Segmented Mattress Spring Element for Independent Deflection

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Solution Overview

Problem

Existing spring elements for mattresses lack optimal support with high production costs, as they often require separate support for each spring element and do not allow for independent deflection of outer parts, limiting the resolution and increasing manufacturing expenses.

Innovation Solution

A spring element design where outer parts are supported by their own springs and connected to a central part via webs, allowing independent deflection and reducing manufacturing costs by eliminating separate support for the central part, with options for various configurations such as four outer parts connected to a single central part via symmetric webs or angled springs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional spring elements are used with a single support structure, then manufacturing costs are reduced, but the support resolution and independent deflection capability are insufficient

Engineering Contradiction:

Improvesupport resolutionVSAvoidstructure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The top plate is segmented into a central part and multiple outer parts (e.g., four outer parts), each capable of independent deflection. Each outer part is connected to the central part via separate connecting parts (webs), allowing independent movement while maintaining structural unity. This segmentation enables higher support resolution without requiring completely separate spring elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The outer parts and central part are formed as a single integrated top plate structure, reducing manufacturing complexity compared to using completely separate components. The connecting parts (webs) are integrated into the top plate, eliminating the need for separate fasteners or attachment mechanisms while still allowing independent deflection of outer parts.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If separate support structures are provided for each spring element, then independent deflection is improved, but manufacturing costs increase

Engineering Contradiction:

Improveindependent deflection capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Each outer part has its own connecting parts (webs) and spring connection, enabling independent deflection similar to separate spring elements. However, the outer parts remain integrated with the central part through these connecting parts, reducing manufacturing complexity and cost compared to completely separate components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The central part serves multiple functions: it provides structural support, connects all outer parts, and acts as a common mounting surface for spring attachment. This multi-functionality reduces the need for additional components and simplifies manufacturing while maintaining independent deflection capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Stability of the object's composition

If the central part is separately supported, then structural stability is improved, but material usage and production costs increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidmaterial usage

Core Design Contradiction:

Stability of the object's compositionVSLoss of substance

Solution Approach 1:

The central part and outer parts are merged into a single integrated top plate structure with connecting parts (webs) that provide both support and flexibility. This eliminates the need for separate central part support structures, reducing material usage while maintaining stability through the integrated design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connecting parts (webs) act as flexible connections that provide structural support while using minimal material. These thin web structures allow the central part to remain stable while reducing overall material consumption compared to rigid separate support structures.

Inventive Principle:

Principle #30Flexible shells and thin films

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 design enhances the support resolution of base mattresses by enabling independent deflection of outer parts, reducing production costs through reduced material usage and eliminating separate support for the central part, while maintaining effective mobility and support characteristics.

Implementation Method 1

a spring body (3) elastically supporting the top plate (2) in relation to the foot (1)

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP2227988B1Spring element for a spring core mattress or a mattress base

Publication Date: 2014.01.01 DIEMER & DR JASPERT GBR

Figure 1a~1b
Figure 2a~2b
Figure 3a~3b

AI summary

The spring element has a spring body for elastically supporting a head plate (2) with respect to a base, where the head part has a central part (4) and two external parts (5). Connecting parts (6) e.g. bars, connect the external parts with the central part such that the external parts are lowered with respect to the central part perpendicular to a plane of the head plate. Springs support the external parts at the base, where the external parts are associated with the connecting parts. The connecting parts are symmetrically arranged.