Sheet Spring Mattress Assembly for Dynamic Load Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing leaf spring assemblies face challenges in accurately 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 well addressed by current technologies.
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 carrying mechanics, similar to coil springs but with improved dynamic response.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional leaf springs are used with lacing wires and border wires, then structural stability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent removes the complex lacing wires, border wires, and fabric restraining elements from the leaf spring assembly. The leaf springs are allowed to function independently without these additional components, simplifying the overall structure while maintaining structural stability through the inherent design of the stacked spring configuration.
Solution Approach 2:
The patent divides the mattress support system into multiple independent leaf spring units stacked in a staggered arrangement. Each spring operates independently, and the segmented structure provides stability without requiring connecting wires or border elements, thus reducing device complexity.
2Force
If dense array of springs is created by stacking multiple sheet members, then load carrying capacity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent pre-forms individual leaf springs with predetermined shapes and curvature before stacking. Each spring is prepared in advance with the correct geometry for its specific position in the staggered array, allowing for simplified assembly by simply stacking the pre-prepared components rather than assembling complex interconnected structures.
Solution Approach 2:
The patent stacks multiple sheet members with springs in a nested configuration where springs from different sheets interlock in a staggered pattern. This nesting arrangement creates a dense spring array with enhanced load capacity while maintaining manufacturing simplicity through modular assembly of standardized components.
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 for both static and dynamic loads, mimicking the response of coil springs while offering a more cost-effective and simpler manufacturing process, with adjustable spring characteristics and firmness through varying shapes and materials.
Implementation Method 1
Each spring in the array may be manufactured by choosing a position for the spring in a rigid sheet, cutting a profile of the sheet spring in the rigid sheet, peeling back or bending the profile or tab of the sheet, and shaping the profile to form the sheet spring
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.