Bagged spring bag and production method thereof

Abstract

The invention discloses a bagged spring bag and a production method thereof, the bagged spring bag comprises a plurality of rows of bagged spring strings arranged in parallel, and each row of bagged spring strings is formed by connecting a plurality of independent bagged springs end to end through cloth bags outside the bagged springs; the upper portions and the lower portions of the multiple rows of bagged spring strings are covered with upper-layer connecting cloth and lower-layer connecting cloth respectively in a connected mode, the upper-layer connecting cloth and the lower-layer connecting cloth between every two adjacent rows of bagged spring strings are directly combined at the gaps of the corresponding bagged springs through welding parts, and the welding parts are formed through ultrasonic welding. Therefore, the multiple rows of bagged spring strings are fixed into a whole, and the distance between every two adjacent bagged spring strings is precisely limited.

Description

Technical Field

[0001] This invention relates to the field of pocket spring technology, and in particular to a pocket spring bag and its manufacturing method. Background Technology

[0002] Pocket springs are widely used in the core of mattresses, sofas, and other furniture. They are formed by arranging and connecting multiple independent pocket springs to create a complete spring pad. In existing technology, a common manufacturing process is "bag first, spring later," where non-woven fabric or other materials are first made into continuous individual bags, and then the springs are pushed into the bags one by one and sealed, forming a single row of pocket springs. Subsequently, these single rows of pocket springs need to be connected in parallel using methods such as gluing, sewing, or welding to form a spring pad with the required width and support performance.

[0003] Reference Figure 1 However, in existing pocket spring manufacturing processes, two layers of fabric are typically welded around the spring to form multiple fabric bags that enclose it. This process often results in non-standard spacing between the springs, making it difficult to precisely control the overall dimensions of the finished product. When pressure is applied to a localized area, the force cannot be evenly distributed through the transmission of pressure between adjacent springs, affecting usability and comfort. Summary of the Invention

[0004] The present invention aims to at least solve one of the technical problems existing in the prior art. To this end, the present invention provides a pocket spring bag and a method for manufacturing the aforementioned pocket spring bag.

[0005] According to a first aspect of the present invention, a pocket spring bag includes multiple rows of parallel pocket spring strings, each row of the pocket spring strings being composed of multiple independent pocket springs connected end-to-end by an external cloth bag; an upper connecting cloth and a lower connecting cloth cover and connect the upper and lower sides of the multiple rows of pocket spring strings, respectively, wherein the upper connecting cloth and the lower connecting cloth are directly joined at the gap between the corresponding pocket springs by a welding part between adjacent rows of pocket spring strings, the welding part being formed by ultrasonic welding, thereby fixing the multiple rows of pocket spring strings into one piece and precisely defining the spacing between adjacent pocket spring strings.

[0006] The pocket spring pack according to embodiments of the present invention has at least the following beneficial effects: by using ultrasonic welding to directly bond the upper and lower connecting fabrics at the gap between adjacent rows of pocket springs to form a welded part, the spacing between adjacent pocket spring strings can be precisely defined. Compared with existing processes, this effectively solves the problem of difficulty in precisely controlling the spacing, making the overall size of the finished spring pad more standardized and stable. Because the finished spring pad has standardized and stable dimensions, it ensures even pressure distribution on all parts of the sleeper's body during use, improving sleep comfort. At the same time, the standardized and stable dimensions also facilitate product packaging, transportation, and storage, reducing damage and waste caused by size deviations. Furthermore, the production process of the present invention is relatively simple, and the ultrasonic welding operation is convenient and quick, improving production efficiency. Moreover, precise spacing control reduces subsequent adjustments and corrections, further shortening the production cycle and reducing production costs.

[0007] According to some embodiments of the first aspect of the invention, the bag of the bagged spring string is made of non-woven or knitted fabric.

[0008] According to some embodiments of the first aspect of the present invention, the upper connecting fabric and the lower connecting fabric are polyester Oxford cloth.

