Pocketed Spring Assembly With Divided Seams for Independent Compression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pocketed spring cores in bedding and seating products compromise the independent action of coil springs due to full-height seams, limiting the realization of their compressive advantages and affecting feel and motion transfer.
Innovation Solution
A pocketed spring assembly with parallel strings of springs, each with upper and lower end turns and central convolutions that decrease in diameter and pitch towards the ends, featuring transverse seams that are cut or treated to create divides, allowing end portions to compress without compressing the middle portion, and optionally arranged in zones with different firmness features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If full-height seams are used to join adjacent pockets in the string of springs, then the structural integrity and continuity of the spring string is maintained, but the independent compression capability of individual springs is compromised
Solution Approach 1:
The transverse seams joining adjacent pockets are segmented by introducing divides that extend partially through the seam height. This segmentation allows the seam to maintain structural continuity while creating independent compression zones for adjacent springs, resolving the contradiction between structural integrity and independent compression capability.
Solution Approach 2:
The seam structure is modified locally by adding divides at specific positions along the transverse seam. This creates different structural properties in different regions of the seam - the divided regions allow independent spring compression while the overall seam maintains structural integrity, applying local quality changes to resolve the contradiction.
2Ease of manufacture
If uniform diameter and pitch springs are used throughout the spring core, then manufacturing simplicity is maintained, but the ability to provide differentiated support and comfort zones is limited
Solution Approach 1:
Springs are configured with different diameters and pitches in different regions of the spring core to provide differentiated support. The patent applies local quality by varying spring parameters in specific zones (e.g., softer springs in head/foot regions, firmer springs in center regions) while maintaining uniform springs within each zone, thus balancing manufacturing simplicity with adaptability.
Solution Approach 2:
The spring core is segmented into multiple zones with different spring characteristics. Each zone contains springs with specific diameter and pitch configurations, allowing the overall system to provide differentiated support while maintaining manufacturing efficiency through standardized production within each zone.
3Adaptability or versatility
If springs with varying diameters and pitches are used, then differentiated comfort and support zones can be created, but manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by configuring springs with specific diameter and pitch variations in predetermined zones rather than uniformly throughout. This allows differentiated comfort capabilities in specific regions while maintaining manufacturing efficiency by limiting complexity to localized areas rather than the entire spring core.
Solution Approach 2:
The spring design incorporates varying diameters and pitches to create dynamic response characteristics in different zones. Softer springs with larger diameters provide different comfort than firmer springs with smaller diameters, creating dynamic adaptability to different body regions while managing manufacturing complexity through systematic zone-based configuration.
4Stability of the object's composition
If transverse seams extend the full height of the spring string, then continuous pocket formation is achieved, but the independent action of adjacent springs is restricted
Solution Approach 1:
The transverse seams are segmented by introducing divides that create partial separations between adjacent pockets. This segmentation maintains continuous pocket formation for structural stability while creating sufficient independence for adjacent springs to compress separately, resolving the contradiction between continuous formation and independent action.
Solution Approach 2:
The divides in the transverse seams act as intermediaries that partially separate adjacent pockets. These intermediary structures maintain the overall continuous pocket formation while allowing independent spring compression, serving as a mediating element between the requirements for continuity and independence.
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
Enhances the feel and motion transfer in bedding or seating products by allowing individual coil springs to perform independently, providing a softer feel and improved comfort by decoupling springs during initial deflection.
Implementation Method 1
Each of the springs has upper and lower end turns and a plurality of central convolutions between the end turns, the convolutions decreasing in diameter and pitch from a middle portion of the spring towards the end turns
Implementation Method 2
Each transverse seam forming adjacent pockets of the string is cut or otherwise treated to create at least one divide so as to enable at least one end portion of the spring to compress without substantially compressing the middle portion of the spring
Data Source
AI summary
A pocketed spring assembly comprises a plurality of parallel strings of springs, each string joined to an adjacent string. Each string comprises a plurality of pockets formed along a length of the string by transverse seams joining first and second plies of fabric on opposed sides of springs. At least one spring is positioned in each pocket. Each spring has two end portions and a middle portion. The convolutions of the middle portion are greater in diameter and pitch than the convolutions of the end portions. Each interior transverse seam is cut or otherwise treated to create at least one divide enabling at least one end portion of the spring to compress without substantially compressing the middle portion of the spring.