Spring Core with Integrated Foam Cushioning Layer for Motion Isolation
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Solution Overview
Problem
Existing spring assemblies using pocket coil springs lack an integrated cushioning layer that enhances the unique feel and support provided by traditional pocket coil springs, leading to potential motion transfer and suboptimal comfort.
Innovation Solution
Incorporating a cushioning layer atop and below the upper end convolution of each coil spring, integrated with a continuous upper fabric layer, to create a spring core that includes a recess for dispensing a liquid foam precursor, forming a flexible foam layer that supports and distributes pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional pocket coil spring assembly is used, then each discrete coil can move independently to support the body, but motion transfer between coils occurs and comfort is suboptimal
Solution Approach 1:
The patent combines multiple functional elements into an integrated unit: the cushioning layer is directly attached to the coil springs, the fabric pocket encases both the spring and cushioning layer, and the continuous upper fabric layer spans across multiple springs. This merging creates a unified structure where the cushioning layer acts as a motion isolation barrier between adjacent coils while the fabric pocket maintains individual spring independence, thereby resolving the contradiction between motion isolation and comfort.
Solution Approach 2:
The patent employs composite material structures by combining the cushioning layer (made from liquid foam precursor) with the coil springs and fabric materials. This composite construction allows the cushioning layer to absorb and dampen motion transfers between springs while the fabric pocket and continuous upper fabric layer provide structural support and comfort, achieving both motion isolation and enhanced comfort simultaneously.
2Ease of operation
If a cushioning layer is added atop the coil springs, then comfort and pressure distribution are improved, but the structural complexity increases
Solution Approach 1:
The fabric pocket serves multiple functions simultaneously: it encases the coil spring for individual movement, contains the cushioning layer for comfort, and connects to the continuous upper fabric layer for structural integrity. By merging these functions into a single component, the patent adds cushioning functionality without proportionally increasing structural complexity.
Solution Approach 2:
The continuous upper fabric layer performs multiple roles: it provides the top surface for the cushioning layer, connects adjacent spring assemblies structurally, and distributes pressure across the mattress surface. This multi-functionality allows the addition of the cushioning layer without requiring separate structural elements, thereby limiting the increase in overall structural complexity.
3Reliability
If the cushioning layer extends below the upper end convolution of each coil spring, then motion transfer is reduced, but manufacturing complexity increases
Solution Approach 1:
The liquid foam precursor is dispensed onto the coil springs while they are in their assembled configuration, allowing the foam to naturally conform to the spring geometry and extend below the upper end convolutions. This preliminary action of dispensing foam in the final configuration eliminates the need for subsequent complex shaping or trimming operations, thereby achieving extended cushioning coverage without significantly increasing manufacturing complexity.
Solution Approach 2:
The liquid foam precursor self-conforms to the coil spring structure and automatically extends below the upper end convolutions through its own expansion and curing process. This self-service characteristic of the foam material eliminates the need for additional manufacturing steps to achieve the desired cushioning layer configuration, maintaining manufacturing simplicity while achieving improved motion isolation.
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 integrated cushioning layer provides enhanced comfort and stability, reducing motion transfer while maintaining the luxurious feel of pocket coil springs, offering improved support and pressure distribution.
Implementation Method 1
a liquid foam precursor is dispensed onto the continuous upper fabric layer and allowed to react and form the cushioning layer
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.