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Solution Overview
Problem
Bedding foundations with legs supported by connector assemblies face issues with load distribution, leading to potential damage and instability, especially when shipped and assembled by customers, as the force exerted on one leg can damage the connector assemblies, rendering the product unusable if any assembly is compromised.
Innovation Solution
A novel bedding foundation design incorporates a stabilizer assembly below each connector assembly at the corners, featuring a leg assembly with a threaded rod and brackets that provide additional stability by supporting the trusses above the ground, ensuring that each leg aids in securing the product's corners and distributing the load more evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If legs are supported by connector assemblies, then the foundation can be assembled with fewer components, but the load force concentrates on the connector assemblies increasing damage risk
Solution Approach 1:
The support structure is divided into two distinct functional segments: connector assemblies for joining trusses and stabilizer assemblies for supporting legs. This segmentation separates the joining function from the load-bearing function, preventing force concentration on the connector assemblies while maintaining component efficiency.
Solution Approach 2:
Stabilizer assemblies act as intermediary components between the legs and the connector assemblies. These intermediaries absorb and distribute the load forces from the legs, preventing direct transmission of concentrated forces to the connector assemblies and reducing damage risk.
2Reliability
If a connector assembly is damaged, then the product cannot function correctly, but using more robust connector assemblies increases product complexity and cost
Solution Approach 1:
The stabilizer assemblies are installed beforehand to cushion and distribute leg loads before they reach the connector assemblies. This preventive measure protects the connector assemblies from damage, ensuring product functionality without requiring overly robust (and complex) connector designs.
Solution Approach 2:
Different parts of the structure have different functional requirements: connector assemblies are optimized for joining trusses with appropriate strength, while stabilizer assemblies are specifically designed for load distribution and protection. This localized optimization allows each component to be appropriately designed without unnecessary complexity.
3Volume of moving object
If bedding foundations are designed for shipping in boxes, then shipping costs decrease, but assembly complexity increases for customer assembly
Solution Approach 1:
The foundation is segmented into discrete components (trusses, connector assemblies, stabilizer assemblies, legs) that can be compactly packaged for shipping. This segmentation enables space-efficient packaging while maintaining clear assembly relationships between components, facilitating customer assembly.
Solution Approach 2:
Connector assemblies and stabilizer assemblies are pre-assembled with attached components (brackets, bolts, washers) before shipping. This preliminary action reduces the number of separate parts customers must handle and assemble, simplifying the customer assembly process while enabling compact packaging.
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
This design enhances the stability and load distribution of the bedding foundation, preventing damage to connector assemblies and allowing for proper assembly and use even if one leg is compromised, while also enabling cost-effective shipping by allowing components to be stacked and shipped in smaller containers.
Implementation Method 1
One of the first and second brackets has a threaded boss and the other of the first and second brackets has a non-threaded opening aligned with the threaded boss. Each of the stabilizer assemblies further comprises a leg assembly comprising a leg and a threaded rod, the threaded rod extending through the non-threaded opening and aligned threaded boss
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A bedding foundation comprises a connector assembly and a stabilizer assembly at each corner of the product for joining perpendicular first and second trusses. Each stabilizer assembly comprises a first bracket secured to the first truss, a second bracket secured to the second truss and a leg assembly comprising a leg and a threaded rod. One of the first and second brackets has a threaded boss and the other of the first and second brackets has an opening aligned with the threaded boss. The threaded rod extends through the aligned threaded boss and opening of the first and second brackets and the leg abuts the lower bracket to support the foundation above the ground.