Nestable Wire Core Bedding Foundation for Compact Shipping
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Solution Overview
Problem
Traditional box spring assemblies are bulky for shipping, requiring expensive presses and ties to compress them, and additional handling costs at the delivery end, where ties must be cut and discarded before applying covering.
Innovation Solution
A nestably stackable wire core bedding foundation with corrugated support wires featuring inverted U-shaped channels that wrap around slats of a base frame, providing increased compressive strength and eliminating the need for staples or additional securing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional coil or bent wire spring modules are used with spaced border wires, then the bedding foundation provides adequate support, but the assemblies become bulky for shipping requiring expensive presses and ties to compress them
Solution Approach 1:
The support wires are formed 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 tight nesting during shipping while maintaining structural integrity and compressive support capabilities.
Solution Approach 2:
The support wires are corrugatedly formed with curved peaks and valleys along their lengths. This curvature allows the wires to flex and adapt during nesting while maintaining their load-bearing capacity, providing compressive support without requiring additional compression equipment.
2Volume of moving object
If assemblies are compressed and tied to reduce shipping space, then shipping efficiency improves, but additional material and handling costs increase at the delivery end
Solution Approach 1:
The design enables self-nesting of assemblies without requiring external tying mechanisms. The corrugated support wires naturally interlock during stacking, eliminating the need for expensive presses and ties while reducing material costs and simplifying the manufacturing process.
3Stability of the object's composition
If ties are used to secure compressed assemblies, then shipping stability improves, but additional handling operations are required at delivery end
Solution Approach 1:
The nested configuration of peaks and valleys provides inherent stability during shipping without requiring additional tying operations. The interlocking structure maintains assembly integrity while allowing rapid loading and unloading at the delivery end, improving productivity.
4Volume of moving object
If simple wire cores are used for nesting, then shipping efficiency improves, but compressive load strength is insufficient
Solution Approach 1:
The corrugated support wires with curved peaks and valleys provide structural strength to handle compressive loads while enabling nesting. The geometry of the corrugations distributes forces effectively, maintaining load-bearing capacity without requiring additional reinforcement that would prevent nesting.
Solution Approach 2:
The combination of border wires, corrugated support wires, and connector wires creates a composite structure that provides both nesting capability and compressive strength. The interconnected wire elements work together to distribute and withstand forces while maintaining the nested configuration.
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 corrugated formed support wires having inverted U-shaped channels formed at the bottom of the corrugated formed support wires adapted to be wrapped over and secured to slats of a wooden base frame.