Spring core with larger diameter of corner springs
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Solution Overview
Problem
The existing spring core constructions in box-spring assemblies often result in undesirable deviations from the desired box-like shape due to the stretching of the cover material, causing inward diagonal pulling of the upper corners.
Innovation Solution
A pocket spring core design where corner springs with distinct characteristics, such as larger diameters or more coil turns, are integrated at the intersections of rows and columns to enhance support and maintain a more pronounced corner sharpness, preventing the cover from distorting and maintaining a cosmetically desirable shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cover material is stretched over the spring core, then the box-spring assembly is assembled, but the upper corners are pulled diagonally inward resulting in deviation from the desired box-like shape
Solution Approach 1:
The patent applies local quality by providing corner springs with different characteristics (larger diameter, more coil turns) specifically at the corner positions where the rows and columns intersect, while other springs in the matrix maintain uniform characteristics. This localized differentiation enhances support at the corner regions to prevent the cover from pulling inward and maintains the desired box-like shape with sharp corners.
2Strength
If corner springs with larger diameter are used, then support in the corner region is enhanced and corner sharpness is improved, but the complexity of the spring core construction increases
Solution Approach 1:
The patent implements local quality by differentiating only the corner springs from the other springs in the matrix. The corner springs have larger diameter and/or more coil turns to provide enhanced support, while the majority of springs maintain uniform characteristics. This approach provides the necessary corner support without requiring complete redesign of the entire spring core, thus limiting the increase in construction complexity.
Solution Approach 2:
The patent applies parameter changes by modifying specific parameters (diameter and number of coil turns) of the corner springs while keeping other parameters consistent with the standard springs. This selective parameter modification allows enhancement of corner support characteristics without fundamentally changing the overall spring core construction methodology.
Data Source
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AI summary
A spring core (10) comprises a plurality of springs (21, 22) which are arranged in columns and rows. The plurality of springs comprises at least one corner spring (22). The corner spring (22) forms an end of one of the rows and an end of one of the columns. The at least one corner (22) spring differs with respect to at least one characteristic from a first adjacent group of the other springs (21) in the same row and a second adjacent group of the other springs (21) in the same column.