Spring Mattress Fabric Compression Assembly to Reduce Deformation
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Solution Overview
Problem
Existing spring mattresses face challenges in ensuring precise sizing, stability, and geometry during assembly, particularly with large dimensions, due to the use of materials like foam, glue, metal frames, and non-woven fabrics, which can lead to deformation and instability over time.
Innovation Solution
A mattress design using a fabric with low elasticity and high resistance, such as cretonne, is wrapped around the spring suspension to maintain compression and stability, eliminating the need for non-woven fabrics and glue, and ensuring consistent size and shape over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If foam blocks and non-woven fabric are used to ensure mattress sizing and stability, then the mattress geometry is maintained, but the manufacturing complexity and material cost increase
Solution Approach 1:
The patent removes foam blocks, non-woven fabric, glue, and metal frames from the traditional mattress assembly, retaining only the essential spring suspension and ticking components. This extraction simplifies the assembly structure while maintaining manufacturing precision through the elastic constraint mechanism.
Solution Approach 2:
The patent changes the physical state of the constraint system from rigid (foam blocks, metal frames) to elastic (fabric under tension). This parameter change allows the constraint to adapt to spring suspension deformation while maintaining mattress geometry, reducing assembly complexity.
2Reliability
If metal frames and glue are used to stabilize the spring layer, then the mattress stability is improved, but the environmental impact and production cost increase
Solution Approach 1:
The patent eliminates metal frames and glue from the mattress assembly, removing harmful materials from the system. Stability is maintained through the elastic fabric constraint that replaces these traditional stabilizing elements, reducing environmental impact while preserving reliability.
Solution Approach 2:
The patent transitions from rigid mechanical constraints (metal frames) and chemical bonds (glue) to elastic mechanical constraints (fabric tension). This parameter change maintains stability while eliminating harmful materials, addressing both reliability and environmental concerns.
3Shape
If rigid framing is used to prevent spring suspension deformation, then the mattress geometry is maintained, but the flexibility and elasticity of the spring layer are reduced
Solution Approach 1:
The patent changes the constraint mechanism from rigid to elastic by using fabric under tension. This elastic constraint maintains mattress geometry while allowing the spring suspension to deform and recover, preserving flexibility and adaptability that rigid framing would eliminate.
Solution Approach 2:
The patent introduces a dynamic constraint system where the fabric tension adapts to spring suspension movement. Unlike static rigid framing, the elastic fabric constraint moves with the springs, maintaining geometry while accommodating flexibility and enabling the spring layer to respond to applied loads.
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 fabric maintains the spring suspension in compression, providing consistent size and stability, reducing deformation and enhancing longevity without the use of foam or glue, while allowing for cost-effective and sustainable production.
Implementation Method 1
the fabric stretches little, whether plastically or elastically, and keeps such a property over time despite regular and significant stresses
Data Source
AI summary
A bedding mattress comprising a spring suspension (1) defining a sleeping plane and a ticking (109, 111) on each side and on the edges. The mattress further comprises a fabric (120, 121, 122, 123) closed around the suspension and maintaining the suspension in compression parallel to the sleeping plane, the ticking (109, 111) being placed outside the fabric (120, 121, 122, 123). The invention further relates to the manufacturing method.