Thermoplastic Spring Structure With Variable Hardness for Quiet Support
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Solution Overview
Problem
Existing springs in furniture, such as those in beds and couches, suffer from deformation over time, noise generation, health risks due to corrosion, inability to provide ergonomic comfort, and mattress perforation, primarily because they are made of metal and have uniform hardness.
Innovation Solution
A thermoplastic lightweight spring with different hardness scales, manufactured from stainless thermoplastic material, featuring a butterfly-shaped female and male die structure with tie pieces for easy installation and enhanced durability, designed to prevent deformation and noise, while ensuring the spring does not perforate the mattress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal springs are used, then spring strength and elasticity are improved, but deformation over time and corrosion occur
Solution Approach 1:
The patent applies parameter changes by transitioning from metal to thermoplastic material, fundamentally altering the material properties. The thermoplastic spring maintains elastic functionality while eliminating corrosion and deformation issues inherent to metal springs. The material parameter change enables the spring to achieve both strength and long-term reliability without the drawbacks of metal corrosion and permanent deformation.
Solution Approach 2:
The patent employs composite materials by using thermoplastic material with integrated reinforcement elements. The spring combines the base thermoplastic material with internal structural reinforcements, creating a composite structure that achieves metal-like strength and elasticity while maintaining the corrosion resistance and deformation resistance of plastic materials.
2Ease of manufacture
If uniform hardness springs are used, then manufacturing simplicity is improved, but ergonomic comfort deteriorates
Solution Approach 1:
The patent applies local quality by creating regions of different hardness within the spring structure. The thermoplastic spring incorporates varying material densities and cross-sectional dimensions to produce soft zones for comfort and hard zones for structural support. This localized differentiation allows the spring to conform to the body's contours and provide ergonomic comfort while maintaining manufacturing feasibility through injection molding techniques.
3Strength
If metal springs are used, then structural strength is improved, but noise generation occurs
Solution Approach 1:
The patent applies this principle by replacing durable metal springs with thermoplastic springs that, while potentially having different service life characteristics, eliminate the noise generation problem entirely. The thermoplastic material's inherent damping properties prevent the metallic clicking and creaking sounds associated with metal spring movement, providing a quiet operating environment.
4Force
If metal springs are used, then load-bearing capacity is improved, but mattress perforation occurs
Solution Approach 1:
The patent applies parameter changes by transitioning from metal to thermoplastic material, fundamentally altering the interaction between the spring and mattress. The thermoplastic material, being less rigid and more compliant than metal, distributes loads more evenly across the mattress surface, preventing the concentrated point loads that cause metal springs to perforate mattresses over time.
Data Source
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AI summary
The present invention relates to a thermoplastic spring, comprising a lower spring base portion (1) and an upper spring base portion (2), a female spring die (3) and a male spring die (4), wherein the female spring die (3) and the male spring die (4) are located between the lower spring base portion (1) and the upper spring base portion (2), wherein a pin is located on the male spring die (4) and a hole is located on the female spring die (3), wherein an installation process of the thermoplastic spring is performed by placing the placing the pin through the hole.