Coil Spring Non-Linear Loading Response for Foam-Like Mattress Comfort
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Solution Overview
Problem
Conventional coil springs exhibit a linear loading response, which does not provide the same level of comfort and support as foam mattresses, and foam mattresses have mechanical property degradation and higher production costs.
Innovation Solution
Design of coil springs with a continuous wire forming a plurality of convolutions, where the diameter and pitch of intermediate convolutions are varied to create a non-linear loading response, providing a softer feel initially and a firmer feel upon further compression, mimicking the support of foam mattresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional linear response coil springs are used, then the manufacturing cost is low and the structure is simple, but the comfort and support level is insufficient compared to foam mattresses
Solution Approach 1:
The patent applies local quality by varying the wire diameter along the length of the coil spring. The wire diameter transitions from a first diameter in the upper portion to a second diameter in the lower portion, creating different stiffness characteristics in different regions. This allows the spring to provide a non-linear loading response that mimics foam mattress comfort while maintaining coil spring manufacturing advantages.
2Ease of operation
If foam mattresses are used to achieve non-linear response and improved comfort, then the comfort level increases, but the production cost increases and mechanical properties degrade over time
Solution Approach 1:
The patent applies parameter changes by modifying the wire diameter parameter along the length of the coil spring. This creates a non-linear loading response where the spring constant varies with compression, providing improved comfort similar to foam mattresses. The solution maintains the cost-effective metal spring manufacturing process while achieving foam-like comfort characteristics through geometric parameter variation.
3Ease of operation
If foam mattresses are used to achieve non-linear response, then the comfort level increases, but the mechanical properties degrade over time
Solution Approach 1:
The patent replaces foam material with metal coil spring construction, effectively substituting a material with known degradation issues (foam) with a more durable material (metal). The varying wire diameter design provides the desired non-linear comfort response while the metal construction ensures long-term mechanical property stability and resistance to degradation over time.
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 coil springs offer a variable and non-linear loading response, providing comfort similar to foam mattresses without the degradation issues, while maintaining a cost-effective production method.
Implementation Method 1
the coil springs of the present invention provide a user with the non-linear support typically seen in a foam mattress, but through the use of springs
Implementation Method 2
The linear response of springs is expressed by Hooke's law which states that the force (F) needed to extend or compress a spring by some distance (D) is proportional to that distance
Data Source
AI summary
A spring is provided that exhibits a variable and non-linear loading response upon compression. The spring comprises a continuous wire having a lower end convolution, an upper end convolution, and a plurality of helical intermediate convolutions. The upper end convolution, the lower end convolution, and the helical intermediate convolutions each have a respective diameter, with the continuous wire further defining a pitch between the various convolutions. In the spring, one or more of the diameters of the convolutions or one or more of the pitches varies along the length of the continuous wire such that the spring exhibits a non-linear loading response upon compression. A mattress is further provided and includes a plurality of the springs arranged in a matrix.