Asymmetrical Coil Spring Structure for Multi-Weight Mattress Support

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Solution Overview

Problem

Traditional spring mattresses provide uneven cushioning support for users of different weights due to linear or non-linear spring compression, leading to discomfort for lighter users and excessive wear, as well as manufacturing difficulties with irregularly shaped springs.

Innovation Solution

Innerspring assemblies featuring asymmetrical springs with a combination of linear and non-linear spring rates, where the upper conical portion compresses before the lower cylindrical portion, ensuring consistent comfort for a range of users and reducing excessive compression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional linear springs are used, then manufacturing is simple and shape is regular, but cushioning support is uneven for users of different weights

Engineering Contradiction:

Improvecushioning support for different weightsVSAvoidmanufacturing difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The spring is divided into two distinct segments: an upper conical portion with non-linear spring rate and a lower cylindrical portion with linear spring rate. This segmentation allows each portion to perform its specific function - the conical portion provides progressive compression for lighter users while the cylindrical portion maintains structural integrity and consistent support for heavier users, thereby resolving the contradiction between adaptability and manufacturing ease.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the spring are given different geometric properties - the upper portion is conical with varying diameter to provide non-linear spring rate, while the lower portion is cylindrical with constant diameter for linear spring rate. This local differentiation of quality allows the spring to adapt to different user weights while maintaining manufacturability through standardized lower portion geometry.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If conical springs with non-linear spring rates are used, then cushioning support improves for lighter users, but excessive compression occurs and lifespan decreases

Engineering Contradiction:

Improvecushioning support for lighter usersVSAvoidmattress lifespan

Core Design Contradiction:

Adaptability or versatilityVSDuration of action of stationary object

Solution Approach 1:

By segmenting the spring into conical and cylindrical portions, the patent limits the compression to primarily the upper conical portion while the lower cylindrical portion maintains its structural integrity. This prevents excessive overall compression that would occur with fully conical springs, thereby extending mattress lifespan while still providing improved cushioning for lighter users.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The conical portion is designed to compress partially under lighter loads, providing the necessary cushioning effect, while the cylindrical portion remains relatively stable. This partial compression approach allows the spring to be soft enough for lighter users without requiring full compression that would lead to excessive wear and reduced lifespan.

Inventive Principle:

Principle #16Partial or excessive action

3Adaptability or versatility

If fully conical springs are used, then non-linear compression is achieved, but manufacturing complexity increases due to irregular shape

Engineering Contradiction:

Improvenon-linear compressionVSAvoidassembly difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The spring is segmented into conical and cylindrical portions, where the cylindrical lower portion provides a regular, standardized geometry that simplifies manufacturing and assembly. This regular shape allows for easier integration into mattress assemblies compared to fully irregular conical springs, while the conical upper portion still provides the desired non-linear compression characteristics.

Inventive Principle:

Principle #1Segmentation

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 a mattress that is soft for lighter users and firm for heavier users, maintaining comfort and extending the lifespan of the mattress while simplifying manufacturing by using a more regular spring shape.

Implementation Method 1

Traditional spring mattresses generally contain an innerspring assembly having a set of springs that provide cushioning support to one or more users. When a user sleeps on the surface of the mattress, he/she applies a weight on the underlying springs, which in turn compress to provide adequate cushioning support.

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9161634B2Asymmetrical combined cylindrical and conical springs

Publication Date: 2015.10.20 DREAMWELL LTD

AI summary

A mattress comprising asymmetrical coil springs with nonlinear spring rates provides comfort to users with different weights. The lower portion of the spring is cylindrical and the upper portion is conical or frustoconical. This arrangement causes the spring to undergo linear compression before undergoing nonlinear compression. The result is a mattress that is sufficiently soft for lighter users and sufficiently firm for heavier users.