Pocketed spring comfort layer having at least one foam layer and method of making same
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Solution Overview
Problem
Mattress manufacturers face challenges in creating a pocketed spring comfort layer that eliminates the need for additional foam or fiber layers, aiming to reduce costs and provide a unique feel combining mini coil springs with polyurethane, visco-elastic, or latex foam comfort.
Innovation Solution
A comfort layer comprising an assembly of interconnected, individually pocketed mini coil springs contained within fabric pockets formed by joining a cushion assembly and non-woven polypropylene fabric with segmented weld seams, allowing for a luxury feel and airflow, which can be manufactured as a separate product or integrated into bedding or seating products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If additional foam or fiber layers are placed above the pocketed spring comfort layer, then the luxury feel and comfort are improved, but the cost and device complexity increase
Solution Approach 1:
The patent combines the pocketed spring structure with foam material by encapsulating mini coil springs within fabric pockets that are integrated with foam layers. This merging eliminates the need for separate foam layers while maintaining both the spring support and foam comfort characteristics, thereby reducing device complexity without sacrificing comfort.
Solution Approach 2:
The invention creates a composite structure where fabric pockets containing mini coil springs are integrated with foam material. This composite approach allows the single comfort layer to provide both the mechanical support of springs and the cushioning comfort of foam, resolving the contradiction between comfort and complexity.
2Ease of operation
If additional foam or fiber layers are placed above the pocketed spring comfort layer, then the comfort is improved, but the manufacturing cost increases
Solution Approach 1:
By merging the pocketed spring structure with foam material into a single integrated comfort layer, the patent eliminates the need to manufacture and assemble multiple separate layers. This reduces manufacturing steps, labor costs, and material handling, thereby lowering overall manufacturing cost while maintaining comfort.
Solution Approach 2:
The integrated comfort layer performs multiple functions simultaneously: it provides spring support, foam cushioning, and fabric enclosure in a single component. This multi-functionality reduces the total number of parts that need to be manufactured and assembled, thereby reducing manufacturing cost.
3Ease of operation
If foam layers are added above the pocketed spring comfort layer, then the luxury feel is achieved, but the airflow is reduced
Solution Approach 1:
The patent applies local quality by creating open weld seams at specific locations within the fabric pockets. These localized openings allow airflow to pass through the comfort layer while the surrounding foam material provides luxury feel. This selective placement of permeable regions maintains both comfort and airflow.
Solution Approach 2:
The open weld seam design creates a porous structure within the fabric pockets, allowing air to flow through the comfort layer. This porous approach enables the foam material to provide luxury feel while maintaining adequate airflow, preventing the harmful effect of complete airflow restriction.
4Ease of operation
If multiple foam layers are used, then the comfort is improved, but the weight and cost increase
Solution Approach 1:
By merging the spring support structure with foam material into a single integrated layer, the patent eliminates the weight of multiple separate foam layers. The combined structure provides equivalent or superior comfort through the synergistic effect of springs and foam, while reducing total weight compared to stacked layers.
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 cost-effective way to create a comfort layer with a luxury feel, reducing the need for additional foam or fiber layers, while offering improved airflow and a unique feel, applicable to various bedding and seating products.
Implementation Method 1
The segmented weld seam may comprise a series of spaced apart weld segments that define a plurality of openings within each weld seam to allow airflow through the comfort layer
Data Source
AI summary
A pocketed spring comfort layer for a bedding or seating product has pockets characterized by the individual mini coil springs of the comfort layer being pocketed with between at least one cushion assembly and a sheet of polypropylene fabric. Each cushion assembly includes at least one foam layer. A segmented seam joins the cushion assembly and the sheet of polypropylene fabric around each of the mini coil springs of the pocketed spring comfort layer. The method of making the pocketed spring comfort layer includes compressing the mini coil springs and creating pockets with a welding horn and an anvil.