Vented Pocketed Spring Comfort Layer for Cooler, Quieter Bedding
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Solution Overview
Problem
Conventional comfort layers in bedding and seating products impede airflow, leading to a warmer feel and noise issues due to fabric constraints, which are not adequately addressed by existing technologies.
Innovation Solution
A comfort layer comprising individually pocketed mini coil springs enclosed in spunlaced aperture nonwoven fabric, allowing increased airflow through the fabric, reducing compression retardation and noise by using permeable fabric with apertures and segmented weld seams for enhanced airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional spunbond nonwoven polypropylene fabric is used to enclose pocketed springs, then the fabric provides structural containment, but airflow through the fabric is retarded leading to a warmer feel
Solution Approach 1:
The patent applies porous materials by using spunlaced nonwoven fabric with intentionally created apertures (holes) throughout the material structure. This porous configuration allows air to pass through the fabric more freely, reducing airflow impedance and enhancing the cooling effect by enabling better breathability and heat dissipation compared to conventional non-porous spunbond fabric.
Solution Approach 2:
The patent uses composite materials by combining spunlaced nonwoven fabric with thermoplastic binder jets to create a hybrid structure. The spunlaced fabric provides the base porous structure for airflow, while the thermoplastic binder jets (applied in segmented patterns) provide structural reinforcement and pocket definition, creating a composite material that balances airflow permeability with mechanical strength.
2Temperature
If fabric with aperture is used to increase airflow, then cooling effect is improved, but fabric expansion creates noise when load is removed
Solution Approach 1:
The patent applies local quality by creating non-uniform distribution of thermoplastic binder jets across the fabric surface. The binder jets are applied in segmented patterns with varying density in different regions, allowing certain areas to have more structural reinforcement than others. This localized reinforcement strategy reduces fabric expansion noise in critical areas while maintaining airflow properties in other regions.
Solution Approach 2:
The patent applies parameter changes by modifying the physical and chemical properties of the fabric through controlled application of thermoplastic binder jets. The binder jets alter the fabric's mechanical parameters (tensile strength, elasticity, dimensional stability) in specific regions, reducing the fabric's tendency to expand and create noise when load is removed, while preserving the overall porous structure for airflow.
3Ease of operation
If semi-impermeable fabric is used to create slow compression feel, then comfort is improved, but airflow is impeded reducing cooling effect
Solution Approach 1:
The patent applies porous materials by using spunlaced nonwoven fabric with inherent apertures that provide natural airflow pathways. This porous structure allows air to pass through freely for cooling while the fabric's base structure still provides the slow compression characteristics associated with comfort, unlike impermeable fabrics that completely block airflow.
Solution Approach 2:
The patent uses composite materials by combining the porous spunlaced fabric base with strategically placed thermoplastic binder jets. This composite structure maintains the fabric's natural slow compression feel from the spunlaced material while the binder jets provide localized reinforcement that does not significantly impede airflow through the aperture structure, achieving a balance between comfort and cooling.
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 comfort layer provides a cooler feel and reduced noise by allowing increased airflow, enhancing the rate of compression and recovery of the coil springs while maintaining comfort and support.
Implementation Method 1
The vented spunlaced aperture nonwoven fabric is permeable to airflow through the fabric material... air may pass through such a permeable material at a higher or increased rate
Implementation Method 2
the rate at which a spring maintained in a pocket of the fabric may compress under load or return to its original height when a load is removed from the pocketed spring
Data Source
AI summary
A comfort layer for a bedding or seating product has fast-acting pockets characterized by the individual mini springs of the comfort layer being pocketed with permeable fabric having apertures therein. Apertures in the fabric facilitate airflow through the fabric. The permeable fabric is specifically structured to facilitate airflow while minimizing noise. Each seam joining opposed pieces of fabric around each of the mini coil springs of the comfort layer may be segmented, allowing air to flow between the segments.