Zoned Pocketed Spring Comfort Layer for Mattress Edge Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current pocketed spring comfort layers in bedding and seating products require additional foam or fiber layers to mask the feel of the springs, increasing costs and complexity, while also lacking varying firmness regions for improved edge support.
Innovation Solution
A pocketed spring comfort layer with different firmness regions is designed, using mini coil springs of varying wire gauge, height, and convolutions, integrated with semi-permeable fabric pockets to provide edge support without the need for additional layers, allowing for reduced foam or fiber usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If additional foam or fiber layers are placed above the pocketed spring comfort layer to mask the feel of springs, then the comfort and smoothness is improved, but the cost and device complexity increase
Solution Approach 1:
The patent applies local quality by varying the firmness of different regions within the comfort layer itself. The comfort layer is divided into multiple zones with different firmness levels, allowing the springs to be felt in some areas while providing comfort in others, eliminating the need for additional masking layers.
Solution Approach 2:
The patent merges the functions of the comfort layer and the spring support layer into a single integrated comfort layer assembly. By combining the spring support function with the comfort function in one layer with varying firmness regions, it eliminates the need for separate additional foam or fiber layers to mask the springs.
2Ease of operation
If additional foam or fiber layers are placed above the pocketed spring comfort layer to mask the feel of springs, then the comfort and smoothness is improved, but the production cost increases
Solution Approach 1:
The comfort layer is constructed with regions of varying firmness to provide comfort while selectively allowing spring feel in certain areas, eliminating the need for additional costly foam or fiber layers.
Solution Approach 2:
The patent extracts the comfort function from separate foam or fiber layers and integrates it directly into the comfort layer with varying firmness regions, removing the need for additional material layers and reducing production costs.
3Ease of manufacture
If uniform firmness is used throughout the pocketed spring comfort layer, then the manufacturing simplicity is maintained, but the edge support is insufficient
Solution Approach 1:
The patent applies local quality by creating different firmness regions within the comfort layer, specifically providing firmer regions at the edges to enhance edge support while maintaining softer regions in the center for comfort, all within a single integrated layer.
Solution Approach 2:
The comfort layer is segmented into multiple regions with different firmness characteristics, including firmer edge regions for support and softer central regions for comfort, allowing differentiated functionality within a single layer structure.
Data Source
Figure 1
Figure 2
Figure 3A~4B
AI summary
A posturized comfort layer (16, 60, 66, 100, 110, 120) for a bedding or seating product has different sections (50, 52) of different firmness due to different mini coil springs (28, 30) within the sections (50, 52). The springs (28, 30) may be individually pocketed between two sheets of non-woven polypropylene fabric (22, 24, 74, 76) joined with circular seams (32) or rectangular seams (80). Each circular seam (32) joins opposed pieces of fabric (22, 24) around one of the mini coil springs (28, 30) with curved segments (26). Alternatively, rectangular seams (80) join opposed pieces of fabric (22, 24) around each of the mini coil springs (28, 30) with linear segments (78). Regardless of the shape of the seams, the different firmness of the different sections (50, 52) of the comfort layer may be due to the mini-coil springs contained in the pockets.