Pocketed Spring Comfort Layer for Zoned Support Without Foam
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Solution Overview
Problem
Existing pocketed spring comfort layers in bedding and seating products lack the ability to provide posturized support without the need for additional foam or fiber layers, which increases costs and complexity.
Innovation Solution
A comfort layer comprising a matrix of individually pocketed mini coil springs with varying diameters and heights, arranged in sections to create different firmness regions, eliminating the need for additional foam or fiber layers by integrating fabric pockets with weld seams to achieve targeted support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a comfort layer is made of uniform pocketed springs, then the structure is simple and manufacturing is easy, but posturized support cannot be achieved
Solution Approach 1:
The comfort layer incorporates mini coil springs of different sizes (first size in head region, second size in foot region, third size in midsection) to provide different firmness levels in different body contact zones. This local differentiation enables posturized support while maintaining a relatively simple manufacturing process compared to multi-layer foam constructions.
2Adaptability or versatility
If additional foam or fiber layers are placed above the pocketed spring comfort layer, then posturized support can be achieved, but the cost and complexity increase
Solution Approach 1:
The invention merges the support function traditionally provided by separate foam or fiber layers directly into the comfort layer itself by using mini coil springs of varying sizes within a single integrated structure. This eliminates the need for multiple separate layers and reduces overall construction complexity.
Solution Approach 2:
The mini coil spring assembly performs multiple functions simultaneously: it provides the comfort layer structure, delivers posturized support through differential spring sizes, and replaces the need for separate foam or fiber comfort layers. This multi-functionality reduces both complexity and cost.
3Adaptability or versatility
If additional foam or fiber layers are used to achieve posturized effect, then support customization is possible, but manufacturing cost increases
Solution Approach 1:
By incorporating mini coil springs of different sizes in specific regions (larger springs in head and foot regions, smaller springs in midsection), the invention achieves customized support characteristics without requiring additional foam or fiber materials. This reduces material quantity and manufacturing cost while maintaining support customization capability.
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
A posturized comfort layer (16, 16a, 16b, 16c, 16d, 16e, 16f, 16g, 16h, 161, 16j, 16k, 161, 16m) for a bedding or seating product (10, 10a) has different sections (40, 42, 40a, 42a, 70, 72, 40c, 42c, 40d, 42d, 94, 96, 40f, 42f, 98, 100, 102, 104, 106, 108, 40h, 42h) of different firmness due to different mini coil springs (26, 28, 52, 54, 60, 64, 80) within the sections. The springs (26, 28, 52, 54, 60, 64, 80) may be individually pocketed between two sheets of non -woven polypropylene fabric (22, 24) joined with circular or rectangular weld seams (30, 31, 74, 82, 88). Regardless of the shape of the weld seams (30, 31, 74, 82, 88), the different firmness of the different sections of the comfort layer may be due to different mini coil springs (26, 28, 52, 54, 60, 64, 80) contained in the pockets (36, 38). All pockets may have the same spring, the springs may be contained in different size weld seams to create pockets of different heights.