One-Piece Plastic Spring Core for High-Load Mattress Support
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Solution Overview
Problem
Existing plastic spring elements for pocket spring mattresses are expensive to assemble and can be damaged under high loads, limiting their mobility and spring effect.
Innovation Solution
A one-piece plastic spring core element with a molded spring body consisting of four separately aligned spring elements in an X-shape between a support plate and a base plate, providing direction-independent force distribution and independent spring action, along with a honeycomb structure and cross-shaped indentations for connecting straps to enhance mobility and stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If plastic spring elements are used instead of metal spring elements, then advantages such as corrosion resistance and design flexibility are achieved, but assembly complexity and cost increase due to multiple parts
Solution Approach 1:
The patent combines multiple separate plastic parts (upper plate, lower plate, and spring element) into a single integrally molded spring core element. This eliminates the need for assembly of multiple components while maintaining the plastic material advantages, directly resolving the contradiction between design flexibility and assembly complexity.
2Adaptability or versatility
If plastic spring elements are used instead of metal spring elements, then advantages such as corrosion resistance and design flexibility are achieved, but assembly time and cost increase due to multiple parts
Solution Approach 1:
The patent combines multiple separate plastic parts (upper plate, lower plate, and spring element) into a single integrally molded spring core element. This eliminates the need for assembly of multiple components while maintaining the plastic material advantages, directly resolving the contradiction between design flexibility and assembly complexity.
3Stability of the object's composition
If spring elements are connected through a web in the center, then structural stability is improved, but direction-independent spring effect and mobility are impaired
Solution Approach 1:
The patent segments the spring core element into four separate spring elements arranged in an X-shape, each independently connected to the upper and lower plates at their outer ends. This segmentation allows each spring element to move independently, providing direction-independent spring effect while maintaining structural stability through the distributed X-shaped arrangement.
4Adaptability or versatility
If spring elements are arranged in an X-shape configuration, then direction-independent force distribution is achieved, but structural complexity increases
Solution Approach 1:
The patent employs an X-shaped arrangement of four spring elements, which is an asymmetric configuration that naturally distributes forces from multiple directions. This asymmetric layout achieves direction-independent force distribution while the integrally molded construction keeps the overall structural complexity manageable.
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
Enables immediate use without assembly, maintains spring effect under high loads, and allows for adjustable hardness and increased mobility through independent spring action and reinforced corner edges.
Implementation Method 1
a spring body being arranged between the support plate and the base plate
Data Source
Figure 1
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AI summary
The element (1) has a spring body (4) arranged between a supporting disk (2) and a base plate (3), where the element is made of a single-piece plastic mold part. The spring body includes two spring elements that are integrated and aligned as X-shaped with respect to a central axis (6) of the element. A semi-circular tilting safety system (7) is formed at angle areas of the spring elements directed to the central axis. Cross-like recesses (9.1-9.4) are provided in an outwardly directed surface of the disk and the base plate for retaining and/or attaching connection straps.