Rectangular Border Wire Spring Core for Lower Steel Use
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Solution Overview
Problem
The high cost of manufacturing spring cores for mattresses is attributed to the expensive steel used for coil springs, with standard gauge wire requiring more material and having lower tensile strength than high tensile strength wire, leading to increased material usage and production costs.
Innovation Solution
The use of a seven-gauge wire with a rectangular cross-sectional configuration for border wires, maintaining the same beam strength as traditional six-gauge round wires, allows for reduced material usage and cost while providing a secure connection between spring end turns and the border wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If six-gauge round wire is used for border wires, then beam strength is maintained, but material cost and wire diameter are higher
Solution Approach 1:
The invention changes the cross-sectional geometry parameter of the border wire from circular to rectangular. This parameter change allows the use of seven-gauge wire (smaller diameter) instead of six-gauge wire while maintaining the same beam strength, thereby reducing material quantity and cost.
Solution Approach 2:
The invention transitions from a two-dimensional circular cross-section to a rectangular cross-section, utilizing the dimensional redistribution of material. The rectangular shape concentrates material more efficiently in the directions requiring strength, achieving equivalent beam strength with less total material.
2Quantity of substance
If seven-gauge wire is used instead of six-gauge wire, then material cost is reduced, but beam strength may be compromised unless cross-section is changed
Solution Approach 1:
The invention applies parameter changes by modifying the cross-sectional shape from circular to rectangular. This allows seven-gauge wire to achieve the same beam strength as six-gauge round wire, resolving the contradiction between material quantity and strength.
3Quantity of substance
If high tensile strength wire is used for coil springs, then less wire is needed and cost is reduced, but manufacturing complexity increases
Solution Approach 1:
The invention changes the material parameter from standard tensile strength wire to high tensile strength wire (greater than 265,000 psi). This parameter change reduces the quantity of wire needed for each coil spring while the patent addresses the manufacturing challenge through specific process modifications.
Data Source
AI summary
A bedding or seating product comprising a spring core including upper and lower border wires. Each of the border wires is generally rectangular in cross-section to reduce wire costs without compromising beam strength of the border wire. Each row of springs of the spring core may be made of a single piece of wire. The rows of springs may be arranged in side-by-side rows and columns and be connected with each other by helical lacing wires.