Pocketed Spring Assembly With Partial Seams for Independent Coil Action
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Solution Overview
Problem
Conventional pocketed spring cores in bedding and seating products often compromise the independent action of springs due to seams extending the full height of the string, limiting the realization of coil spring advantages in terms of feel and motion transfer.
Innovation Solution
A pocketed spring assembly with parallel strings of springs, each comprising fabric plies joined by transverse and longitudinal seams, featuring springs with upper and lower end turns and central convolutions that decrease in diameter and pitch towards the ends, allowing partial separation of adjacent pockets for improved independent spring action.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If seams extend the full height of the string of springs, then the structural integrity and manufacturing simplicity are improved, but the independent action of individual springs is compromised
Solution Approach 1:
The transverse seams are segmented to terminate at different heights within the string of springs, creating zones of partial separation between adjacent pockets. This allows the spring assembly to be divided into functionally independent sections while maintaining structural integrity through the fabric string construction.
Solution Approach 2:
Different regions of the string of springs have different seam configurations - some areas have seams extending fully through the height while others have seams terminating at intermediate heights. This local variation in seam structure creates zones with different degrees of pocket independence, optimizing both structural integrity and independent spring action in different locations.
2Manufacturing precision
If springs have uniform diameter and pitch, then manufacturing consistency is improved, but the ability to provide customized firmness zones is reduced
Solution Approach 1:
The spring assembly incorporates springs with varying diameters and pitches in different zones of the mattress. Central zones may use springs with larger diameters and wider pitches for softer support, while edge zones use springs with smaller diameters and tighter pitches for firmer support, allowing customized firmness regions while maintaining manufacturing precision through controlled variation.
3Reliability
If transverse seams join fabric plies completely, then pocket definition is improved, but motion transfer between adjacent springs is increased
Solution Approach 1:
The transverse seams are segmented to terminate at intermediate heights rather than extending completely through the string, creating partial separations between adjacent pockets. This segmentation maintains adequate pocket definition for spring containment while reducing the transmission of motion between adjacent springs, as the incomplete seam structure allows for independent movement of neighboring springs.
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. At least one spring is positioned in each pocket. An upper end of each transverse seam is below the upper surface of the string so as to partially separate adjacent pockets within a string of springs. 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.