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, allowing air to enter and exit through gaps in the seams, providing a luxury feel without heat retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visco-elastic foam or latex foam pads are used to cover spring cores, then a luxury feel with slow compression and recovery is achieved, but heat retention increases and body heat dissipation slows down
Solution Approach 1:
The patent uses open-cell foam material instead of closed-cell foam material. The open-cell structure allows air circulation through the comfort layer, enabling body heat to dissipate while maintaining the slow compression and recovery characteristics that provide a luxury feel. This resolves the contradiction by allowing thermal energy to escape through the porous structure without sacrificing the visco-elastic comfort properties.
2Stability of the object's composition
If fabric material is used to pocket springs, then the springs are contained and supported, but fabric expansion creates noise when load is removed
Solution Approach 1:
The patent uses a thin film material to form the fabric pockets containing the springs. The thin film structure is flexible enough to contain and support the springs during compression, but thin and compliant enough to minimize expansion noise when the load is removed. The film conforms to the spring movement without creating significant fabric expansion sounds.
3Temperature
If air permeable fabric is used for pockets, then airflow through the comfort layer is enabled, but compression and recovery rates become too fast
Solution Approach 1:
The patent changes the air permeability parameter of the foam material to an optimal intermediate value. The open-cell foam allows airflow through the comfort layer for heat dissipation, but the foam's cellular structure and density are controlled to restrict airflow enough to maintain slow compression and recovery rates. This parameter optimization resolves the contradiction between enabling airflow and maintaining slow mechanical response.
4Duration of action of moving object
If semi-impermeable fabric material is used for pockets, then airflow through the fabric is reduced to slow spring compression, but heat retention may increase
Solution Approach 1:
The patent uses a composite structure combining open-cell foam material with a thin film fabric. The open-cell foam provides controlled airflow through its cellular structure to enable heat dissipation while maintaining slow compression rates. The thin film fabric contains the springs without significantly restricting the foam's airflow properties. This composite approach resolves the contradiction by allowing both slow compression and heat dissipation to occur simultaneously.
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 solution provides a comfort layer with slow compression and recovery characteristics similar to visco-elastic foam, but with improved airflow management, reducing heat retention and noise, and allowing for adjustable airflow to enhance user comfort.
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
Implementation Method 2
air to enter and exit through gaps in the seams, providing a luxury feel without heat retention... the rate of airflow through weld seams controls compression and recovery
Implementation Method 3
improved airflow management, reducing heat retention... allows air to enter and exit the pockets at different flow rates
Data Source
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.