maintaining reliable edge support.
Solution Approach 2:
The border construction serves multiple functions: it provides edge support, defines the perimeter of the spring assembly, and can be integrated with the shipping wrapper. This multi-functionality reduces the number of separate components needed, simplifying the overall manufacturing process.
2Manufacturing precision
If separate foam encasements are built for different pocketed spring assembly sizes, then proper fit is achieved, but production time and labor costs increase
Solution Approach 1:
The border is constructed from the same modular spring strings that make up the main assembly, allowing for standardized production units. This segmentation enables consistent sizing and faster assembly compared to custom-fit foam encasements for each size variant.
Solution Approach 2:
The border is constructed as part of the spring assembly manufacturing process itself, rather than as a separate post-assembly step. This preliminary action integrates edge support creation into the main production line, improving productivity without sacrificing precision.
3Reliability
If foam buckets are used to encase pocketed spring assemblies, then edge support is provided, but additional manufacturing steps and costs are incurred
Solution Approach 1:
The patent merges the border construction with the spring assembly manufacturing by using identical materials (fabric and spring strings) and processes. This eliminates the need for separate foam materials and encasement steps, simplifying manufacture while providing reliable edge support.
Solution Approach 2:
The invention changes the material parameter from foam to fabric-spring construction for the border, allowing it to be manufactured using the same processes and materials as the main assembly, thereby improving ease of manufacture.
4Reliability
If pocketed spring assemblies require additional edge support to be added, then edge support is provided, but manufacturing costs increase
Solution Approach 1:
The spring strings serve dual purposes: they form the main body of the pocketed spring assembly and simultaneously create the border when arranged in a rectangular pattern. This universality eliminates the need for additional edge support components, reducing manufacturing costs.
Solution Approach 2:
The border and main assembly are merged into a single integrated structure constructed from the same spring strings and fabric, eliminating the need for separate edge support components and reducing overall manufacturing costs.
Data Source
AI summary
A pocketed spring assembly comprises a plurality of parallel strings of springs, each string joined to at least one adjacent string, each string comprising first and second opposed plies of fabric and a plurality of pockets formed along a length of the string by transverse seams joining the first and second plies. At least one spring is positioned in each pocket. Exterior strings have identical springs in their pockets. Interior strings have two different springs along their length, the outermost springs being firmer than the interior core springs. The pocketed spring assembly has increased firmness or edge support along all four sides due to the different coil springs of the assembly.