Ready-to-assemble mattress foundations
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Solution Overview
Problem
Existing ready-to-assemble mattress foundations require manual stabilization of legs during assembly, which can be cumbersome and does not allow for easy adjustment or retrofitting to change the appearance or height of the foundation.
Innovation Solution
A ready-to-assemble mattress foundation design featuring corner connector assemblies with pins having internal and external threads, and central support assemblies with internal threads, allowing for easy attachment and detachment of legs without manual stabilization, enabling adjustable height and aesthetic flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual stabilization of legs is required during assembly, then the leg positioning can be precisely controlled, but the assembly process becomes cumbersome and time-consuming
Solution Approach 1:
The corner brackets are designed with integrated finger structures that automatically engage with the legs during assembly. The fingers provide mechanical guidance and stabilization without requiring manual intervention, allowing the assembly process to be self-servicing while maintaining precise leg positioning.
Solution Approach 2:
The finger structures on the corner brackets act as intermediary elements between the legs and the corner connectors. These fingers provide the necessary mechanical interface for automatic engagement and positioning, eliminating the need for direct manual stabilization while ensuring accurate leg placement.
2Stability of the object's composition
If the mattress foundation is designed as a fixed structure, then the structural integrity is maintained, but the ability to adjust height or appearance is limited
Solution Approach 1:
The corner connector assembly is designed with detachable components including the pin and fastener system, allowing the structure to transition from a fixed state during assembly to a configurable state for height adjustment. The dynamic design enables users to add or remove legs and adjust their positions while maintaining structural integrity through the robust finger engagement mechanism.
Solution Approach 2:
The corner connector is divided into separate functional components: corner brackets with integrated fingers, a pin for alignment, and a fastener for retention. This segmentation allows individual components to be assembled and disassembled independently, enabling height adjustment and aesthetic customization while preserving the overall structural integrity of the mattress foundation.
3Reliability
If corner brackets with keyed surfaces and hollow pins are used, then the leg positioning is secured, but the assembly requires multiple components and steps
Solution Approach 1:
The corner bracket design merges the positioning finger structures directly into the bracket body, eliminating the need for separate positioning components. The pin and fastener work together as an integrated retention system, reducing the total number of discrete parts while maintaining reliable leg securing through the combined action of finger engagement and threaded fastening.
Data Source
AI summary
A ready-to-assemble mattress foundation including a plurality of rails forming a mattress foundation having a plurality of corners. The mattress foundation includes a plurality of corner connector assemblies coupling the rails together at the corners. Each of the corner connector assemblies includes a first corner bracket; a second corner bracket; a pin including internal threads and external threads; and a fastener threadably engaging the external threads of the pin to retain the pin relative to the corner brackets. The pin extends through the first apertures and the second apertures. The mattress foundation includes a plurality of central support assemblies coupled to one or more of the rails. Each of the central support assemblies includes a body having internal threads. The mattress foundation includes a plurality of legs each including a threaded rod and threadably received within the internal threads of the pin and the central support assemblies.