Coiled Spring Element Structure for Low-Friction Mattress Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing spring elements used in mattresses and under-mattresses lack optimal spring properties, particularly in terms of minimizing friction and ensuring even load distribution, and do not easily allow for adjustment of spring hardness without altering rigidity or cross-sectional dimensions.
Innovation Solution
The spring element features coiled spring arms that surround support plates, allowing for vertical movement under load, adjustable stroke, and varying spring hardness by changing the wrapping angle, while being produced in a compact, one-piece design from plastic using injection molding, with detachable head plates for enhanced flexibility and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spring arms are designed with straight sections and kink-like bends, then manufacturing is simpler, but horizontal movement components occur causing friction and reduced support quality
Solution Approach 1:
The spring arms are designed with a coiled, arc-shaped configuration instead of straight sections with kink-like bends. This curved geometry allows the spring arms to flex smoothly in the vertical direction while minimizing horizontal movement components, thereby reducing friction between the spring element and the supported mattress.
2Ease of manufacture
If spring arms have fixed length and configuration, then manufacturing is easier, but spring hardness cannot be adjusted without changing rigidity properties
Solution Approach 1:
The spring hardness can be adjusted by changing the wrapping angle of the coiled spring arms around the support plates. By varying this geometric parameter, different spring characteristics can be achieved without altering the fundamental one-piece construction or cross-sectional dimensions, maintaining manufacturing simplicity while providing adaptability.
3Length of moving object
If spring arms are made longer to increase stroke, then spring hardness decreases, but compactness is reduced
Solution Approach 1:
The coiled, arc-shaped design of the spring arms allows for increased stroke through the wrapping configuration rather than simply extending the arm length. The curved geometry provides mechanical advantage, enabling greater displacement while maintaining spring hardness through the rigidity of the arm material and cross-section.
4Productivity
If spring elements are produced in one piece using injection molding, then production cost is reduced and assembly is simplified, but undercuts must be avoided limiting design flexibility
Solution Approach 1:
The coiled spring arms are designed with smooth, continuous curves that branch off tangentially from the base plate and wrap around support plates. This curved geometry avoids sharp undercuts and directional changes that would complicate injection molding, while still providing the necessary mechanical functionality and design flexibility.
5Stability of the object's composition
If spring arms coil tightly around support plates, then horizontal movement is better compensated, but spring element size increases
Solution Approach 1:
The degree of wrapping of the spring arms around the support plates can be varied to optimize the balance between stability and compactness. By adjusting the wrapping angle and coil tightness, sufficient horizontal movement compensation can be achieved while controlling the overall dimensions of the spring element.
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 minimizes horizontal movement, ensures even load transfer, allows for adjustable spring hardness without changing rigidity, and facilitates cost-effective production and assembly, providing improved point elasticity and reduced tendency to tilt, while maintaining high resolution and ease of manufacturing.
Implementation Method 1
the spring arms can be coiled in an arc shape, which means that the spring arms do not have any discontinuities in the sense of kink-like bends at any point
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Spring element (10) for elastically supporting a seat or lying element in the direction of a spring axis (1) with a base plate, a first plurality of support plates spaced apart from the base plate in the direction of the spring axis (1), separated from one another and in particular arranged distributed around the spring axis ( 12,14,16,18) and a first plurality of spring arms (30,32,34,36), which connect the support plates to the base plate, the support plates (12,14,16,18) being used to improve the spring properties of the spring element. are each connected to the base plate via a spring arm (30,32,34,36) coiled around an axis parallel to the spring axis.