Pocketed Spring Assembly With Split Seams and Ventilation
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Solution Overview
Problem
Conventional pocketed spring cores in bedding and seating products, which use springs of uniform diameter and pitch, do not fully realize the independent action of individually pocketed springs due to seams extending the full height of the string, compromising the feel and motion transfer.
Innovation Solution
A pocketed spring assembly with parallel strings of springs, each with individually pocketed coils and ventilation openings, where the transverse seams are positioned below the upper surface to partially separate adjacent pockets, allowing for independent spring action and improved airflow, and varying string heights and 'split top' features to create zones of different firmness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If transverse seams extend the full height of the string of springs, then the pockets are fully separated and enclosed, but the independent action of individual springs is compromised
Solution Approach 1:
The transverse seam is segmented into two parts: an upper portion that stops below the upper surface of the string, and a lower portion that extends to the lower surface. This segmentation allows the upper ends of adjacent springs to move independently while the lower ends remain connected for structural stability, resolving the contradiction between full pocket enclosure and independent spring action.
2Ease of manufacture
If conventional pocketed spring cores use uniform springs, then manufacturing is simplified, but the ability to create zones of different firmness is limited
Solution Approach 1:
The patent applies local quality by creating different zones within the mattress with varying spring characteristics. Some strings contain springs with larger diameters for softer zones, while other strings contain springs with smaller diameters for firmer zones. This allows the mattress to provide different firmness levels in different areas while maintaining a unified manufacturing process.
3Stability of the object's composition
If strings of springs are tightly enclosed without ventilation, then structural integrity is maintained, but airflow and cooling are reduced
Solution Approach 1:
The fabric pockets are designed with porous characteristics that allow airflow through them. The transverse seams are positioned to maintain pocket enclosure while permitting air passage. This creates a balance between maintaining structural integrity through proper pocket formation and enabling ventilation for cooling through the porous fabric and seam design.
Data Source
AI summary
A pocketed spring assembly comprises a plurality of parallel strings of individually pocketed springs of different heights. Each string is joined to an adjacent string. Each string has first and second opposed plies of fabric and a plurality of pockets formed along a length of the string by transverse seams joining the plies. 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 when the spring is relaxed. The strings of springs have ventilation openings to increase airflow.