Composite material spring module with integrally formed attachment fittings

Abstract

Composite material spring modules (16) and methods of manufacture are described having a fiber reinforced composite material spring body (32) with attachment fittings (34, 36) integrally formed about the spring body (32). The attachment fittings (34, 36) are molded of a flexible material which dynamically responds to changes in the shape of the spring body (32) upon deflection. Integral formation of the fittings (34, 36) with the spring body (32) provides a unified single piece module which is readily attachable to any structure where spring support is desired. The composite material spring modules (16) are described as a mattress foundation (10), by attachment to high and low profile frames (12) and to an overlying grid (14). Methods of manufacture of the composite material spring modules (16) with integrally formed attachment fittings (34, 36) are described. Methods of assembly of flexible weight bearing structures such as mattress foundations (10) using the composite material spring modules (16) are also described.

Description

[0001] Field [0002] This application is a subsequent application with serial number 08 / 487,022 filed on June 7, 1995. [0003] The present invention finds use as flexible elements in weight supporting structures, in particular, plastic composite elastics for flexible body weight supporting structures such as mattresses, cushions and furniture. Background technique [0004] Resilient members used as flexible supports in support structures such as cushions, mattresses and furniture are usually made of spring steel and wire. See US188636, US488378, US1887058, US4535978, US4339834 and US5558315 for details. Attempts have also been made to make elastic supports from plastic materials, see US4530490, US4736932, US5165125 and US5265291 for details. Although the development of fiber-reinforced plastic elastic parts is quite fast, its application in flexible support structures such as cushions, furniture and mattresses shows that it is difficult to provide suitable means for the co...

AI Technical Summary

Problems solved by technology

Reducing the overall height of the torsion spring module results in a spring that is too stiff and reduces the desired deflection characteristics and ability to cushion heavy loads and recover

Also, during life testing, it is often difficult to predict the cycle time to failure value with a shortened height wire spring module and is usually shorter than a higher height wire spring module

Images