[0009] According to a second embodiment of the present invention, a method for producing a pocket spring bag includes multiple rows of parallel pocket spring strings. Each row of pocket spring strings consists of multiple independent pocket springs connected end-to-end by an external fabric bag. An upper connecting fabric and a lower connecting fabric cover and connect the top and bottom of the multiple rows of pocket spring strings, respectively. Between adjacent rows of pocket spring strings, the upper connecting fabric and the lower connecting fabric are directly joined at the gaps between the corresponding pocket springs via a welded portion. The welded portion is formed by ultrasonic welding, thereby fixing the multiple rows of pocket spring strings into a single unit and precisely defining the spacing between adjacent pocket spring strings. The method includes the following steps: S100: Provides multiple rows of pre-filled pocket springs; S200: In each row of the bagged springs, a spacer is placed inside the cloth bag between adjacent bagged springs; S300: Tensile and guide the upper and lower connecting fabrics to the upper and lower sides of the multi-row bag spring string respectively; S400: The upper connecting fabric, the multiple rows of bagged springs and the lower connecting fabric are stacked together, and a welding device is used to weld them at the positions corresponding to the partitions; S500: The partition prevents the upper and lower surfaces of the bag of the bag spring string at its location from being welded together, while allowing the upper connecting fabric at that location to be welded to the adjacent upper fabric and the lower connecting fabric to the adjacent lower fabric to form a welded part, thereby connecting multiple rows of bag spring strings into an integral spring pad.

[0010] The method for producing pocket spring packs according to a second aspect of the present invention has at least the following beneficial effects: By placing spacers inside the fabric bag between adjacent pocket springs and welding at the corresponding spacer positions, the present invention can precisely define the spacing between adjacent pocket spring strings. Compared with existing processes, this effectively solves the problem of difficulty in precisely controlling the spacing, resulting in more standardized and stable overall dimensions of the finished spring pads and improving product quality. This method employs highly automated production equipment and processes, such as automatic stacking robots and laser welding equipment, enabling rapid and accurate completion of the assembly and welding process of pocket spring packs, significantly improving production efficiency, shortening the production cycle, and reducing production costs. Furthermore, the welded parts formed by ultrasonic welding or laser welding have high strength and firmness, firmly fixing multiple rows of pocket spring strings into one unit, enhancing the overall structural stability of the pocket spring pack. During use, it effectively prevents the spring strings from shifting or deforming, ensuring the performance and service life of the spring pads. Furthermore, the production method of this invention is applicable to pocket springs, connecting fabrics, and spacers of different specifications and materials. It can flexibly adjust the production process parameters according to actual needs to produce various types of pocket spring bags, meet the needs of different customers, and has strong market adaptability.

[0011] According to some embodiments of the second aspect of the present invention, in step S200, the material of the spacer is metal, thermosetting plastic or high melting point plastic.

[0012] According to some embodiments of the second aspect of the present invention, in step S300, the upper connecting fabric and the lower connecting fabric are tensioned by at least one set of rubber-coated feeding rollers to achieve a preset tension.

[0013] According to some embodiments of the second aspect of the present invention, in step S400, the welding device is an ultrasonic welding device, which has ultrasonic welding heads arranged vertically and vertically and capable of moving towards each other.

[0014] According to some embodiments of the second aspect of the present invention, the upper and lower ultrasonic welding heads clamp the stacked materials at positions corresponding to the spacers and perform welding.

[0015] According to some embodiments of the second aspect of the present invention, the welded portion formed in step S500 is positioned offset from the position of the spring in the bag spring string.

[0016] According to some embodiments of the second aspect of the present invention, in step S500, the welding apparatus is configured with two or more sets of ultrasonic transducers to simultaneously generate multiple welded parts.

[0017] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments, wherein: Figure 1 This is a front view schematic diagram of a bagged spring bag in the prior art; Figure 2 This is a front view schematic diagram of a bagged spring bag according to an embodiment of the present invention; Figure 3 This is a top view schematic diagram of a bagged spring bag according to an embodiment of the present invention; Figure 4 This is a schematic flowchart of a method for producing a bagged spring bag according to an embodiment of the present invention.

[0019] Reference numerals: 100 for bagged spring string; 110 for bagged spring; 200 for upper connecting fabric; 300 for lower connecting fabric; 400 for welded part; 500 for spacer. Detailed Implementation

[0020] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0021] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0022] In the description of this invention, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0023] In the description of this invention, unless otherwise explicitly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly. Those skilled in the art can reasonably determine the specific meaning of these terms in this invention in conjunction with the specific content of the technical solution. In the description of this invention, the terms "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in any suitable manner in one or more embodiments or examples.

