Spring core with integrated cushioning layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional spring cores, particularly those using pocket coil springs, lack enhanced support and comfort, as they do not effectively integrate cushioning to improve the unique feel and motion isolation provided by independent coil movement.
Innovation Solution
Incorporating a cushioning layer atop and extending below the upper end convolution of each coil spring, integrated with a continuous fabric layer that defines recesses for a liquid foam precursor to form a flexible foam layer, providing additional support and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cushioning layer is added atop the coil springs to enhance comfort and support, then the comfort and support are improved, but the device complexity increases
Solution Approach 1:
The cushioning layer is integrated with the fabric pockets enclosing the coil springs, merging two separate components (cushioning layer and fabric pockets) into a unified structure. This integration adds comfort functionality while minimizing the increase in overall structural complexity by utilizing the existing fabric pocket framework.
Solution Approach 2:
The fabric pockets serve multiple functions: they enclose the coil springs to enable independent motion, and simultaneously serve as the structural framework for integrating the cushioning layer. This multi-functionality allows the same component to provide both motion isolation and enhanced comfort without requiring additional separate structures.
2Ease of operation
If the cushioning layer extends below the upper end convolution of each coil spring, then the body contouring is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The fabric pockets are预先 constructed to extend below the upper end convolutions of the coil springs, creating pre-defined recesses or spaces. This preliminary action establishes the structural framework before the cushioning layer is added, allowing the cushioning layer to be positioned accurately within these pre-formed boundaries without requiring high-precision positioning during assembly.
Solution Approach 2:
The cushioning layer is configured to extend specifically below the upper end convolutions of the coil springs in targeted areas where body contouring is needed, rather than uniformly across the entire mattress surface. This localized approach provides enhanced contouring precision where needed while reducing overall manufacturing complexity.
Data Source
AI summary
A spring core is provided that includes a plurality of coil springs having an upper portion and a lower portion that collectively define an interior cavity. The spring core further includes a continuous upper fabric layer that covers each coil spring and defines a recess in the interior cavity of each coil spring. A cushioning layer is positioned atop the continuous upper fabric layer and extends into the recess in the interior cavity of each coil spring. A mattress assembly is further provided that includes the spring core, an upper body supporting layer, and a lower foundation layer. Methods of producing a spring core are further provided.