A spring element for mattresses and a method for making a spring element for mattresses
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Solution Overview
Problem
Existing mattress spring elements with coaxial double springs suffer from bending and noise issues due to length differences during compression, leading to discomfort and noise for users.
Innovation Solution
A spring element design featuring a first and second helical spring connected as a single piece with a deformable, tubular casing to maintain coaxial alignment and reduce noise, where the second spring is more rigid and nested inside the first, with a low-friction casing made from non-woven fabric to prevent excessive offset and facilitate smooth movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a first outer spring with greater length and lesser rigidity and a second inner spring with shorter length and greater rigidity are used to provide gradual compliance, then the comfort for the user is improved, but the coaxial alignment is lost during compression causing bending and noise
Solution Approach 1:
The second spring is nested inside the first spring, with both springs sharing a common longitudinal axis. The casing envelops both springs to maintain their nested configuration and prevent lateral displacement during compression, ensuring they remain coaxial and eliminating bending and noise issues.
Solution Approach 2:
A deformable, tubular casing is introduced to envelop both springs. This casing allows axial compression while constraining lateral movement, maintaining coaxial alignment between the two springs during compression and preventing the bending and noise problems that occur without such约束.
2Strength
If the second spring has smaller diameter coils closer together to increase rigidity, then the rigidity is improved, but the difference in length causes bending during compression
Solution Approach 1:
The second spring is nested inside the first spring, with both springs sharing a common longitudinal axis. The casing envelops both springs to maintain their nested configuration and prevent lateral displacement during compression, ensuring they remain coaxial and eliminating bending and noise issues.
Solution Approach 2:
A deformable, tubular casing is introduced to envelop both springs. This casing allows axial compression while constraining lateral movement, maintaining coaxial alignment between the two springs during compression and preventing the bending and noise problems that occur without such约束.
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 provides a silent and comfortable mattress experience by minimizing noise and maintaining coaxial alignment of springs, enhancing the overall performance and reducing manufacturing costs.
Implementation Method 1
a deformable, tubular casing to maintain coaxial alignment and reduce noise, where the second spring is more rigid and nested inside the first, with a low-friction casing made from non-woven fabric to prevent excessive offset and facilitate smooth movement
Data Source
Figure 1~2c
AI summary
Described is a spring element for mattresses, comprising a first helical spring (2) extending along a longitudinal axis (A) between its first end (2a) and its second end (2b), and a second helical spring (4) extending inside the first spring (2) along the longitudinal axis (A) between its first end (4a), proximal to the first end (2a) of the first spring (2), and its second end (4b) located at a predetermined axial distance from the second end (2b) of the first spring (2). The spring element also comprises a casing 5 which is deformable and at least partly tubular positioned around the first spring (2) to form a chamber (6) for containing the first (2) and the second spring (4), wherein the casing (5) has at least one neck (7) interposed between the second end (4b) of the second spring (4) and the second end (2b) of the first spring (2) for separating the chamber (6) into a first compartment (6a), containing a portion (8a) of the first spring (2) and the second spring (4), and a second compartment (6b), containing an end portion (8b) of the first spring 2.