Radial Plastic Spring Element for Stable Mattress Support
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Solution Overview
Problem
Existing spring elements for mattresses lack a stable and symmetrical design that prevents overlapping during manufacturing and provides optimal spring properties, leading to inefficiencies in production and performance.
Innovation Solution
The spring element features radially extending arms with inward and outward sections that form a separate cover plate, creating a symmetrical and stable support surface, with the inward ends connecting to form a non-overlapping, one-piece design made of plastic, allowing for easy removal from molds and enhancing spring properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spring arms are designed to extend radially outwards and back inwards without overlapping, then manufacturing ease and mold removal are improved, but structural complexity increases due to the need for symmetrical non-overlapping configuration
Solution Approach 1:
The spring body is divided into multiple spring arms that are configured to extend radially outwards and back inwards without overlapping. This segmentation allows each arm to be independently formed in the mold and facilitates easy removal while maintaining structural integrity
Solution Approach 2:
The spring arms are designed with asymmetrical positioning where they extend radially outwards and then curve back inwards at different angles and positions, ensuring they do not overlap when viewed in the spring direction. This asymmetrical configuration enables easy mold removal while creating a stable support surface
2Manufacturing precision
If cover plates are made separate from other spring arms, then manufacturing precision and stability are improved, but device complexity increases due to additional separate components
Solution Approach 1:
The cover plates are formed as separate sections from the spring arms, allowing each cover plate to be precisely formed and positioned. This segmentation enables better control over the upper support surface geometry while maintaining a relatively simple overall structure
Solution Approach 2:
The separate cover plates serve multiple functions: they form the upper support surface, provide structural stability, and can be configured to work with the spring arms to distribute loads. This multi-functionality reduces the need for additional separate components
Data Source
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AI summary
The element has a spring body (3) connecting a lower supporting surface (1) with an upper supporting surface (2). The spring body has spring arms (4), which are outwardly guided away from the lower supporting surface and guided back inwardly, when viewing in a spring direction (I). The two spring arms are connected with each other at a radially outside lying end (5) and run radially inward with a common section (6). The two spring arms form a circular, circle or oval shaped bend together up to a connection point, where the spring element is made of plastic.