Sheet Spring Array Mattress Assembly for Simplified Load Modeling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing leaf spring assemblies for cushioning articles, such as mattresses, face challenges in modeling and improving load mechanics, particularly for moving loads, due to complex dynamic responses and the restraining effects of lacing wires, border wires, and fabric, which are not accurately captured by current equations or models.
Innovation Solution
The development of a mattress assembly with an array of springs formed from metallic rigid sheets, where springs are created by cutting and bending sections of the sheet to form a dense array, allowing for staggered alignment and stacking of sheet members to enhance load mechanics, similar to coil springs but with improved dynamic response.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If leaf springs are used in a matrix arrangement, then the cushioning article provides load support, but the dynamic response and load mechanics are difficult to model accurately due to complex interactions with restraining elements
Solution Approach 1:
The leaf spring assembly is segmented into discrete springs arranged in a matrix, with each spring independently supported by the rigid sheet. This segmentation allows for simplified analysis of individual spring behavior while maintaining overall load support functionality, reducing the complexity of modeling dynamic responses compared to continuous leaf spring systems
Solution Approach 2:
A rigid sheet is introduced as an intermediary element between the leaf springs and the support structure. This rigid sheet provides a stable foundation that simplifies the boundary conditions for spring analysis, eliminating the need to model complex interactions with flexible restraining elements while maintaining load support reliability
2Stability of the object's composition
If lacing wires, border wires, and fabric are used to restrain leaf springs, then the assembly maintains structural integrity, but the restraining effects complicate the dynamic response and make accurate modeling challenging
Solution Approach 1:
The complex restraining elements (lacing wires, border wires, fabric) are extracted from the model and replaced with a simplified rigid sheet support structure. This extraction eliminates the difficult-to-model interactions while maintaining the essential function of providing structural integrity and stable boundary conditions for the leaf springs
3Quantity of substance
If a dense array of springs is formed from stacked sheet members, then load distribution is improved, but the manufacturing process becomes more complex
Solution Approach 1:
Multiple sheet members are merged into a single integrated structure where the rigid sheet provides both the support base and the spring elements. This combining of functions allows for formation of dense spring arrays through stacking and bonding processes, achieving high spring density while maintaining manufacturing feasibility through unified structure creation
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 approach provides improved load mechanics and dynamic response comparable to coil springs, with springs that compress and yield effectively under both downward and transverse loads, offering a more accurate and efficient method for load distribution and support.
Implementation Method 1
springs that compress and yield effectively under both downward and transverse loads
Data Source
AI summary
The mattress assemblies have an array of springs extending from a sheet. Each spring in the array may be manufactured by choosing a position for the spring, cutting a profile of the sheet spring in the sheet, peeling back or bending the profile or tab of the sheet, and shaping the profile to form the sheet spring. The array of springs may be formed from creating a plurality of such springs along rows and columns. In certain embodiments, multiple sheets may be stacked to form the sheet spring array.