Injection-Molded Spring Frame Assembly for Point-Elastic Cushions
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Solution Overview
Problem
Existing spring elements and upholstery systems face challenges in achieving optimal comfort, support, and point elasticity while minimizing weight, space requirements, and costs, especially in outdoor applications where compactness and durability are crucial.
Innovation Solution
A spring element comprising a majority of closed spring frames connected to form a stable, modular structure with a large effective contact surface, allowing for easy production via injection molding and enabling high-resolution point elasticity. This spring element can be integrated into a cushion with a spring arrangement, providing enhanced comfort and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional spring elements are used to provide suspension and comfort, then comfort and support are improved, but weight, space requirements, and installation height increase
Solution Approach 1:
The spring element is divided into multiple closed spring frames arranged one above the other, each frame being a segmented structure that contributes to the overall suspension function. This segmentation allows for reduced material usage while maintaining comfort and support properties.
Solution Approach 2:
The spring frames are arranged in a vertical stacking configuration, utilizing the vertical dimension efficiently. This dimensional arrangement provides suspension and comfort functions while minimizing horizontal space requirements and reducing overall installation height compared to traditional spring systems.
2Ease of operation
If traditional spring elements are used to provide suspension and comfort, then comfort and support are improved, but installation height and cost increase
Solution Approach 1:
The spring element consists of multiple closed spring frames stacked vertically, with each frame contributing a portion of the total suspension function. This segmentation allows the system to achieve required comfort levels in a more compact vertical arrangement, reducing installation height.
Solution Approach 2:
The spring frames are designed with flexible connections that allow dynamic deformation under load. This dynamic behavior enables the spring element to provide adequate suspension and comfort support within a reduced installation height, as the frames can deform vertically without requiring excessive vertical space.
3Ease of operation
If point-elastic functional layers are used to absorb pressure at specific points, then pressure distribution is improved, but manufacturing complexity increases
Solution Approach 1:
The spring element is segmented into multiple identical closed spring frames that can be manufactured separately and then stacked. Each frame is a simple closed structure that is easy to manufacture, yet the segmented arrangement collectively provides point-elastic pressure distribution when compressed.
Solution Approach 2:
The spring frames are designed with specific geometric parameters (frame size, spacing, and configuration) that can be adjusted to optimize pressure distribution characteristics. By changing these parameters, the system achieves point-elastic functionality while maintaining manufacturing simplicity through standardized frame designs suitable for injection molding or other efficient manufacturing processes.
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 described spring element and cushion system offer improved comfort, support, and point elasticity, while being lightweight, compact, and cost-effective, making them suitable for outdoor applications and easy to produce and expand.
Implementation Method 1
a spring element consisting of a plurality of closed spring frames, each enclosing an inner region, which are connected to form a spring body... the spring frames are arranged one above the other without overlapping... providing enhanced comfort and support
Data Source
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AI summary
Known spring elements with connected spring frames are to be further developed to enable their production using a standard injection molding process, thus making large-scale production simple and – after acquiring suitable tooling – cost-effective. Furthermore, it should be ensured that suitable cushions with optimal point elasticity can be created using such spring elements. The undercut-free geometry of a single spring element also allows for the cost-effective production of injection molds for a spring assembly. This is achieved by manufacturing a spring element from a plurality of spring frames that taper upwards.Provided that the spring frames are designed such that their inner area is at most the same size as the next smaller spring frame and these are positioned without overlapping, such a construction can be easily manufactured as a one-piece injection-molded part. Furthermore, such a spring element has numerous design advantages, most notably that the entire spring assembly can be manufactured as a single, undercut-free injection-molded part.