Microalloyed Innerspring Coils for Mattress Durability Without Added Weight
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Solution Overview
Problem
Conventional innerspring cores in mattresses lose strength and durability due to repetitive stress cycles, requiring additional padding layers that increase bulk and weight, while alternative designs and materials have not effectively addressed these issues.
Innovation Solution
Innerspring cores utilizing high-carbon steel wire alloyed with elements like titanium and copper, combined with heat treatment processes, to create stronger and more durable coil springs that maintain performance over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional layers of padding are added to strengthen the innerspring core, then the durability and comfort of the mattress are improved, but the bulk and weight of the mattress assembly increase
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition of the steel wire through microalloying with titanium (0.005-0.050 wt%) and copper (0.100-0.300 wt%), along with controlled carbon content (0.550-0.990 wt%). This alters the material properties to achieve superior strength and durability without adding bulk or weight through additional padding layers.
Solution Approach 2:
The patent employs composite materials by creating a multi-element alloy system combining high-carbon steel with microamounts of titanium and copper. This composite alloy structure provides enhanced mechanical properties including tensile strength and fatigue resistance, allowing the spring to withstand repetitive stress cycles without requiring additional protective layers.
2Ease of manufacture
If conventional steel wire is used for coil springs, then the manufacturing process is simple, but the springs lose tensile strength and become weaker over time due to repetitive stress cycles
Solution Approach 1:
The patent modifies the chemical parameters of the steel wire by incorporating specific ranges of carbon (0.550-0.990 wt%), titanium (0.005-0.050 wt%), and copper (0.100-0.300 wt%). These parameter changes enhance the wire's tensile strength and fatigue resistance while maintaining manufacturability through conventional coil spring forming processes.
3Reliability
If the coil springs are made stronger through alternative designs, then the innerspring core durability is improved, but additional layers of padding are still required
Solution Approach 1:
The patent achieves enhanced innerspring core durability through parameter changes in the steel wire composition rather than through structural modifications. The microalloyed wire maintains the simple coil spring geometry while providing superior strength, eliminating the need for additional padding layers or complex multi-strand constructions.
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 microalloyed coil springs exhibit improved durability and resistance to compression cycles, maintaining a longer working life and reducing the need for additional padding layers, thereby enhancing mattress comfort and reducing weight.
Implementation Method 1
The steel wire may include one or more alloying elements such as titanium and copper and capable of imparting greater strength and durability to the innerspring core
Implementation Method 2
combined with heat treatment processes, to create stronger and more durable coil springs
Data Source
AI summary
The systems and methods described herein include innerspring assemblies or innerspring cores for use with cushioning articles such as mattresses. The innerspring core may have one or more coil springs formed from a high-carbon steel wire alloyed with one or more suitable alloying elements such as titanium and copper and capable of imparting greater strength and durability to the innerspring core.