Spring Core with Integrated Cushioning Layer for Pressure Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional spring cores lack enhanced cushioning and support, which can lead to inadequate comfort and motion transfer in mattress assemblies, as they do not effectively integrate advanced cushioning technologies with pocket coil springs.
Innovation Solution
The integration of a cushioning layer atop and below the coil springs, utilizing a continuous fabric layer to dispense and cure a foam precursor, creating a supportive and pressure-distributing surface that enhances comfort and reduces motion transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional spring core without integrated cushioning is used, then the structure is simpler and manufacturing is easier, but comfort and pressure distribution are inadequate
Solution Approach 1:
The patent combines the spring core and cushioning layer into a single integrated assembly. The cushioning layer is positioned directly atop the coil springs and extends below the upper end convolution of each coil spring, merging the support function of springs with the comfort function of cushioning material into one unified structure that provides both structural support and pressure distribution.
Solution Approach 2:
The invention uses composite construction by combining different materials - the metallic coil springs provide structural support while the cushioning layer (which may be foam, fiber, or other soft material) provides comfort and pressure distribution. This composite approach allows each material to perform its optimal function while working together as a unified system.
2Reliability
If a cushioning layer extending below the upper end convolution is integrated, then comfort and pressure distribution are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The cushioning layer is merged with the spring assembly in a single integrated construction. By positioning the cushioning layer to extend below the upper end convolution of each coil spring, the design creates a unified structure where the cushioning and spring systems work together as one component rather than separate layers, simplifying the overall assembly process.
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 provides improved comfort and support by distributing pressure effectively, while minimizing motion transfer between users, offering a luxurious feel and increased durability through the use of flexible foams and fabric layers in mattress assemblies.
Implementation Method 1
utilizing a continuous fabric layer to dispense and cure a foam precursor, creating a supportive and pressure-distributing surface
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.