[0024] Reference Figure 1 In existing technologies, pocket spring bags typically combine multiple individually pocketed springs to form a filling layer with good support and breathability. Traditional pocket spring manufacturing processes usually employ a "spring-first, bag-second" approach, where the spring is pushed to a predetermined position before the bag is sewn or welded. However, the spring is prone to positional shift during the pushing process, especially when the pusher plate contacts the spring's outer diameter. The spring may deviate from its preset position due to rotation or sliding, resulting in the spring not being centered in the bag during final sealing, or even contacting the seam, affecting product quality and lifespan. Furthermore, during bag processing after spring pushing, the spring's elasticity can interfere with the bonding process of the upper and lower fabric layers, affecting sealing quality and even leading to problems such as unstable bag dimensions and inconsistent shrinkage.

[0025] Reference Figure 2 and Figure 3This invention proposes a pocket spring bag, comprising multiple rows of parallel pocket spring strings 100. Each row of pocket spring strings 100 is composed of multiple independent pocket springs 110 connected end-to-end by an external fabric bag. An upper connecting fabric 200 and a lower connecting fabric 300 cover and connect the top and bottom of the multiple rows of pocket spring strings 100, respectively. Between adjacent rows of pocket spring strings 100, the upper connecting fabric 200 and the lower connecting fabric 300 are directly joined at the gaps between corresponding pocket springs 110 by a welding part 400. The welding part 400 is formed by ultrasonic welding, thereby fixing the multiple rows of pocket spring strings 100 into a single unit and precisely defining the spacing between adjacent pocket spring strings 100.

[0026] In a specific embodiment, springs of appropriate specifications are selected and placed into cloth bags to form multiple independent pocket springs 110. Then, the multiple independent pocket springs 110 are connected end-to-end using a sewing process to prepare multiple rows of parallel pocket spring strings 100. The number of pocket springs 110 in each row of pocket spring strings 100 can be adjusted according to actual needs. An upper connecting fabric 200 and a lower connecting fabric 300 matching the size of the pocket spring strings 100 are prepared. The lower connecting fabric 300 is laid flat on a workbench, and then multiple rows of pocket spring strings 100 are placed parallel to each other on the lower connecting fabric 300, ensuring that the relative positions between each row of pocket spring strings 100 initially meet the design requirements. Next, the upper connecting fabric 200 is placed over the multiple rows of pocket spring strings 100. Using ultrasonic welding equipment, welding is performed at the gaps between the corresponding pocket springs 110 on the upper connecting fabric 200 and the lower connecting fabric 300. During welding, by adjusting the parameters of the ultrasonic welding equipment, such as welding power and welding time, it is ensured that the welding part 400 can firmly bond the upper connecting fabric 200 and the lower connecting fabric 300 together. Since welding is performed at the gaps between the pocket springs 110, the welding part 400 can precisely limit the spacing between adjacent rows of pocket spring strings 100, ensuring it meets design standards. After welding, the pocket spring bag undergoes a comprehensive inspection. The strength of the welding part 400 is checked to ensure that the multiple rows of pocket spring strings 100 are firmly fixed together. Simultaneously, professional measuring tools are used to measure the overall dimensions of the finished pocket spring bag, verifying the accuracy of the spacing between adjacent spring strings and whether it meets design requirements.

[0027] In other embodiments, before laying the upper connecting fabric 200 and the lower connecting fabric 300, positioning auxiliary devices are first installed on both sides of each row of bagged spring strings 100. These positioning auxiliary devices can be graduated positioning plates, which allow for more accurate adjustment of the initial spacing between each row of bagged spring strings 100. After positioning is completed, the upper connecting fabric 200 and the lower connecting fabric 300 are laid, followed by the ultrasonic welding process. This further improves the accuracy of the spacing between adjacent spring strings.

