Rectangular Border Wire Spring Assembly for Nestable Bedding Foundations
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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, which reduces material usage and shipping costs without compromising beam strength, by reshaping the wire from a circular to a rectangular cross-section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If round border wire is used, then the spring assembly can be manufactured with standard materials, but the shipping space requirements increase and costs rise
Solution Approach 1:
The patent applies asymmetry by changing the border wire cross-section from a symmetric circular shape to a rectangular shape. This rectangular configuration allows the spring assembly to be nested more efficiently during shipping, reducing the overall shipping volume while maintaining structural integrity and beam strength.
2Strength
If three-gauge wire is used, then beam strength is maintained, but material cost and weight increase
Solution Approach 1:
The patent applies parameter changes by transitioning from three-gauge round wire to four-gauge rectangular wire. The rectangular cross-section geometry compensates for the smaller wire gauge, maintaining the necessary beam strength while reducing the overall wire weight and material cost.
3Weight of stationary object
If four-gauge wire is used, then material cost is reduced, but beam strength decreases unless wire shape is changed
Solution Approach 1:
The patent applies composite materials by combining four-gauge wire with a rectangular cross-sectional geometry. This composite approach (material + shape) achieves the same beam strength as three-gauge round wire while using less material, thereby reducing both weight and cost.
4Quantity of substance
If smaller diameter wire is used, then material usage is reduced, but structural integrity may be compromised
Solution Approach 1:
The patent applies asymmetry by using a rectangular cross-section instead of a circular one. This asymmetric shape distribution optimizes the material layout to maintain structural integrity and beam strength while using less wire material overall.
Solution Approach 2:
The patent applies parameter changes by altering the wire cross-section geometry from circular to rectangular. This geometric parameter change allows smaller gauge wire to achieve the same structural performance, reducing material quantity while preserving reliability.
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 rectangular border wire configuration enables the use of less steel, reducing manufacturing costs and allowing for secure connections between support wires and the border wire, facilitating efficient stacking and shipping while maintaining structural integrity.
Implementation Method 1
The support wires are generally corrugated along their lengths, having a plurality of flattened peaks and a plurality of flattened valleys. The flattened peaks are generally co-planar with the plane defined by the border wire, and the flattened valleys are displaced beneath and intermediate of the peaks.
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.