Spring Wire Support Layout for Variable Mattress Firmness
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Solution Overview
Problem
Existing foundation units and innerspring mattresses face challenges in varying their surface support, which limits their ability to adjust firmness and comfort according to user preferences.
Innovation Solution
A variable spring surface system utilizing elongated spring elements enveloped in pliant carriers, such as felt, secured to the top surface of foundations or mattresses using fastening systems like staples or C-rings, allowing for customizable firmness by adjusting the number and placement of spring wire supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional coil springs are used in foundations and mattresses, then structural support is provided, but the surface support and firmness cannot be varied or customized
Solution Approach 1:
The patent divides the continuous coil spring structure into discrete, individual spring elements that can be independently selected and positioned. Each spring element is wrapped in a fabric carrier that allows it to be handled and installed separately, enabling customized arrangements to achieve variable surface support and firmness levels across different zones of the foundation or mattress.
Solution Approach 2:
The patent applies different spring element densities, sizes, and firmness characteristics to different local zones of the foundation or mattress surface. By varying the distribution and properties of individual spring elements across specific areas, the system creates localized zones of different support characteristics, allowing customization for specific user needs or body regions.
2Ease of operation
If coil springs are secured to grid wire surfaces, then structural stability is achieved, but adjustment and customization of spring placement is difficult
Solution Approach 1:
The patent introduces a fabric carrier as an intermediary component between the spring element and the grid wire surface. This fabric carrier serves as a mediator that facilitates easy handling, positioning, and installation of the spring element while also providing a reliable attachment mechanism through staples or other fasteners that penetrate the fabric to secure the spring in place.
Solution Approach 2:
The spring elements are pre-wrapped in fabric carriers before installation, which prepares them for easy handling and precise positioning on the grid wire surface. This preliminary preparation allows workers to quickly install and adjust spring elements without complex assembly steps, while the fabric carrier itself is designed to provide reliable retention once fastened.
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
Enables nearly infinite customization of firmness in foundations and mattresses, providing enhanced comfort and support by allowing for varying densities and firmness distribution across the surface.
Implementation Method 1
an elongated spring element... comprising a spring metal rod
Data Source
AI summary
A spring wire support for foundations and innerspring mattresses, and a variable spring surface deck for a foundation and variable spring surface for a mattress. The spring wire support comprises an elongated spring element enveloped in a pliant carrier, with the carrier including an attachment margin. The variable spring surface deck for a foundation comprises a plurality of the spring wire supports secured as desired to an upper surface of a foundation. The variable spring surface for a mattress comprises a plurality of the spring wire supports located between top and adjacent convolutions of rows or columns of springs of the mattress.