Nestable Wire Core Bedding Foundation With Resilient Support Wires
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Solution Overview
Problem
Traditional box spring assemblies are bulky, costly to ship, and lack resiliency, while existing nestably stackable bedding foundations offer reduced shipping costs but minimal spring back.
Innovation Solution
A bedding foundation with a nestably stackable wire core assembly featuring resilient support wires with flattened peaks and valleys, and helically shaped arms that provide compressive strength and resiliency, allowing for increased load-bearing capacity and improved shipping efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coil or modular box springs are used, then the bedding foundation provides good resiliency and support, but it increases shipping space requirements and manufacturing costs
Solution Approach 1:
The support wires are configured with peaks and valleys that allow one bedding foundation assembly to be nested within another. The valleys of upper assemblies fit into the peaks of lower assemblies, enabling compact stacking and reducing shipping volume while maintaining the structural integrity and resiliency of individual units
2Volume of moving object
If box spring assemblies are compressed to reduce shipping space, then shipping volume is reduced, but expensive pressing equipment and additional operations are required
Solution Approach 1:
The support wires are pre-formed during manufacturing with a corrugated configuration containing peaks and valleys. This preliminary shaping allows the assemblies to be naturally compacted through stacking without requiring subsequent compression operations, eliminating the need for expensive pressing equipment and reducing manufacturing complexity
3Volume of moving object
If nestably stackable bedding foundation is used, then shipping costs are reduced, but the assembly has little resiliency or spring back
Solution Approach 1:
The support wires are designed with specific geometric parameters including peak-to-valley spacing, wire diameter, and corrugation depth that allow them to be pre-formed for nesting while retaining elastic properties. The material selection and wire configuration enable the structure to provide both compactability for shipping and resiliency for support functionality
4Strength
If traditional box spring assemblies are manufactured, then adequate support structure is provided, but manufacturing and shipping costs increase
Solution Approach 1:
The bedding foundation is segmented into modular units with standardized support wire configurations that can be manufactured independently and then assembled. This segmentation allows for simplified production processes, reduced manufacturing costs, and efficient stacking arrangements that maintain structural support while lowering overall system cost
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 solution enables efficient storage and shipment of bedding foundations while providing enhanced resiliency and compressive strength, meeting specific firmness requirements and reducing assembly costs.
Implementation Method 1
the support wires of foundation of the present invention have some resiliency or give due to their configuration
Implementation Method 2
the support wire valleys of the first assembly may enter into the voids between the peaks of the support wires of the second assembly
Data Source
AI summary
A stackable wire core assembly for a bedding foundation which may be nestably stacked with numerous other such assemblies for transportation, thereby avoiding the need to compress and tie the assembly for shipping. The wire core assembly includes an upper wire grid, including a border wire and support wires extending between the ends of the border wire. Each support wire has resilient portions extending downwardly from the plane of the upper wire grid, each resilient portion having a flat bottom adapted to be secured to a wooden base frame and curved arms extending upwardly from opposed ends of the flat bottom.