Box Spring Cover Structure for Smooth Fit and Ripple Control
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Solution Overview
Problem
Conventional box spring covers often result in fabric ripples at the middle portion, creating an unfinished appearance due to the elastic band's uneven tension and varying fabric stretch properties, making it difficult to achieve a smooth and uniform fit.
Innovation Solution
A box spring cover with stretchable triangular panels positioned at the corners, secured with a hem that extends under the foundation, using elastic panels to maintain a horizontal orientation and prevent displacement, ensuring a smooth appearance by inhibiting wrinkles and ripples.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a typical box spring cover uses an elastic band around the perimeter, then the edges of the cover draw together, but fabric ripples appear at the middle portion of the box spring
Solution Approach 1:
The cover is divided into multiple panels (front, back, left side, right side) with stretchable corner panels at each corner. This segmentation allows each panel to be independently tensioned, eliminating the ripple problem that occurs with a single continuous elastic band by distributing the tension forces evenly across the box spring surface.
Solution Approach 2:
Stretchable corner panels are specifically positioned at the corners where tension is most needed. These corner panels have elastic properties concentrated at the corners, providing localized tension control that prevents fabric ripples in the middle portions while maintaining smooth edges at the corners.
2Manufacturing precision
If elastic bands are used to draw edges together, then the cover fits tightly, but uniform tension force is difficult to provide due to varying elastic band tension along its length
Solution Approach 1:
Instead of one continuous elastic band, the cover uses multiple discrete stretchable corner panels at each corner. This segmentation simplifies the tension distribution system by replacing a complex continuous elastic band with multiple simpler, identical corner panels that each provide uniform radial tension from their respective corners.
Solution Approach 2:
The stretchable corner panels are positioned asymmetrically at the corners rather than uniformly distributed along the perimeter. This asymmetric placement at the corners creates optimal tension geometry that naturally distributes force evenly across the rectangular box spring surface, simplifying the overall tension distribution mechanism.
3Shape
If the cover is made to fit tightly, then the appearance is improved, but the cover may become dislodged or have side panels drawn between the foundation and mattress
Solution Approach 1:
The stretchable corner panels provide localized tension at the corners, creating a secure anchor point system that holds the cover in place without requiring excessive overall tension. This localized corner tensioning maintains tight fit and prevents dislodging while avoiding the side panel draw-in problem that occurs with uniform perimeter elastic bands.
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 clean, crisp, and tight fit around the box spring, reducing or eliminating wrinkles, maintaining a smooth appearance with minimal adjustment needed, and resisting displacement during housekeeping, thus enhancing the aesthetic and functional performance of the cover.
Implementation Method 1
an elastic panel is configured to urge the hem of the cover into a horizontal orientation
Implementation Method 2
In a further aspect the method includes stretching an underside stretchable panel prior to sewing the panel to a hem
Data Source
AI summary
A foundation or box spring cover for use in conjunction with a box spring comprising four panels configured to fit over edges of the box spring, at least two of the panels being adjacent panels of exposed, continuous, non-stretch fabric, and at least one stretchable panel positioned at a corner of the cover and configured to be oriented at an underside of the box spring. In one aspect the cover includes a hem configured to extend under the edges of the box spring, and where the triangular panel is off-set from the edges of the box spring. The hem is configured to have a concealed edge that operates to catch upon a bottom edge of the foundation to secure the sides of the cover into position so as to withstand a housekeeping action applied to the bedding such as tucking in bedding between a mattress and the foundation. A method of manufacture includes stretching the stretchable panel prior to sewing onto adjacent hems.