Separated pocket spring mattress with cut through string, and method and apparatus for production of such mattress

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Solution Overview

Problem

Pocket-spring mattresses are expensive and complex to manufacture, and they suffer from issues like excess cover material accumulation, poor air circulation, and rigidity, leading to discomfort and inefficiency.

Innovation Solution

A spring mattress design with longitudinal strings and slits between adjacent springs, allowing increased separation and efficient use of cover material, which facilitates easier manufacturing and improved air circulation while maintaining comfort.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If springs are enclosed individually in pockets with cover material, then each spring can flex separately increasing user comfort, but the manufacturing becomes much more expensive and complex requiring large quantities of material and many joining steps

Engineering Contradiction:

Improveuser comfortVSAvoidmanufacturing complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The mattress is divided into multiple strings, each containing multiple springs enclosed in individual pockets. This segmentation allows each spring to flex independently while organizing them into manageable units for manufacturing and assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Springs are nested within individual cover pockets, which are then grouped into strings. The covers enclose the springs completely, creating a nested structure that provides individual spring support while maintaining manufacturing efficiency

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of operation

If springs are enclosed in pockets with cover material, then individual spring flexibility is achieved, but the mattresses become comparatively heavy and compact

Engineering Contradiction:

Improveindividual spring flexibilityVSAvoidmattress weight

Core Design Contradiction:

Ease of operationVSWeight of stationary object

Solution Approach 1:

Thin cover material is used to enclose each spring in a pocket, providing just enough enclosure to allow individual spring flexion without adding excessive weight. The covers are sized to fit the springs with minimal excess material

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

Instead of trying to reduce spring enclosure material while maintaining flexibility, the invention inverts the approach by accepting the necessary cover material for flexibility but optimizing the overall mattress structure to reduce total weight through efficient string construction and minimal excess material

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If cover material is used to enclose springs in pockets, then springs become resilient individually, but excess cover material accumulates at the top and bottom of the strings forming false lofts

Engineering Contradiction:

Improvespring resilienceVSAvoidfalse loft formation

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The cover material is pre-sized and pre-positioned to fit the springs exactly, with calculations made in advance to determine the correct length and width of covers needed. This preliminary planning prevents excess material accumulation at the top and bottom of strings

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The dimensions of the cover material are precisely controlled and adjusted to match the spring dimensions and desired separation distances. By changing the parameters of cover size and positioning, the invention eliminates false loft formation while maintaining spring resilience

Inventive Principle:

Principle #35Parameter changes

4Quantity of substance

If the mattress is made compact with springs close together, then material usage is reduced, but air circulation through the mattress is impaired

Engineering Contradiction:

Improvematerial usage efficiencyVSAvoidair circulation

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

Different regions of the mattress have different spring densities and separation distances. By varying the local quality of spring arrangement, the invention optimizes material usage in some areas while ensuring adequate air circulation in others, particularly in zones where breathability is most needed

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9554656B2Separated pocket spring mattress with cut through string, and method and apparatus for production of such mattress

Publication Date: 2017.01.31 STARSPRINGS AB

AI summary

A spring mattress with longitudinal strings comprising a plurality of interconnected coil springs (1) enclosed in covers (2) is described, wherein a plurality of such parallel strings are arranged side by side and interconnected by surface attachment between abutting surfaces. Furthermore, a slit is provided between at least two springs located adjacent to one another within the same string, which slit allows an increased interjacent separation distance (SA) to be formed between, said adjacent springs. Also described are a method and a device, respectively, for manufacturing a corresponding mattress.