Integrated Compression-Tension Spring Unit for Phased Deformation
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Solution Overview
Problem
Existing mattress springs, typically made of helically wound steel coils, face inefficiencies in material usage and cost due to the need for multiple coils to achieve comfort, as reducing wire gauge to save mass compromises stiffness, and previous designs fail to efficiently combine springs for improved characteristics.
Innovation Solution
A complex spring unit is formed by integrating multiple spring portions, including helical and flat coil springs of varying diameters, where each portion deforms differently during compression to provide a phased spring characteristic, allowing for efficient material use and enhanced comfort without excessive height or cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the number of individual coils is increased to improve comfort, then comfort level is improved, but material usage and cost increase
Solution Approach 1:
The spring is divided into multiple distinct spring portions (first, second, third spring portions) with different structural characteristics - helical coils, flat coils, and varying diameters - each segment contributing differently to the overall comfort characteristic, allowing differentiated functionality without increasing total material usage
Solution Approach 2:
Different portions of the spring have different local properties - some portions are under compression while others are under tension during compression, with varying wire diameters and coil configurations optimized for specific functional requirements, enabling efficient material distribution
2Weight of moving object
If wire gauge is reduced to decrease spring mass, then mass is reduced, but spring stiffness is compromised
Solution Approach 1:
The spring uses wire of substantially uniform gauge throughout, but achieves varying stiffness characteristics through different local configurations - helical vs flat coils, different diameters, and different activation sequences - maintaining adequate stiffness without requiring variable wire thickness
Solution Approach 2:
The spring exhibits dynamic behavior where different portions become active at different stages of compression - the second spring portion activates first, followed by the first and third portions - creating a progressive stiffness characteristic that provides comfort while maintaining structural integrity
3Ease of operation
If multiple discrete springs are combined to improve spring characteristic, then spring characteristic is improved, but device complexity increases
Solution Approach 1:
Multiple spring portions with different functional characteristics are merged into a single integrally formed spring unit, eliminating the need for separate components and complex assembly mechanisms while achieving the desired progressive compression characteristic
Solution Approach 2:
The single spring unit performs multiple functions simultaneously - providing compression resistance, tension resistance, progressive stiffness characteristics, and structural support - that would otherwise require multiple separate spring components
4Ease of operation
If multiple discrete springs are combined to improve spring characteristic, then spring characteristic is improved, but manufacturing efficiency decreases
Solution Approach 1:
Multiple spring portions are formed in a single continuous operation from a single length of wire, eliminating the need for separate manufacturing processes and assembly steps, thereby maintaining high manufacturing efficiency while achieving complex spring characteristics
Solution Approach 2:
The single manufacturing process produces a multi-functional spring unit with varying diameters, coil configurations, and activation sequences, achieving what would otherwise require multiple discrete manufacturing operations
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 integrated spring unit offers improved comfort and stability with efficient material usage, providing a phased deformation that enhances user experience while reducing the overall mass and cost of the spring unit.
Implementation Method 1
during compression of the complex spring unit the spring portions become elastically deformed according to the following phases
Data Source
Figure 1~4
AI summary
A complex spring unit (1.0) comprises at least a first spring portion (12) and a second spring portion (145, which first and second spring portions are integrally formed wherein the first spring portion is arranged in use to be placed under compression and the second spring portion is arranged in use to be placed under tension, during compression of the complex spring unit.