Coil Spring Bracket Assembly for Durable Cushion Support
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Solution Overview
Problem
Existing upholstery designs for seating and mattresses are difficult to assemble, prone to component failure due to stress on springs and fasteners, and do not effectively maintain cushion support and comfort over time.
Innovation Solution
A coil spring bracket assembly featuring flat springs spanning a furniture frame, with cross members and helical springs that bias the flat springs toward a support plane, anchored by brackets at the ends of the cross members to distribute stress and facilitate easier assembly and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flat springs and helical springs are used to support the cushion on the furniture frame, then the cushion can be supported and maintained in shape, but the design becomes difficult to assemble and install due to limited access to the open interior of the furniture frame
Solution Approach 1:
The support system is divided into modular components: flat springs for cushion support, helical springs for suspension, cross members for structural support, and brackets for anchoring. This segmentation allows each component to be assembled and tested separately before installation, significantly improving ease of manufacture while maintaining reliable cushion support.
Solution Approach 2:
The brackets are pre-assembled with the cross members and springs are pre-attached to the cross members before installation into the furniture frame. This preliminary assembly action allows components to be prepared in advance with good access, reducing the complexity of final installation into the confined interior space of the furniture frame.
2Ease of operation
If flat springs and helical springs are used to support the cushion, then the cushion can be forced back up when force is removed, but the stress over time breaks the springs and fasteners
Solution Approach 1:
The helical springs are pre-attached to the cross members and positioned to provide suspension before the cushion is installed. This beforehand cushioning allows the springs to gradually adjust to the cushion's weight and distribute stress evenly over time, preventing sudden shock loads that would break the springs and fasteners while maintaining cushion recovery capability.
Solution Approach 2:
The cross members serve as intermediary elements between the helical springs and the flat springs. They distribute the stress from the helical springs across multiple attachment points and transfer loads to the furniture frame through brackets, reducing the stress concentration on individual springs and fasteners while maintaining the cushion recovery function.
3Duration of action of stationary object
If cross members and multiple springs are used to support the cushion, then support and comfort are maintained, but the number of components and assembly steps increases
Solution Approach 1:
The brackets are designed to perform multiple functions simultaneously: anchoring the cross members to the furniture frame, providing mounting points for the helical springs, and distributing structural loads. This merging of functions reduces the total number of separate components needed while extending product lifespan through robust support.
Solution Approach 2:
The cross members serve multiple purposes: providing structural support within the furniture frame, serving as mounting points for helical springs, distributing loads from the flat springs, and enabling easy assembly through pre-attachment features. This multi-functionality reduces overall device complexity while maintaining long-lasting cushion support.
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 design provides robust support for cushions, reduces the likelihood of component failure, maintains comfort, and simplifies assembly, resulting in increased product lifespan and reduced labor costs.
Implementation Method 1
at least one helical spring extending from the at least one cross member to the at least one flat spring to bias the at least one flat spring toward the support plane
Data Source
AI summary
A coil spring bracket assembly that supports a cushion on a furniture frame is disclosed. A flat spring spans the furniture frame along a support plane to support the cushion. A cross member spanning the furniture frame is aligned with and spaced from the flat spring. A helical spring extends from the cross member to the flat spring to bias the flat spring toward the support plane. A bracket is disposed at opposite ends of the cross member to anchor the cross member to the furniture frame. The bracket includes a top portion that extends outwardly over the furniture frame along the support plane, a middle portion that extends from the top portion into the furniture frame, and a bottom portion that extends inwardly from the middle portion to abut a portion of the cross member in overlapping relationship.