Pocketed Spring Assembly With Nested Coils for Zoned Comfort
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Solution Overview
Problem
Current spring core constructions in bedding and seating products, such as pocketed coil spring assemblies, do not adequately address the need for optimal distribution of hardness and comfort, particularly in absorbing stresses and providing a resilient surface.
Innovation Solution
A pocketed spring assembly with alternating single and nested coil springs, where the transverse seams are partially divided to create separate pockets, allowing for staggered arrangement of springs and improved engagement with users, combined with cushioning materials and an upholstered covering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compound nested pocketed springs are used with inner spring individually encased in fabric pocket, then noise and interference during flexing is minimized, but manufacturing complexity increases
Solution Approach 1:
The patent applies nesting by placing the inner spring within the outer spring, and the inner spring within a fabric pocket, creating a nested structure that minimizes noise and interference during flexing while maintaining a compact design
Solution Approach 2:
The patent segments the spring system into separate outer spring and inner spring components, with the inner spring individually encased in a fabric pocket, allowing independent optimization of each component's function and reducing overall system interference
2Ease of operation
If varying spring count or wire gauge is used to achieve differing degrees of hardness, then comfort and strength requirements are met, but device complexity increases
Solution Approach 1:
The patent applies local quality by using nested springs with different wire gauges and configurations in specific zones (head, toe, body) to provide locally optimized hardness and support characteristics, allowing different regions of the mattress to have tailored comfort properties without requiring entirely different spring systems throughout
Solution Approach 2:
The nested spring configuration allows varying degrees of hardness to be achieved through the combination of outer and inner springs with different properties, rather than requiring separate spring systems, thereby reducing overall device complexity while maintaining zoned comfort
3Ease of manufacture
If transverse seams are fully continuous forming connected pockets, then manufacturing is simpler, but individual coil performance is reduced
Solution Approach 1:
The patent segments the transverse seams by inserting fabric extensions between the seams and the springs, creating isolated pockets for each spring while maintaining relatively simple manufacturing processes. This segmentation allows each spring to function independently without interference from adjacent springs
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
This configuration enhances comfort by allowing individual coil performance and provides a softer feel during initial deflection, while maintaining strength and resilience across the surface.
Implementation Method 1
The first inner spring is nested within the second outer spring... providing a resilient and comfortable seating or sleeping surface
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 comprising first and second opposed plies of fabric and a plurality of pockets formed along a length of the string by transverse seams joining the first and second plies, and at least one spring positioned in each pocket. At least one said string has a single spring in one pocket and a pair of nested springs in an adjacent pocket in alternating fashion along the length of the string, the pair of nested springs having a taller spring and a shorter spring. A portion of each transverse seam forming the adjacent pockets of the at least one string is divided from an upper surface of the at least one string downwardly so as to partially separate the adjacent pockets.