Pocketed spring unit having multiple inner springs
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Solution Overview
Problem
Current pocketed spring units in the bedding industry do not fully customize support for different body parts or personalize bedding products effectively, limiting user experience and customization options.
Innovation Solution
A pocketed spring unit comprising multiple concentrically arranged coil springs enclosed in fabric pockets, with varying spring rates and dimensions, allowing for progressive firmness adjustment and customizable support by engaging inner springs as compression increases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional inserts such as foam cylinders or pocketed spring coils are provided in pocketed spring units, then differing degrees of firmness can be imparted to different pocket strings, but the full potential of customization particularly with respect to differentiated support of different body parts or personalization of bedding products is not achieved
Solution Approach 1:
The patent applies nesting by placing multiple inner pocketed springs (second and third springs) inside the outer pocketed spring (first spring). Each inner spring is enclosed within the pocket of the outer spring, creating a nested configuration. This allows progressive engagement of springs at different compression levels, enabling differentiated support for different body parts while maintaining a relatively compact structure.
Solution Approach 2:
The patent segments the spring unit into multiple independent pocketed springs with different spring rates (first, second, and third springs). Each spring can be independently designed with specific characteristics to provide targeted support. This segmentation allows customization of firmness at different zones and compression levels without requiring a completely separate spring unit for each function.
2Adaptability or versatility
If multiple inner springs are arranged concentrically with varying spring rates, then variable rate progressive performance is achieved with smooth transition from softer to firmer response, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-assembling the inner pocketed springs (second and third springs) within the pocket of the outer spring (first spring) before the final pocketing process. This allows the inner springs to be positioned and secured in advance, simplifying the subsequent manufacturing steps. The inner springs are prepared and placed ready for the pocketing operation, reducing complexity during the main manufacturing process.
Solution Approach 2:
The nested arrangement of multiple pocketed springs within each other enables progressive engagement based on compression depth. The outer spring engages first providing softer support, while inner springs engage at greater compression depths providing firmer support. This nested structure achieves variable rate progressive performance where the total spring rate changes smoothly as different springs are engaged, allowing customization of the force-compression characteristic.
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
Enables variable and customizable support by smoothly transitioning from a softer to a firmer response based on individual spring rates, providing tailored firmness and limitless zoning capabilities in bedding products.
Implementation Method 1
A coil spring, also known as helical spring, has a spring rate which relates compression (or stretching) of the spring and force exercised by the spring.
Data Source
Figure 1~2
Figure 3~4a
Figure 4b
AI summary
A pocketed spring unit comprises a first pocketed spring (11), a second pocketed spring (12) arranged inside the first pocketed spring (11), and a third pocketed spring (13) arranged inside the second pocketed spring (12).