Pocketed spring comfort layer and method of making same
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Solution Overview
Problem
Existing comfort layers in seating and bedding products, particularly those using visco-elastic foam, retain heat and create noise due to fabric expansion, lacking airflow control and luxury feel without heat retention.
Innovation Solution
A comfort layer comprising individually pocketed springs within semi-impermeable or impermeable fabric pockets, with controlled airflow through weld seams, allowing air to enter and exit at varying rates based on load, mimicking the luxury feel of visco-elastic foam without heat retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visco-elastic foam pad is used to cover spring cores, then luxury feel and slow compression characteristics are improved, but heat retention and slow heat dissipation occur
Solution Approach 1:
The comfort layer is divided into multiple individually pocketed springs, each enclosed in its own fabric pocket. This segmentation allows air to flow between and through the pockets, enabling heat dissipation while maintaining the slow compression characteristics of visco-elastic foam through the controlled airflow resistance of the fabric material.
2Strength
If fabric material is used to pocket springs, then structure and support are improved, but noise is generated due to fabric expansion
Solution Approach 1:
The fabric material used to enclose the springs is designed with specific porosity characteristics that allow it to dampen the expansion and contraction movements of the springs. This porous structure absorbs the mechanical energy that would otherwise generate noise, while still providing the necessary structural support and maintaining airflow properties.
3Ease of operation
If fabric material is made semi-impermeable to airflow, then slow compression characteristics are improved, but airflow control is reduced
Solution Approach 1:
The fabric material exhibits different airflow properties at different locations and under different conditions. The semi-impermeable nature of the fabric provides slow compression characteristics, while the gaps between individual fabric pockets allow controlled airflow. This local variation in permeability enables both slow compression response and adaptable airflow control depending on the applied load.
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
Provides a cooling effect and maintains the slow compression and recovery characteristics of visco-elastic foam while preventing heat retention and noise, enhancing the comfort and feel of seating and bedding products.
Implementation Method 1
The fabric pocketing material within which the springs are contained may be semi-impermeable to airflow through the fabric material. As used herein, the term 'semi-impermeable' means that 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 when a load is removed from the pocketed spring.
Implementation Method 2
each spring being contained within a fabric pocket... the rate at which a spring maintained in a pocket of the fabric may compress under load or return to its original height when a load is removed from the pocketed spring
Data Source
AI summary
A comfort layer for a bedding or seating product has slow-acting pockets characterized by the individual mini coil springs of the comfort layer being pocketed with either semi-impermeable or impermeable fabric. Each weld 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 mini coil springs and creating pockets with a welding horn and an anvil.