[0028] It is understandable that by using ultrasonic welding to directly combine the upper connecting fabric 200 and the lower connecting fabric 300 to form a welded part 400 at the gap of the pocket springs 110 between two adjacent rows of pocket spring strings 100, the spacing between adjacent pocket spring strings 100 can be precisely defined. Compared with existing processes, this effectively solves the problem of difficulty in precisely controlling the spacing, making the overall size of the finished spring pad more standard and stable. Because the finished spring pad has a standard and stable size, it ensures that the force is evenly distributed on all parts of the sleeper's body during use, improving sleep comfort. At the same time, the standard and stable size also facilitates product packaging, transportation, and storage, reducing damage and waste caused by size deviations. Furthermore, the production process of this invention is relatively simple, and the ultrasonic welding operation is convenient and quick, improving production efficiency. Moreover, precise spacing control reduces subsequent adjustments and corrections, further shortening the production cycle and reducing production costs.

[0029] In a specific embodiment, the bag for the pocket spring string 100 is made of non-woven fabric. By selecting non-woven fabric of suitable specifications and quality, it is cut into strips of a certain size according to design requirements. The width of the strip should be slightly larger than the diameter of a single spring, and the length is determined based on the number of pocket springs 110 required for each row and the size of the springs, ensuring that multiple springs are completely wrapped and allowing for sewing allowance at both ends. Then, individual springs are placed sequentially on the cut non-woven fabric strips, and the strips are sewn along the edges of the springs using a sewing machine to form individual pocket springs 110. During the sewing process, attention should be paid to the evenness and strength of the stitching to avoid missed seams or loose stitches, ensuring that the springs are securely wrapped inside the non-woven fabric bag. Multiple individual pocket springs 110 are sewn together through the beginning and end of the non-woven fabric bag to form a complete row of pocket spring strings 100. When stringing them together, the spacing between adjacent pocket springs 110 should be uniform, and the tightness of the stringing can be adjusted according to actual needs. Finally, the prepared non-woven fabric bagged spring strings 100 are assembled, with an upper connecting fabric 200 and a lower connecting fabric 300 covering the top and bottom respectively. Ultrasonic welding is then performed at the gaps between adjacent spring strings to complete the production of the bagged spring bag. Understandably, the production process of non-woven fabric is relatively simple, and the raw material cost is low, effectively reducing the overall production cost of bagged spring bags and improving the product's market competitiveness. Furthermore, non-woven fabric has good breathability, allowing air to circulate freely between the springs and the bag, reducing moisture and stuffiness, helping to keep the spring pads dry and hygienic, and extending their service life.

[0030] In other embodiments, the pouch for the spring pack 100 is made of knitted fabric. A soft, moderately elastic knitted fabric is selected and cut into pieces of appropriate shape and size according to the spring's size and arrangement requirements. The elasticity of the knitted fabric better accommodates the spring's stretching and deformation, providing cushioning and support. The spring is then placed in the center of the cut knitted fabric piece, and the edges of the knitted fabric are folded inwards and sewn together by hand or machine, tightly encasing the spring inside the knitted pouch. During sewing, care must be taken to maintain the elasticity of the knitted fabric to avoid excessive stretching that could cause deformation or tearing at the seam. Multiple knitted pouches containing springs are connected by their edges to form a row of spring packs 100. The elasticity of the knitted fabric itself can be utilized, employing special connection methods such as knotting or weaving to make the connection more secure and flexible. Finally, the multiple rows of spring packs 100 are assembled and welded to the upper connecting fabric 200 and the lower connecting fabric 300 to create the final spring pack. Understandably, knitted fabric has good elasticity, which allows it to better adapt to the stretching and deformation of springs, providing more even support and making spring mattresses more comfortable to use, better conforming to the curves of the human body. Furthermore, the soft texture of knitted fabric does not produce noticeable friction or irritation when in contact with the body, improving sleep comfort, making it especially suitable for high-end mattresses and other products with high comfort requirements.

