Mattress Foundation Corner Structure for Sag-Resistant Support
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Solution Overview
Problem
Mattress foundations with unsupported corners tend to sag, leading to material overstretching and wrinkling of the upholstery due to the lack of structural support, resulting in an unattractive appearance.
Innovation Solution
The introduction of internal corner structures with a vertical extent, a base, a grid support deck, and a body structure that provides rigid support and a rounded exterior profile, which fits within the frame and grid components of the mattress foundation, ensuring structural integrity and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If corners are left essentially unsupported to simplify structure, then device complexity is reduced, but foundation stability deteriorates leading to sagging
Solution Approach 1:
The corner structure is divided into distinct functional segments: a base portion that interfaces with the frame, a vertical support portion that provides height and structural reinforcement, and a grid support deck that interfaces with the mattress grid. This segmentation allows each part to perform its specific function optimally while maintaining overall structural integrity without excessive complexity.
Solution Approach 2:
The corner structure implements local quality by providing concentrated structural support precisely where needed - at the corners - rather than uniformly throughout the entire foundation. The vertical support portion and reinforced grid support deck at corners address the specific stability issue at these locations without adding unnecessary complexity to the overall simple foundation design.
2Loss of substance
If corners are left essentially unsupported to reduce materials, then loss of substance is reduced, but upholstery quality deteriorates due to overstretching and wrinkling
Solution Approach 1:
The corner structure provides localized reinforcement specifically at corner areas where upholstery stress is concentrated. This local quality approach ensures that upholstery material is properly supported and distributed at these critical points, preventing overstretching and wrinkling that would otherwise occur, while not requiring additional materials throughout the entire foundation structure.
Solution Approach 2:
The corner structure is pre-installed on the frame before the upholstery is applied. This preliminary action ensures that the structural support is already in place to properly distribute and support the upholstery material, preventing defects like wrinkling and overstretching before they occur during the upholstery installation process.
3Stability of the object's composition
If corner support is added to prevent sagging, then foundation stability is improved, but device complexity increases
Solution Approach 1:
The corner structure is segmented into modular components (base portion, vertical support portion, grid support deck) that can be independently manufactured and then assembled. This segmentation allows for simplified manufacturing of individual parts while achieving the combined effect of comprehensive corner support, balancing stability improvement with manageable structural complexity.
Solution Approach 2:
The corner structure serves multiple functions simultaneously: it provides vertical support to prevent sagging, reinforces the grid support deck, creates a rounded corner aesthetic, and provides attachment points for upholstery. This multi-functionality means that a single corner structure component addresses multiple stability and aesthetic requirements without requiring separate elements for each function, thereby limiting the increase in device complexity.
Data Source
AI summary
An internal corner structures for mattress foundations that sit at each corner between the frame and the grid. The rigid member contains a base, body and grid support deck. The base member sits atop the foundation frame and contains two flanges that overlap the frame and guide the positioning of the internal corner structure relative to the frame. The body structure supports the grid deck and has a rounded exterior profile to provide a rounded smooth contour to the mattress foundation corners, and has a plurality of square shaped openings that extend in both a vertical and horizontal direction. The grid support deck sits atop the body structure and provides support to the mattress foundation grid, and has engagement clips that engage and position the grid and an edge guard that functions to disperse a load and protect the engagement clips from impact.