Progressive Spring Coils for Weight-Adaptive Mattress Support
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Solution Overview
Problem
Traditional spring mattresses provide uneven cushioning support for users of different weights due to linear spring rates, leading to discomfort for lighter users and excessive compression for heavier users, making it challenging to find a mattress suitable for a wide range of users.
Innovation Solution
The implementation of progressive spring coils with multiple spring portions having different spring rates, including linear and non-linear rates, to create a three-phased load deflection response curve, ensuring consistent comfort across varying user weights by using asymmetrical progressive spring coils with conical, cylindrical, or hyperbolic shapes and varying pitches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional linear spring rates are used, then the spring structure is simple and easy to manufacture, but the cushioning support is uneven for users of different weights
Solution Approach 1:
The spring is divided into multiple segments or zones with different spring rates. Specifically, the spring includes a first portion with a first spring rate and a second portion with a second spring rate, where the spring rates differ to provide progressive support. This segmentation allows the spring to adapt to different weight ranges while maintaining a relatively simple overall structure.
Solution Approach 2:
Different portions of the spring are assigned different local properties (spring rates) to optimize performance for specific weight ranges. The first portion has one spring rate characteristic while the second portion has another, allowing each local region to contribute differently to the overall cushioning support based on the applied load.
2Adaptability or versatility
If non-linear springs with significant compression are used, then comfort for light and heavy users can be similar, but the compression may be excessive and unsuitable for bed life
Solution Approach 1:
The spring employs a dynamic spring rate that changes based on the compression level. The progressive spring rate design allows the spring to be softer initially for light users and progressively firmer as compression increases, without requiring excessive overall compression. This dynamic characteristic maintains comfort consistency while preserving bed life.
Solution Approach 2:
The spring's physical parameters (spring rate) are changed progressively through its compression range. By designing different portions with different spring rates, the spring achieves parameter changes that provide consistent comfort across weight ranges while avoiding excessive compression that would compromise durability.
3Adaptability or versatility
If progressive spring coils with multiple portions are used, then comfort consistency is achieved, but the manufacturing complexity increases
Solution Approach 1:
The progressive spring coil is manufactured by dividing the spring into distinct portions or sections, each with specified spring rate characteristics. This segmentation approach allows for standardized manufacturing processes for each portion while achieving the complex progressive performance through their combination.
Solution Approach 2:
The manufacturing process assigns different local qualities (spring rates) to different portions of the spring coil. By controlling the wire diameter, coil diameter, or pitch in specific local regions during fabrication, the desired progressive spring rates are achieved without requiring entirely new manufacturing methods.
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 progressive spring coils provide a consistent level of firmness for users of different weights, offering initial softness for lighter users and sufficient firmness for heavier users, while maintaining durability and preventing coil interaction, thus enhancing comfort and support in innerspring assemblies like mattresses.
Implementation Method 1
a first spring portion comprising a top end and a bottom end and having a first spring rate... a second spring portion comprising a top end and a bottom end and having a second spring rate... a third spring portion disposed between the first spring portion and the second spring portion, wherein the third spring portion has a third spring rate
Data Source
AI summary
A progressive spring coil comprises a first spring portion comprising a top end and a bottom end and having a first spring rate, wherein the first spring rate is substantially linear or substantially nonlinear; a second spring portion comprising a top end and a bottom end and having a second spring rate, wherein the second spring rate is substantially linear or substantially nonlinear; and a third spring portion disposed between the first spring portion and the second spring portion, wherein the third spring portion has a third spring rate, wherein the third spring rate is substantially linear or substantially nonlinear.