Multi-sectional sinuous spring for furniture
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Solution Overview
Problem
Conventional sinuous wire springs used in furniture manufacturing are difficult to install, leading to increased worker injuries and compensation claims due to the high effort required in clipping them onto sofa rails, and they are costly to produce and assemble.
Innovation Solution
A three-piece sinuous spring design where a middle section is folded under and over the other sections and securely clipped, forming a single piece of the correct length and tension, reducing the effort needed for installation and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional single-piece sinuous springs are used, then the spring provides continuous support, but the installation process requires high worker effort and causes injuries
Solution Approach 1:
The sinuous spring is divided into multiple separate sections (front section, middle section, rear section) that can be handled and installed independently. This segmentation reduces the size and weight of each component, making them easier for workers to manipulate and install without excessive effort, while still providing continuous support when assembled together with connectors.
2Device complexity
If conventional sinuous springs are used, then the spring structure is simple, but the manufacturing and assembly costs are high
Solution Approach 1:
Dividing the spring into standardized sections allows for more efficient manufacturing processes, including automated production of individual sections and connectors. This segmentation enables better resource utilization, reduced material waste, and simplified assembly operations, ultimately lowering manufacturing and assembly costs despite the increased component count.
Solution Approach 2:
The introduction of connectors as intermediary components facilitates the assembly process by providing standardized connection points between spring sections. These connectors simplify the joining operation, reduce assembly time, and enable more efficient manufacturing workflows, contributing to cost reduction.
3Force
If conventional sinuous springs are used, then the spring provides adequate tension, but the assembly process is difficult and time-consuming
Solution Approach 1:
The segmented spring design allows workers to assemble sections in a modular fashion, improving assembly speed and productivity. Each section can be prepared and positioned independently before connection, reducing the overall complexity and time required for complete spring assembly while maintaining the necessary tension characteristics.
Solution Approach 2:
Spring sections and connectors can be pre-assembled or pre-positioned before final installation, allowing for more efficient assembly operations. This preliminary preparation reduces the time and effort required during the main assembly process, increasing overall productivity.
Data Source
AI summary
Method and apparatus for an improved sinuous spring for use on the seat box of a piece of furniture. The sinuous spring includes three pieces wherein a middle piece or section is placed in between a front and rear section. After the middle section is placed between the other two sections, the middle section would be folded so as to be disposed under one section and over the top of the other section and then clipped securely so that a single piece of spring having the correct length and tension is formed in the process.