Pocketed spring assembly including cushion pads and buckling members with additives

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Solution Overview

Problem

Conventional pocketed spring mattresses suffer from undesirable bridging effects due to foam or cushioning layers acting as a bridge, affecting the independence of coil springs and compromising the feel and motion transfer between sleeping partners.

Innovation Solution

A pocketed spring assembly with individually pocketed coil springs, cushion pads, and buckling members, where each coil spring is retained in its own inner pocket, and the cushion pads are protected by fabric covers, eliminating direct contact with the coil springs, and incorporating additives like phase change materials and antimicrobial agents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If foam or cushioning layers are attached to the upper surface of the pocketed spring assembly, then the mattress provides cushioning comfort, but the foam layer acts as a bridge that transfers load between adjacent springs, compromising the independence of coil springs

Engineering Contradiction:

Improvecushioning comfortVSAvoidspring independence

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The cushioning function is segmented from the spring support function by placing individual cushion pads within each fabric pocket, ensuring that cushioning comfort is provided locally without creating a continuous bridging layer that would compromise spring independence

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cushion pads are nested inside the fabric pockets that already contain the coil springs, allowing the cushioning element to be contained within the same structural unit as the spring, thereby preventing the cushioning material from acting as a bridge between adjacent springs

Inventive Principle:

Principle #7Nested doll (Nesting)

2Device complexity

If un-pocketed coil springs are used with cushioning pads, then the structure is simpler, but the coil springs may damage the cushioning pads and compromise the feel of the assembly

Engineering Contradiction:

Improvestructure simplicityVSAvoidcushion pad integrity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The cushion pads are nested inside the fabric pockets along with the coil springs, providing a protective enclosure that prevents direct contact between the metal springs and the cushioning material, thereby preserving pad integrity while maintaining structural simplicity

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The fabric pocket acts as a flexible shell that encloses both the coil spring and cushion pad, providing protection to the cushioning pad from mechanical damage by the spring while allowing the assembly to maintain its simple structure

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS12604993B2Pocketed spring assembly including cushion pads and buckling members with additives

Publication Date: 2026.04.21 L & P PROPERTY MANAGEMENT CO

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 with an additive are positioned in each outer pocket. At least one cushion pad, at least one buckling member with an additive or any combination thereof may be individually pocketed inside an outer pocket.