Spring core assembly and mattress assembly
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Solution Overview
Problem
Current mattress assemblies with spring core layers face material wastage due to the need for cutouts and recesses to create different lying zones, which is inefficient and costly.
Innovation Solution
A spring core assembly with varying grammage fabrics for its spring pockets, where the bottom fabric has a higher grammage than the top fabric, and different spring coils with distinct diameters to create distinct zones without material wastage, ensuring optimal support and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cutouts and recesses are provided in foam layers to create different lying zones, then different hardness zones are achieved, but material wastage increases
Solution Approach 1:
The patent applies local quality by varying the grammage of fabrics at different locations within the spring pocket assembly. The bottom fabric has a higher grammage (e.g., 100-150 g/m²) than the top fabric (e.g., 60-80 g/m²), creating different hardness zones without material wastage. This resolves the contradiction by achieving zone differentiation through localized property variation rather than physical cutouts.
2Adaptability or versatility
If foam layers with different characteristics are provided to create lying zones, then comfort is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the functions of multiple foam layers with different characteristics into a single spring pocket assembly. By combining fabrics of different grammages (top fabric and bottom fabric with different weights) within the same assembly, the invention achieves multiple lying zones in one integrated structure, reducing manufacturing complexity compared to assembling multiple separate foam layers.
Solution Approach 2:
The spring pocket assembly uses composite materials by combining fabrics with different grammages (e.g., lighter top fabric and heavier bottom fabric) to create zones with different hardness characteristics. This composite approach achieves the functionality of multiple specialized foam layers while simplifying the overall structure and manufacturing process.
3Strength
If the grammage of bottom fabric is increased to improve support, then support and durability are enhanced, but weight increases
Solution Approach 1:
The patent applies local quality by strategically placing higher grammage fabric only where needed for support (the bottom fabric) while using lighter fabric where less support is required (the top fabric). This localized approach to varying fabric weight achieves the necessary support and durability without unnecessarily increasing the overall weight of the mattress assembly.
Data Source
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AI summary
The invention relates to a spring core assembly for a mattress assembly. The spring core assembly comprises at least one spring pocket that has a bottom fabric, a top fabric as well as at least one spring coil located between the bottom fabric and the top fabric. A grammage of the bottom fabric is different to a grammage of the top fabric. Further, a mattress assembly is described.