Pocketed spring comfort layer
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Solution Overview
Problem
Existing comfort layers in seating and bedding products, such as those made of visco-elastic foam or latex, retain heat due to their closed cell structure, leading to discomfort and noise issues associated with airflow through fabric pockets in pocketed spring cores.
Innovation Solution
A comfort layer comprising individually pocketed springs within semi-impermeable or non-permeable fabric pockets, where the rate of airflow is controlled through strategically designed seams, allowing for slow compression and recovery without heat retention, mimicking the luxury feel of visco-elastic or latex foam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visco-elastic foam or latex pads are used to provide luxury feel and slow compression characteristics, then comfort and luxury feel are improved, but heat retention increases due to closed cell structure
Solution Approach 1:
The patent introduces airflow channels and ventilation holes within the comfort layer structure, allowing air to flow through the material. This pneumatic approach replaces the closed-cell foam structure with an open system that enables heat dissipation while maintaining the slow compression characteristics needed for luxury feel.
Solution Approach 2:
The comfort layer incorporates porous or perforated materials that allow air permeation. These materials provide both the slow compression response needed for comfort and the airflow pathways necessary to prevent heat retention, resolving the contradiction between luxury feel and thermal management.
2Temperature
If ventilation holes are added to pocketed spring mattress to improve airflow, then heat dissipation is improved, but fabric noise increases due to fabric expansion
Solution Approach 1:
The patent applies different fabric treatments or materials in different locations. Specifically, it uses non-permeable fabric in areas where noise would be generated, while maintaining ventilation holes and airflow channels in other areas where thermal management is prioritized. This localized differentiation resolves the conflict between heat dissipation and noise reduction.
Solution Approach 2:
The patent pre-treats or pre-selects specific fabric types with particular properties (non-permeable, low-noise characteristics) before assembly. By choosing fabrics with inherent noise-reducing properties and pre-configuring the ventilation system, the design prevents noise generation at the source while maintaining effective airflow for heat dissipation.
3Object-generated harmful factors
If non-permeable fabric is used to reduce noise, then fabric noise is reduced, but airflow through the comfort layer is restricted
Solution Approach 1:
The comfort layer is divided into multiple sections with different fabric permeability characteristics. Non-permeable fabric sections are used in areas where noise reduction is critical, while permeable sections with ventilation holes are placed in areas where airflow is prioritized for heat dissipation. This segmentation allows both requirements to be met simultaneously in different locations.
Solution Approach 2:
Different fabric permeability properties are applied to different regions of the comfort layer. Non-permeable, noise-reducing fabric is used in specific locations, while permeable, airflow-friendly fabric is used in other locations. This local differentiation enables the system to reduce noise where needed while maintaining adequate airflow for thermal 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 a luxurious feel with slow compression and recovery characteristics similar to visco-elastic or latex foam, while preventing heat retention and reducing noise by managing airflow, thus enhancing user comfort and product performance.
Implementation Method 1
the fabric material, while permitting some airflow through the material, does so at a rate which retards or slows the rate at which a spring maintained in a pocket of the fabric may compress under load or return to its original height
Implementation Method 2
These visco-elastic pads, as well as the latex pads, impart a so-called luxury feel to the mattress or cushion. These pads also, because of their closed cell structure, retain heat and are slow to dissipate body heat
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
A comfort layer (16, 16a, 50, 56, 56a, 132, 140) for a bedding or seating product (10, 60) has slow-acting pockets (44, 44a, 84, 84a) characterized by the individual springs of the comfort layer being pocketed with either semi-impermeable or non-permeable 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.