Rectangular Border Wire Bedding Foundation for Nestable Shipping
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Solution Overview
Problem
Existing bedding foundations with round border wires are bulky and costly to ship due to space requirements, and using smaller diameter wires to reduce material while maintaining beam strength has not been effectively achieved.
Innovation Solution
A bedding foundation with a nestably stackable spring assembly featuring a rectangular border wire configuration, allowing for the use of a four-gauge wire instead of a three-gauge wire without compromising beam strength, enabling cost savings through reduced material usage and secure mounting of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a smaller diameter wire (four-gauge) is used to reduce material cost, then wire material cost decreases, but beam strength is compromised
Solution Approach 1:
The patent changes the cross-sectional geometry parameter of the border wire from circular to rectangular. This allows using a smaller diameter wire (four-gauge instead of three-gauge) while maintaining the same beam strength through the rectangular cross-section configuration, thereby reducing material cost without compromising structural integrity
Solution Approach 2:
The patent creates a composite structural configuration by combining the rectangular cross-section border wire with the nestably stackable spring assembly. This composite structure achieves both cost reduction through smaller wire gauge and maintains required strength through the optimized rectangular geometry and nesting arrangement
2Volume of moving object
If the spring assembly is compressed to reduce shipping space, then space requirements decrease, but additional pressing and tying operations are required
Solution Approach 1:
The patent implements a nestably stackable spring assembly where multiple assemblies can be nested within each other for shipping. This nesting capability reduces shipping volume without requiring compression presses or tying operations, thereby reducing both space requirements and manufacturing process complexity
Solution Approach 2:
The patent divides the bedding foundation into separate components (base and spring assembly) that can be manufactured independently and shipped separately. The spring assembly is designed as a discrete, self-contained unit with a rectangular border wire configuration that enables stable nesting without additional fastening operations
3Ease of manufacture
If the border wire has a round cross-section, then manufacturing is simpler, but larger diameter wire (three-gauge) is required which increases material cost
Solution Approach 1:
The patent changes the cross-sectional shape parameter from circular to rectangular, allowing the use of smaller gauge wire (four-gauge) that costs less material while providing equivalent or superior beam strength for the same weight, thereby reducing material cost without significantly complicating manufacturing
Data Source
AI summary
A bedding foundation having a nestably stackable spring assembly including a border wire having a generally rectangular cross-section. The foundation's spring assembly may be nestably stacked with numerous other such assemblies for transportation, thereby avoiding the need to compress and tie the assembly for shipping. Each foundation assembly includes a number of corrugated support wires having alternating peaks and valleys. The border wire is generally rectangular in cross-section to reduce wire costs without compromising beam strength of the border wire.