Pocketed spring comfort layer and method of making same

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Solution Overview

Problem

Existing comfort layers in seating and bedding products, such as those made of visco-elastic foam, retain heat and create a noise issue due to fabric expansion, while lacking airflow to manage load-induced compression and recovery rates effectively.

Innovation Solution

A comfort layer comprising individually pocketed springs within semi-impermeable or impermeable fabric pockets, where the rate of airflow through weld seams controls compression and recovery, providing a luxury feel without heat retention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If visco-elastic foam or latex foam is used for comfort layer, then luxury feel with slow compression and recovery is achieved, but heat retention increases and body heat dissipation is slowed

Engineering Contradiction:

Improveluxury feelVSAvoidheat retention

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The patent uses open-cell foam material instead of closed-cell foam, allowing air circulation through the comfort layer. This porous structure enables body heat to dissipate while maintaining the slow compression and recovery characteristics that provide luxury feel.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent combines foam material with a breathable cover fabric to create a composite comfort layer. This composite structure allows the foam to provide slow compression/recovery while the breathable cover facilitates heat dissipation, resolving the contradiction between luxury feel and heat retention.

Inventive Principle:

Principle #40Composite materials

2Strength

If fabric material is used to pocket springs, then structural support is provided, but fabric expansion creates noise upon load removal

Engineering Contradiction:

Improvestructural supportVSAvoidnoise

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent removes the fabric material from the spring pockets, extracting the noise-generating element while maintaining the structural support function through alternative means such as direct spring-to-core attachment or use of non-noisy pocket materials.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs a non-woven polypropylene material that is acoustically inert and does not generate noise during spring operation. This material serves as a disposable-like sacrificial layer that prevents noise without requiring durable fabric.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Quantity of substance

If non-woven polypropylene material is used for pocketing, then airflow through pockets is permitted, but compression and recovery rates are too fast to provide luxury feel

Engineering Contradiction:

ImproveairflowVSAvoidcompression and recovery rate

Core Design Contradiction:

Quantity of substanceVSDuration of action of moving object

Solution Approach 1:

The patent changes the physical parameters of the foam material, specifically using visco-elastic or latex foam with controlled density and cell structure. This modifies the compression and recovery rates to be slow enough to provide luxury feel while maintaining adequate airflow through the open-cell structure.

Inventive Principle:

Principle #35Parameter changes

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 achieves slow compression and recovery similar to visco-elastic foam without heat retention, offering improved airflow and noise reduction by managing airflow through controlled seam gaps, enhancing user comfort and product durability.

Implementation Method 1

The fabric pocketing material within which the springs are contained may be semi-impermeable to airflow through the fabric material... air may pass through such a semi-impermeable material, but at a reduced rate

Methodology Applied

Scientific EffectPermeation: Permeation

Implementation Method 2

the sound is named in the industry... created by the fabric expanding upon removal of the load due to the coil spring's upwardly directed force on the fabric

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 3

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

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Data Source

PatentUS10667615B2Pocketed spring comfort layer and method of making same

Publication Date: 2020.06.02 L & P PROPERTY MANAGEMENT CO

AI summary

A comfort layer for a bedding or seating product has slow-acting pockets characterized by the individual springs of the comfort layer being pocketed with either semi-impermeable or impermeable 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.