Spring-Coil Assembly With Foam-Like Nonlinear Compression
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Solution Overview
Problem
Conventional spring-based mattresses exhibit linear load-deflection characteristics, leading to inconsistent comfort for users of different weights, as lighter users compress the springs less, resulting in a different feel compared to heavier users, whereas foam mattresses provide non-linear compressive properties but are more expensive and difficult to manufacture.
Innovation Solution
A spring-coil assembly with alternating rows of encased springs in a partially compressed state and shorter springs, arranged to mimic the non-linear load-deflection characteristics of foam, allowing for improved comfort across a range of user weights without the manufacturing complexities of foam mattresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional symmetric helical springs are used, then the manufacturing process is simple and cost-effective, but the load-deflection response is linear and does not mimic foam characteristics
Solution Approach 1:
The spring is divided into multiple segments along its length, with each segment having a different coil radius. This segmentation allows the spring to exhibit non-linear load-deflection characteristics that mimic foam behavior, while still using conventional manufacturing processes for each individual segment.
Solution Approach 2:
The spring transitions from a symmetric helical design to an asymmetric design where coil radius varies along the length of the spring. This asymmetry creates the non-linear mechanical response characteristic of foam materials, resolving the contradiction between manufacturing simplicity and foam-like behavior.
2Reliability
If non-linear spring coils with progressively smaller radius are used, then the load-deflection response becomes non-linear, but the complex dynamic response of cellular foam is not achieved
Solution Approach 1:
Different segments of the spring are given different local geometric properties, specifically varying coil radii. This local quality variation along the spring length enables the complex dynamic response characteristic of foam while maintaining a relatively simple overall spring structure that does not require entirely new designs.
3Adaptability or versatility
If foam material is used to provide non-linear compressive properties, then the comfort consistency for users of different weights is improved, but the manufacturing cost and difficulty increase significantly
Solution Approach 1:
The invention copies the load-deflection characteristics of foam materials through a spring design with varying coil radii. Instead of using actual foam, the spring geometry is designed to replicate foam's non-linear compressive behavior, achieving comfort consistency for users of different weights while maintaining the cost-effectiveness and manufacturing simplicity of traditional spring mattresses.
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
The solution provides a spring-based mattress with non-linear load-deflection characteristics similar to foam, offering consistent comfort for users of varying weights while maintaining the cost-effectiveness of traditional spring mattresses.
Implementation Method 1
Steel coil springs of conventional symmetric helical design have a well know linear spring response
Data Source
AI summary
Systems and methods include a spring-coil assembly having non-linear load-deflection characteristics that are substantially similar to foam. In particular, the systems and methods described herein include a first set of encased springs that are in a partially compressed state and a second set of shorter springs. These two sets of springs may be arranged in alternating rows such that the resulting spring-coil assembly displays non-linear load-deflection characteristics similar to foam.