Bedding/seating product with locked corners
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Solution Overview
Problem
Existing bedding and seating products with wooden frames oriented 'on edge' face challenges in securing side rails to head or foot rails, leading to instability and increased risk of damaging connector assemblies under load, which can render the product unsupported if one assembly is damaged.
Innovation Solution
A novel stabilizer assembly is introduced, featuring a combination of connector and stabilizer assemblies at each corner, with a leg assembly that includes a threaded rod extending through aligned openings and bosses, providing additional stability and distributing load to adjacent trusses, thus reducing stress on the stabilizer brackets and threaded rods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a connector assembly is used to join wooden rails oriented 'on edge', then the rails can be connected, but the connector assembly is spaced above the bottom of the furniture piece and does not provide sufficient stability to the bottom of the furniture piece
Solution Approach 1:
The connector assembly is divided into two separate components: a first connector block attached to one rail and a second connector block attached to the perpendicular rail. These blocks are spaced apart vertically, with the first block near the bottom of the furniture piece providing ground-level stability, while the second block connects to the perpendicular rail. This segmentation allows each block to perform its function independently without requiring a single complex assembled connector.
2Reliability
If legs are supported by connector assemblies, then the product is raised off the ground, but the force exerted by a load on one of the legs is transferred directly to one of the connector assemblies which increases the odds of damaging one of the connector assemblies
Solution Approach 1:
The stabilizer assembly includes a stabilizer block positioned between the leg assembly and the first connector block to absorb and distribute loads. This cushioning element is installed beforehand to prevent direct force transmission to the connector assemblies, reducing the risk of damage before it occurs. The stabilizer block acts as a protective buffer that safeguards the connector assemblies from excessive stress during normal use.
3Stability of the object's composition
If a stabilizer assembly is added below the connector assembly to improve stability, then the bottom of the furniture piece gains stability, but the device complexity increases
Solution Approach 1:
The stabilizer assembly is merged with the connector assembly components. The stabilizer block is integrated into the same corner region where the connector blocks are attached, and the leg assembly serves dual purposes as both a stabilizing element and a support structure. This merging approach provides bottom stability while minimizing the addition of separate, independent components that would increase overall complexity.
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 enhances stability by distributing the load to adjacent trusses, reducing the risk of connector assembly damage and ensuring the product remains supported even if one leg assembly is compromised, while allowing for easy assembly without tools.
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 of the first and second brackets, respectively
Implementation Method 2
The connector assembly comprises two connector blocks which upon assembly are joined by a tapered pin. The tapered pin fits through aligned openings in tongues of the connector blocks
Implementation Method 3
The leg has a generally planar upper portion which abuts the first and second trusses to support the trusses above the ground and provide additional stability to the trusses
Data Source
Figure 1
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Figure 3
AI summary
A bedding or seating product (10) comprises a connector assembly (28) and a stabilizer assembly (70) at each corner of the product for joining perpendicular first and second upholstered trusses (20, 22 and 24). Each stabilizer assembly (70) comprises a first bracket (72) secured to the first truss, a second bracket (74) secured to the second truss and a leg assembly (90) comprising a leg (92) and a threaded rod (94). One of the first and second brackets has a threaded boss (86) and the other of the first and second brackets has an opening (80) aligned with the threaded boss (86). The threaded rod (94) extends through the aligned threaded boss (86) and opening (80) of the first and second brackets (72, 74) and the leg (92) abuts the first and second trusses to assist supporting the product (10) above the ground.