Skewed Wire Support Module for Multi-Directional Bedding Loads
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Solution Overview
Problem
Existing nestably stackable wire bedding foundations with support legs parallel or perpendicular to the wire grid assembly are inadequate in resisting forces from multiple directions, and they complicate efficient manufacturing, storage, and shipping.
Innovation Solution
The design of support modules with skewed predominantly straight support legs and specific wire configurations that connect to a wire grid assembly, providing four mounting points and allowing for easy stacking and attachment to a base structure, enhancing the foundation's ability to handle forces from multiple directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If support legs are oriented parallel or perpendicular to the wire grid assembly, then resistance to lateral or longitudinal forces is improved, but resistance to forces from multiple directions deteriorates
Solution Approach 1:
The support legs are positioned at asymmetric angles relative to the wire grid assembly, specifically with first and second support legs extending at an angle between 15-75 degrees from vertical, while third and fourth support legs extend at different angles. This asymmetric configuration allows the structure to resist forces from multiple directions effectively, rather than being optimized for only lateral or longitudinal forces.
2Productivity
If wire assemblies are made nestably stackable, then efficiency in warehousing and shipping is improved, but structural complexity increases
Solution Approach 1:
The wire assemblies are designed to be nestably stackable, where portions of the upper wire assembly fit at least partially within the lower wire assembly when stacked. This nesting configuration reduces the overall height of stacked assemblies, improving warehousing and shipping efficiency without requiring complex additional components.
Solution Approach 2:
The support structure is divided into multiple support modules, each with its own set of support legs and wire grid sections. This segmentation allows the assemblies to be stacked independently and nested together, facilitating easier stacking and removal while maintaining structural integrity.
3Ease of manufacture
If support modules have four mounting points for connection to wire grid, then ease of attachment to base structure is improved, but manufacturing complexity increases
Solution Approach 1:
Each support module is designed with four mounting points that serve multiple functions: connecting the support legs to the wire grid assembly and providing attachment points to the base structure. This universal design simplifies the overall manufacturing process by using the same mounting points for multiple connection purposes, rather than requiring separate attachment mechanisms.
Data Source
AI summary
A support module for use in a bedding foundation to support a support surface above a bedding foundation base, the support module being of an independent wire form configured to define a top portion, a bottom portion, and four predominantly straight support legs, wherein the support legs are skewed with respect to each other, such that each respective support leg is not parallel to any of the other support legs. The top of each support leg is bent to be oriented into a common first plane to form the top portion, which may be connected to a wire grid assembly to form a nestable bedding foundation.