Resilient unit
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Solution Overview
Problem
Man-made foams used in resilient pads are not cost-effectively recyclable and take a long time to degrade naturally, prompting industries to seek alternatives.
Innovation Solution
A resilient unit comprising a plurality of pocketed coil springs with coils of different diameters arranged in an array, encased in individual pockets formed by joined layers of material, providing compressibility and flexibility, and optionally incorporating natural substrate layers for improved performance and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If man-made foams are used to provide resilience in pads, then comfort and support are improved, but recyclability deteriorates and degradation time increases
Solution Approach 1:
The patent changes the material parameter from synthetic foam to natural materials (wool, cotton, hemp, etc.), fundamentally altering the material composition to achieve both resilience performance and environmental sustainability. This parameter change enables the pad to be recyclable and biodegradable while maintaining comfort and support functions.
Solution Approach 2:
The patent uses composite material construction by combining multiple natural layers (wool layer, cotton layer, hemp layer) with different properties. Each layer contributes specific characteristics - wool provides warmth and moisture absorption, cotton provides softness and breathability, hemp provides durability and structure. This composite approach achieves superior overall performance while maintaining recyclability.
2Adaptability or versatility
If pocketed coil springs with different diameter coils are used, then customization and performance optimization are improved, but device complexity increases
Solution Approach 1:
The patent applies local quality by varying the coil diameter at different locations along the spring - the upper portion has a first diameter while the lower portion has a second diameter. This local variation allows optimization of different regions for different functions: the upper section provides softer comfort while the lower section provides stronger support. The pocketed spring structure also applies local quality by individually enclosing each spring to control its expansion and compression independently.
Solution Approach 2:
The spring structure is segmented into multiple functional zones with different coil diameters, allowing each segment to perform its specific function. The pocketed construction further segments the springs from each other, enabling independent operation and customization of each spring's characteristics within the pad assembly.
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
The solution offers a stable, quiet, and customizable resilient pad that provides comfort, support, and protection without the environmental drawbacks of man-made foams, using less material while allowing for recyclability and varying stiffness characteristics.
Implementation Method 1
each spring comprises a number of coils... the unit being compressible in the axial direction of the springs
Implementation Method 2
a plurality of pocketed coil springs arranged in an array
Implementation Method 3
The layers may be welded together, for example ultrasonically or thermally
Implementation Method 4
The layers may be welded together, for example ultrasonically or thermally
Implementation Method 5
The ability to deform can provide comfort... or can absorb energy from an impact, to provide protection
Data Source
AI summary
A resilient unit suitable for providing comfort, convenience, support or protection is described. The unit typically takes the form of a pad comprising a plurality of pocketed coil springs arranged in an array, each spring being substantially encased in an individual pocket, and the unit being compressible in the axial direction of the springs, wherein each spring comprises a number of coils, and in respect of at least some springs the coils at opposed ends are of different diameter.