Skewed Wire Support Module for Nestable Bedding Foundations

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Solution Overview

Problem

Existing nestably stackable wire bedding foundations lack sufficient resistance to forces from multiple directions and have complex assembly and handling issues due to parallel or perpendicular support legs, which hinder efficient manufacturing, storage, shipping, and stacking.

Innovation Solution

The support module features skewed predominantly straight support legs with unequally spaced pairs, forming a cross-bracing structure that connects to a wire grid with multiple mounting points, allowing for improved resistance to forces from multiple directions and facilitating easy stacking and unstacking by preventing wire ends from catching during assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If support legs are oriented parallel or perpendicular to the sides of the wire grid assembly, then resistance to lateral or longitudinal forces is improved, but resistance to forces from multiple directions deteriorates

Engineering Contradiction:

Improveresistance to lateral or longitudinal forcesVSAvoidresistance to forces from multiple directions

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The support legs are positioned asymmetrically relative to the wire grid assembly, with at least one support leg positioned at an angle that is not parallel or perpendicular to the sides of the wire grid assembly. This asymmetric positioning allows the support structure to effectively resist forces from multiple directions while maintaining structural integrity.

Inventive Principle:

Principle #4Asymmetry

2Productivity

If wire assemblies are made nestably stackable, then efficiency in warehousing and shipping is improved, but complexity of assembly and handling increases

Engineering Contradiction:

Improveefficiency in warehousing and shippingVSAvoidcomplexity of assembly and handling

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The wire grid assembly is designed to be nestably stackable, with the configuration allowing one wire assembly to be stacked atop another like wire assembly. Portions of the upper wire assembly fit at least partially within the lower wire assembly, reducing the height of stacked assemblies while maintaining ease of handling and assembly.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The wire grid assembly is divided into support modules that can be independently positioned and assembled. This segmentation allows for easier handling and stacking while maintaining the overall structural integrity of the bedding foundation.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If support modules are designed with skewed support legs, then resistance to forces from multiple directions is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveresistance to forces from multiple directionsVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentUS7360263B2Bedding foundation support module

Publication Date: 2008.04.22 HICKORY SPRINGS MFG

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.