Reverse Coil Head Innersprings for Stable Coil Interconnection
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Solution Overview
Problem
Existing mattress innerspring designs face challenges in achieving optimal interengagement and stability of coils, leading to potential leaning issues when compressed, which affects the overall performance and comfort of the mattress.
Innovation Solution
The design introduces a reverse coil head coil with offset terminal ends and a gradient arm, allowing for improved interconnection and stability through a lacing wire system, where the terminal ends are aligned on the same side of the coil body, enabling independent movement and adjusted spring rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal convolutions are designed to facilitate interengagement of spring coils, then interconnection stability is improved, but coil complexity increases
Solution Approach 1:
The patent applies asymmetry by designing the terminal convolution with an offset portion that is asymmetric relative to the coil axis. The offset portion includes a straight portion extending offset from the coil axis, creating an asymmetric geometry that facilitates interengagement with lacing wire while maintaining manufacturing feasibility. This asymmetric design improves interconnection stability without requiring complex multi-component assemblies.
2Loss of substance
If high tensile strength wire is used to minimize convolutions, then material usage is reduced, but manufacturing costs and equipment wear increase
Solution Approach 1:
The patent applies parameter changes by optimizing the wire gauge and tensile strength parameters to achieve a balance between material efficiency and manufacturing cost. Instead of using high tensile strength wire that minimizes convolutions, the patent uses standard gauge wire (e.g., 14-16 gauge) with moderate tensile strength, combined with an optimized convolution design that achieves the same performance. This parameter optimization reduces equipment wear and manufacturing costs while maintaining material efficiency.
3Stability of the object's composition
If terminal ends are positioned on opposite sides of the coil body, then structural balance is improved, but interengagement stability deteriorates
Solution Approach 1:
The patent applies inversion by reversing the conventional arrangement of terminal ends. Instead of positioning terminal ends on opposite sides of the coil body (conventional approach), the patent positions both terminal ends on the same side of the coil body. This inverted arrangement creates an asymmetric configuration that improves interengagement stability with lacing wire while the gradient arm provides the necessary structural balance and leans counter to the coil body.
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
This configuration enhances the stability and comfort of the mattress by minimizing leaning tendencies and allowing for easier assembly, while maintaining material efficiency and reducing manufacturing costs.
Implementation Method 1
A gradient arm is located between one terminal convolution and one of the plurality of convolutions
Implementation Method 2
a generally helical coil body with a plurality of turns of wire
Implementation Method 3
mattress innersprings, made of matrices or arrays of a plurality of wire form springs or coils
Data Source
AI summary
A reverse coil head coil and innerspring has a generally cylindrical and helical wire form coil body and opposing coil ends which terminate on opposite sides of a reference plane that passes through the coil body. The reverse coil head coils are interconnected in a matrix to form an innerspring wherein only one terminal end of each coil is located at a perimeter of the innerspring. Variations in the number and pitch of helical turns of the coil body are also disclosed.