Segmented Mattress Spring Arms for Off-Centre Load Stability
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Solution Overview
Problem
Existing mattress springs with one-piece designs face challenges in manufacturing complexity and lateral stability, particularly under off-centre vertical loads, due to their tapered shape.
Innovation Solution
The use of separate, preformed spring arms with support lugs on the inner sides of bearing surfaces provides improved stability and flexibility, allowing for varied designs with enhanced spring behavior by ensuring constant contact and immediate reaction force even under deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate spring arms are used instead of a one-piece design, then manufacturing complexity is reduced and design flexibility is increased, but structural cohesion and load distribution may be compromised
Solution Approach 1:
The spring element is divided into multiple separate spring arms (typically four) that are clipped onto the bearing shells. Each spring arm is an independent component that can be manufactured separately using simple tools, then assembled onto the bearing structure. This segmentation reduces manufacturing complexity while maintaining structural integrity through the bearing shell connection points.
2Speed
If spring arms are arranged laterally on bearing shells, then response time is improved by eliminating idle stroke, but bearing shells must rotate about axes before spring arms can provide full reaction force
Solution Approach 1:
The spring arms are pre-positioned in a laterally arranged configuration around the bearing shells, ready to engage immediately when load is applied. The support lugs are pre-formed on the spring arms to contact the bearing surfaces, eliminating the need for initial rotation or adjustment. This preliminary positioning ensures immediate response without idle stroke while the bearing shells simply rotate on their fixed axes.
3Reliability
If support lugs are provided on spring arms, then idle stroke is eliminated and reaction force is provided immediately, but manufacturing precision requirements increase
Solution Approach 1:
The support lugs are provided only at specific locations on the spring arms where they contact the bearing surfaces, rather than requiring the entire spring arm to be precisely formed. This localized feature approach allows the majority of the spring arm to be manufactured with standard tolerances, while only the small support lug contact areas require precise positioning to ensure proper engagement with the bearing surfaces.
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
This design enhances the spring's response to both central and off-centre loads, preventing idle travel and providing consistent reaction force, thus improving the overall spring behavior and manufacturing simplicity.
Implementation Method 1
the elastic plastic material of the spring arms can be loaded optimally and evenly
Data Source
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AI summary
The mattress spring has curved arms (3) which are mounted between upper and lower support plates (2). Clips (5) on the ends of the arms fit over mounting bars (4) on the plates and flexible plates (7) on the opposite side support the arms against their surface.