Nestable Bedding Spring Assembly for Reduced Sway Shipping
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Solution Overview
Problem
Existing bedding foundations with nestably stackable spring assemblies face challenges in stability during shipping and assembly, leading to increased costs due to compression and tying requirements, which compromise their structural integrity and stability.
Innovation Solution
A bedding foundation design featuring a nestably stackable spring assembly with a rectangular border wire and additional stabilizer wires, where the support and connector wires are corrugated and secured to each other, allowing for efficient stacking and reduced height during shipping, while maintaining stability through the unique configuration of flattened peaks and valleys.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If compression and tying operations are applied to reduce space requirements, then shipping space efficiency is improved, but manufacturing cost increases and structural integrity is compromised
Solution Approach 1:
The spring assembly is divided into modular units with standardized dimensions that can be nested within each other. Each module contains complete functional elements (border wire, support wires, connector wires, stabilizer wires) that maintain structural integrity independently, allowing segmentation without compromising overall strength or requiring complex compression/tying operations.
Solution Approach 2:
Multiple spring assembly modules are designed to nest within each other in a hierarchical arrangement. The corrugated support wires create peaks and valleys that allow adjacent modules to interlock and nest efficiently, reducing total volume for shipping while maintaining structural integrity without compression or tying.
2Stability of the object's composition
If additional wires are added to increase stability, then foundation stability is improved, but device complexity increases
Solution Approach 1:
Each wire type in the assembly performs multiple functions simultaneously. For example, support wires provide both structural support and nesting geometry; connector wires join multiple components while maintaining flexibility; stabilizer wires prevent sway while allowing controlled movement. This multi-functionality reduces the need for additional specialized components, maintaining stability without proportionally increasing complexity.
Solution Approach 2:
The wire assembly incorporates controlled flexibility and movement capabilities. The corrugated geometry of support wires allows elastic deformation under load while maintaining overall structural stability. Connector wires and stabilizer wires are positioned to allow dynamic adjustment during use, providing stability when needed while accommodating natural movement, thereby achieving high stability without excessive structural complexity.
3Length of moving object
If compression is applied to reduce individual thickness, then shipping efficiency is improved, but structural integrity is compromised
Solution Approach 1:
The spring assembly modules are pre-configured with corrugated support wires and positioned stabilizer wires that create an inherent nesting geometry before shipping. This preliminary arrangement allows modules to stack and nest efficiently without requiring compression during shipping, maintaining structural integrity while achieving compact dimensions through intelligent geometric design rather than forceful compression.
Data Source
AI summary
A bedding foundation having a nestably stackable spring assembly, including a border wire. The foundation's spring assembly may be nestably stacked with numerous other such assemblies for transportation, thereby avoiding the need to compress and tie the assembly for shipping. Each spring assembly includes support wires having alternating peaks and valleys along with stabilizer wires having alternating peaks and valleys. The valleys of the stabilizer wires are secured to the valleys of the support wires. The peaks of the stabilizer wires are secured to longitudinal wires extending parallel the sides of the border wire.