Reinforced Spring Core Edges Without Metal Frame Reinforcement
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Solution Overview
Problem
Existing spring cores with metal edge reinforcement are labor-intensive and costly to produce, leading to high transport costs due to their large volume and low weight, which hinders cost optimization, especially when produced in large numbers.
Innovation Solution
A spring core design where opposite edge springs are connected to two adjacent springs, forming a nested arrangement within the spring strand gaps, with thicker wire and enhanced material properties to achieve improved edge stability and hardness, allowing for simpler and cost-effective production while maintaining edge reinforcement functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a metal frame edge reinforcement is used, then edge stability is improved, but production cost and labor intensity increase significantly
Solution Approach 1:
The patent changes the material parameters by using wire of greater thickness (6-10 mm) for edge springs compared to regular springs (4-6 mm), and modifies the spring geometry with fewer coils (3-5 coils) versus regular springs (5-7 coils). These parameter changes create sufficient edge stability without requiring a complex metal frame structure, thereby reducing production costs and labor intensity while maintaining the required edge reinforcement function.
Solution Approach 2:
The patent replaces the expensive and labor-intensive metal frame reinforcement with a simpler, more economical spring configuration using standard pocket spring materials and construction methods. This substitution uses cheaper components (regular wire thickness and standard spring designs) that achieve the same functional outcome without the high production costs associated with metal frame assembly.
2Stability of the object's composition
If a metal frame edge reinforcement is used, then edge stability is improved, but transport cost increases due to large volume and low weight
Solution Approach 1:
By modifying spring parameters (wire thickness, coil count, spring geometry) rather than adding a bulky metal frame, the patent achieves edge stability with a more compact structure. This reduces the overall volume of the spring core, thereby lowering transport costs while maintaining the required structural integrity and edge reinforcement.
3Ease of manufacture
If simpler production methods are used, then production cost is reduced, but edge reinforcement hardness may be compromised
Solution Approach 1:
The patent carefully selects specific parameter ranges that balance manufacturability with performance: wire thickness of 6-10 mm provides sufficient hardness and structural integrity, while 3-5 coils maintains edge stability. These parameters are chosen to achieve the required edge reinforcement hardness through standard production methods without compromising strength, thus reducing production costs while maintaining performance.
Solution Approach 2:
The patent applies different spring configurations to different locations: edge springs have greater wire thickness and fewer coils to provide localized hardness and structural support where needed, while regular springs have standard specifications for comfort. This local differentiation ensures edge reinforcement hardness is maintained in critical areas while allowing simpler, more cost-effective production overall.
Data Source
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AI summary
A spring core with a large number of spirally wound springs (3, 4) arranged next to one another with parallel axes, several of which are arranged one behind the other in a row and form a strand of springs (1, 2), and an edge reinforcement is designed in such a way that the edge reinforcement is attached to at least two opposite edges of the spring core is formed by springs (3), which are each connected to two springs (4) of the adjacent spring strand (1).