Pocketed Spring Assembly With Individually Pocketed Cushion Pads
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Solution Overview
Problem
Conventional pocketed spring mattresses suffer from an undesirable bridging effect due to foam or cushioning layers, which compromise the independent motion of coil springs and affect the feel of the mattress, as the coil springs can damage the cushioning pads and alter the assembly's performance.
Innovation Solution
A pocketed spring assembly design where each coil spring is encapsulated in its own inner pocket within a fabric string, with cushion pads and buckling members also individually pocketed, preventing direct contact between the springs and pads and allowing for independent movement and preserving the integrity of the cushioning materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If foam or cushioning layers are attached to the upper surface of the pocketed spring assembly, then the mattress structure is completed and provides cushioning, but the bridging effect occurs where a load applied to one side affects the other side, compromising independent motion
Solution Approach 1:
The cushioning function is segmented from the spring assembly by placing individual cushion pads inside each fabric pocket rather than using a continuous foam layer. This segmentation allows each spring-cushion pair to operate independently, eliminating the bridging effect while maintaining complete mattress structure.
Solution Approach 2:
The continuous foam or cushioning layer is extracted and replaced with discrete cushion pads positioned within individual pockets. This extraction removes the bridging mechanism that connected adjacent springs, allowing independent motion while still providing necessary cushioning support.
2Device complexity
If coil springs are placed directly with cushioning pads, then the assembly is simplified, but the coil springs may damage the cushioning pads and affect the feel of the assembly
Solution Approach 1:
A fabric pocket acts as an intermediary between the coil spring and cushioning pad. The fabric enclosure protects the cushioning pad from direct contact with the spring, preventing damage while allowing the spring to compress and expand. This mediator maintains cushioning pad integrity without significantly increasing assembly complexity.
Solution Approach 2:
The cushioning pad is nested inside the fabric pocket, which in turn encloses the coil spring. This nested structure protects the delicate cushioning pad from the mechanical spring while maintaining a compact assembly. The nested arrangement preserves cushioning integrity with minimal added complexity.
3Shape
If a sheet of foam acts as a bridge across the spring assembly, then the mattress surface is continuous and smooth, but the load distribution causes undesirable bridging effect affecting motion transfer
Solution Approach 1:
The continuous foam surface is segmented into discrete cushion pads within individual pockets. While each pocket is separate, the overall mattress surface maintains continuity through the arrangement of multiple pockets. This segmentation eliminates load bridging while preserving surface smoothness for comfortable contact.
Data Source
AI summary
A pocketed spring assembly comprises a plurality of parallel strings of springs, each string joined to at least one adjacent string, each string comprising one piece of fabric folded into first and second opposed plies. Outer pockets are formed along each string by transverse seams joining the first and second plies. One pocketed spring, at least cushion pad and at least one buckling member are positioned in each outer pocket. At least one cushion pad, at least one buckling member or any combination thereof may be individually pocketed inside an outer pocket.