MATTRESS WITH IMPROVED INTERNAL SPRING STRUCTURE

Description

BACKGROUND OF THE INVENTION

(a) Technical Field of the Invention

The present invention generally relates to mattress, and more particularly to a mattress with improved internal spring structure.

(b) Description of the Prior Art

In general mattress manufacturing, the internal support springs placed between the cushion layers are typically made by winding metal wire, which is then arranged to form a supporting plane. Soft cushion layers, such as foam padding, are placed on the upper and lower contact surfaces to provide fixed positioning of the springs and enhance comfort. The spring layer in the middle provides cushioning or vibration reduction when the mattress is compressed, achieving the purpose of comfortable contact. The most common design of springs is usually made from metal wire with a circular cross-section. With this structure and under constant spring parameters, a larger cross-sectional area results in better elasticity and greater load-bearing capacity. Therefore, to meet the requirements of better elasticity and greater load-bearing capacity, thicker metal wires are used. This, in turn, increases the amount of metal wire needed, making the overall mattress structure heavier and the production cost higher. Consequently, it becomes challenging to effectively enhance the comfortable elasticity of assembled springs while appropriately reducing the overall structure's weight for lowering production costs. This practical design requirement has become the target for active development and improvement within the mattress industry today.

SUMMARY OF THE INVENTION

In this invention, the springs of the mattress are designed with a rectangular cross-section, which enhances the support and rebound strength of the springs. This design allows the springs to withstand multidirectional forces under the same cross-sectional area, effectively reducing the overall weight of the spring arrangement. It addresses the current shortcomings of traditional mattresses, which are often heavy and lack practical elasticity.

The main objective of this invention is to use a rectangular cross-section design for the metal helical wire structure of the springs. This significantly improves the effective load-bearing capacity for the same unit cross-sectional area, providing a stable and comfortable feel when lying on the mattress. This design directly reduces the overall weight of the mattress structure, greatly enhancing its practical comfort. It also achieves the practical goal of lowering production costs for mattresses.

The foregoing objectives and summary provide only a brief introduction to the present invention. To fully appreciate these and other objects of the present invention as well as the invention itself, all of which will become apparent to those skilled in the art, the following detailed description of the invention and the claims should be read in conjunction with the accompanying drawings. Throughout the specification and drawings identical reference numerals refer to identical or similar parts.

Many other advantages and features of the present invention will become manifest to those versed in the art upon making reference to the detailed description and the accompanying sheets of drawings in which a preferred structural embodiment incorporating the principles of the present invention is shown by way of illustrative example.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is perspective diagram showing a mattress according to an embodiment of the present invention.

FIG. 2 is a perspective diagram showing a spring of the mattress of FIG. 1.

FIG. 3 is a perspective diagram showing a three-section design for the spring of FIG. 2.

FIG. 4 is a perspective diagram showing the spring of FIG. 2 wrapped in a fabric envelop.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following descriptions are exemplary embodiments only, and are not intended to limit the scope, applicability or configuration of the invention in any way. Rather, the following description provides a convenient illustration for implementing exemplary embodiments of the invention. Various changes to the described embodiments may be made in the function and arrangement of the elements described without departing from the scope of the invention as set forth in the appended claims.

The present invention discloses a mattress with an improved internal spring structure. As shown in FIG. 1 to 4, a mattress 10 according to an embodiment of the present invention includes an upper cushion 101, a lower cushion 102, and multiple springs 11 arranged between the upper and lower cushions 101 and 102. The upper and lower cushion surfaces 101 and 102 are covered with fabric on the outside, forming a complete mattress structure. The improvement of the present invention lies in the springs 11 which are made of steel wire with a rectangular cross-section. Chamfers or rounded corners are formed at each corner of the rectangular cross-section to avoid sharp edges, resulting in a nearly octagonal rectangular cross-section. The springs 11 are manufactured into a coil form using specialized equipment. The middle section of each spring 11 has the largest coil diameter, and it gradually tapers into a slightly conical shape towards both ends, which helps prevent frictional noise between adjacent metal rings when the springs 11 are compressed. Typical springs 11 are made of high-carbon steel wire, stainless steel wire, or alloy steel wire, with a carbon content of 0.62%-0.90%. In the present embodiment, the steel wire is made from high-carbon steel. The rectangular cross-section of the entire steel wire has a long side length between 1.4 to 3.0 mm and a short side length between 0.7 to 2.3 mm. Comparative tests on traditional circular cross-section steel wire springs 11 with the same cross-sectional area show that a rectangular cross-section of 1.4 mm×0.7 mm provides approximately the same spring support strength as a circular steel wire with a cross-sectional diameter of 1.4 mm. When the rectangular cross-section has a long side of 2.2 mm and a short side of 1.5 mm, the spring support strength is equivalent to a circular steel wire with a cross-sectional diameter of 2.2 mm. It is clear that under the same support strength, the material usage for rectangular cross-section springs in the present embodiment is significantly less than that of circular cross-section springs. The material usage can be reduced by an average of 20-36%. For a mattress, depending on its size and cushioning needs, hundreds to thousands of springs are typically arranged. This reduction in material usage leads to a significant decrease in the overall weight of the mattress, which is especially beneficial for different comfort needs where the number of springs 11 used varies greatly. This results in substantial cost savings in mattress production. Therefore, the improved design for the springs 11 in the present embodiment provides practical benefits in terms of comfort, material savings, weight reduction, and ease of handling, making it a novel development in the mattress industry.

Additionally, the springs 11 of the present invention can also be manufactured as a three-section integrated structure. The three sections are of equal length and are connected at the upper and lower junctures 12, where the cross-sections of the steel wire of neighboring sections are rotated 90 degrees and perpendicular to each other. This forms a three-section integrated elastic structure with different load-bearing characteristics for each section. By altering the orientation of the cross-sections, the springs 11 are divided into upper and lower cushioning sections 111, 112 and a middle support section 113. This design allows the springs 11 to naturally provide mutual support under load, resulting in a more stable support section 113 in the middle. When the springs 11 are compressed, the upper and lower cushioning sections 111, 112 respond to forces from different directions, allowing for quicker rebound and more stable placement without shifting. The integrated design of the springs 11, with rotational orientation in different sections, is typically used for lengths within 300 mm, which is more common for large mattress production. Each spring 11 is encased in an individual fabric envelop 20 for precise positioning and alignment, providing not only convenience in processing and assembly but also ensuring stability and safety during installation. This design meets the requirements for independent load-bearing, making it particularly effective for ensuring stability and comfort in mattresses designed with individually springs.

The arrangement and assembly of the springs 11 in this invention are similar to the independent packaging arrangement of current spring mattresses. Specifically, the springs 11, wound and shaped through machinery, are covered with non-woven or woven fabric and form independent fabric envelopes 20. The springs 11 are then arranged between the upper and lower cushions 101 and 102 of the mattress, resulting in a complete mattress structure. With the independently packaged springs 11, designed with a rectangular cross-section and arranged in precise positions, the mattress provides localized, independent elastic support according to varying pressures and forces. This ensures that the mattress maintains safe, stable, and comfortable support when in use, providing the desired comfort and functionality.

In summary, the improved internal spring structure for mattresses in the present invention involves springs made from steel wire with a rectangular cross-section. Each corner of the rectangle is chamfered or rounded to eliminate sharp edges. The springs are designed with a tapered shape, having the largest coil diameter in the middle section that gradually decreases towards both ends. This design prevents interference during compression and expansion of the springs, thereby ensuring elastic safety and comfort in practical use.

While certain novel features of this invention have been shown and described and are pointed out in the annexed claim, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the claims of the present invention.