Flexible support structure with composite material spring modules mounted directly on frame members and related assembly equipment and methods-microtek iii

Abstract

Composite material spring modules have a fiber reinforced composite material spring body with attachment fittings integrally formed about the spring body. The attachment fittings are molded of a flexible material which dynamically responds to changes in the shape of the spring body upon deflection. Integral formation of the fittings with the spring body provides a unified single piece module which is readily attachable to any structure where spring support is desired. In one embodiment, a mounting foot is configured for mounting of the spring module directly to a planar surface of a supporting frame member by a fastener, or alternatively configured to engage with a frame member without use of a fastener. The composite material spring modules exhibit the properties of stiffness and return to uncompressed state from total depth deflection without set. The composite material spring modules with integrally formed attachment fittings are described in combination with a mattress foundation, by attachment to high and low profile frames and to an overlying grid. Methods of manufacture of the composite material spring modules with integrally formed attachment fittings are also described. Methods of assembly of flexible weight bearing structures such as mattress foundations using the composite material spring modules with integrally formed attachment fittings are also described.