Pocketed spring assembly comprising strings of springs with tabs
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Solution Overview
Problem
Existing pocketed spring assemblies in bedding and seating products are weak at glue lines and lack adequate airflow, leading to potential warmth issues and reduced durability.
Innovation Solution
A pocketed spring assembly design that joins strings of springs using longitudinal seams instead of glue, creating gaps between pockets for improved airflow and enhanced structural integrity, allowing air to flow freely and cool the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If adjacent strings of pocketed springs are glued together to form a unitary assembly, then the assembly is formed efficiently, but the strength and reliability of the assembly is reduced at the glue lines
Solution Approach 1:
The patent replaces the chemical bonding method (glue) with a mechanical bonding method (sewing/stitching) to join adjacent strings of pocketed springs. The sewing machine creates robust mechanical interconnections through stitches that pass through the fabric pockets and connect the springs, eliminating the weak glue lines while maintaining efficient automated assembly.
2Strength
If pocketed spring assembly uses conventional construction, then it provides structural support, but it lacks adequate airflow causing warmth issues
Solution Approach 1:
The patent creates a porous structure by leaving gaps between adjacent pockets of neighboring strings. These gaps are intentionally designed spaces that allow air to circulate freely through the assembly, providing cooling effects while the fabric pockets and springs maintain their structural support function. The porous configuration enables thermal management without sacrificing mechanical integrity.
3Stability of the object's composition
If separating seams extend the full height of pockets, then pockets are fully enclosed, but airflow between adjacent pockets is restricted
Solution Approach 1:
The patent applies partial action by extending the separating seams only partially along the height of the pockets rather than the full height. This partial separation creates controlled gaps between adjacent pockets, allowing air to flow through the assembly while still providing sufficient fabric coverage for structural stability. The seams provide just enough enclosure to maintain pocket integrity while permitting the desired airflow.
Data Source
AI summary
A pocketed spring assembly comprises a plurality of parallel strings of springs held together with tabs. Longitudinal seams joining overlapping tabs extend generally the same direction as the strings of springs. Pockets are formed along a string of springs by aligned separating seams. At least one spring is positioned in each pocket. Each separating seam joins opposed plies of the string and keeps the spring in its pocket. Ends of aligned separating seams are spaced from each other, thereby improving airflow between pockets.