[0031] In a specific embodiment, the upper connecting fabric 200 and the lower connecting fabric 300 are made of polyester Oxford cloth. Polyester Oxford cloth has high strength and abrasion resistance, and can withstand greater external forces without easily being damaged. When used as the upper connecting fabric 200 and the lower connecting fabric 300, it can effectively fix the multi-row pocket springs 100, preventing them from shifting or deforming during use, and ensuring the overall structural stability of the pocket spring bag. Furthermore, polyester material has good chemical corrosion resistance, resisting the erosion of common acids and alkalis in daily life, and is not easily deteriorated or damaged. This allows the pocket spring bag to maintain good performance under various environmental conditions, extending the product's service life. In addition, after special treatment, polyester Oxford cloth has certain waterproof and moisture-proof properties, effectively preventing moisture from penetrating into the pocket springs 110, avoiding rust and corrosion due to moisture, and ensuring the normal performance of the springs. At the same time, the waterproof and moisture-proof characteristics also help keep the spring pads dry and clean, improving user comfort.

[0032] Reference Figure 3 and Figure 4 This invention proposes a method for producing a pocket spring bag, used to produce the pocket spring bag as described above. The method includes the following steps: S100: Provides multiple rows of pre-filled pocket springs; S200: In each row of bagged springs, a spacer is placed inside the cloth bag between adjacent bagged springs; S300: Tensile and guide the upper and lower connecting fabrics to the upper and lower sides of the multi-row bag spring string respectively; S400: The upper connecting fabric, multiple rows of bagged springs and the lower connecting fabric are stacked together and welded at the positions corresponding to the partition using a welding device; S500: The spacer prevents the upper and lower surfaces of the bag of the bag spring string at its location from being welded together, while allowing the upper connecting fabric at that location to be welded to the adjacent upper fabric and the lower connecting fabric to the adjacent lower fabric, forming a welded part, thereby connecting multiple rows of bag spring strings into an integral spring pad.

[0033] In a specific embodiment, firstly, springs of suitable specifications and elasticity are selected, such as high-carbon steel springs with a diameter of 60mm and a height of 200mm. Each spring is then inserted into a 0.5mm thick non-woven fabric bag, and the bags are sewn together end-to-end using a sewing machine to form an individual pocket spring 110. Then, according to design requirements, multiple individual pocket springs 110 are connected end-to-end using a sewing process to prepare multiple rows of parallel pocket spring strings 100, each row containing 10 pocket springs 110.

[0034] A plastic spacer 500 with a thickness of 1mm is selected. The spacer 500 is rectangular in shape, with a length slightly smaller than the gap width between adjacent pocket springs 110 and a width of 20mm. Using a special placement tool, the spacer 500 is accurately placed inside the cloth bag between adjacent pocket springs 110 in each row of pocket spring strings 100, ensuring that the spacer 500 is centered and firmly fixed.

[0035] Polyester Oxford cloth, with a thickness of 0.8 mm, is selected as the upper connecting fabric 200 and the lower connecting fabric 300. The upper connecting fabric 200 and the lower connecting fabric 300 are respectively installed on the tensioning device. By adjusting the tension of the tensioning device, the upper connecting fabric 200 and the lower connecting fabric 300 are kept flat and taut. Then, a guiding device is used to accurately guide the upper connecting fabric 200 and the lower connecting fabric 300 above and below the multi-row bag spring string 100, ensuring that the upper and lower connecting fabrics 300 are aligned with the bag spring string 100.

[0036] The upper connecting fabric 200, the multi-row bagged spring string 100, and the lower connecting fabric 300 are sequentially stacked together using a stacking device to form a whole. Then, the stacked assembly is placed on the worktable of the ultrasonic welding equipment, and the position of the welding device is adjusted so that it is aligned with the location of the spacer 500.

[0037] After welding, the spacer 500 effectively prevents the upper and lower surfaces of the bag spring strings 100 at its location from being welded together. At the location of the spacer 500, the upper connecting fabric 200 is firmly bonded to the adjacent upper fabric, and the lower connecting fabric 300 is firmly bonded to the adjacent lower fabric through ultrasonic welding, forming a welded part 400. These welded parts 400 precisely fix multiple rows of bag spring strings 100 into a whole, accurately defining the spacing between adjacent bag spring strings 100, ultimately resulting in a spring pad with standard overall dimensions and stability.

[0038] It is understood that this invention, by placing spacers 500 inside the fabric bag between adjacent pocket springs 110 and welding at the corresponding spacers 500, can precisely define the spacing between adjacent pocket spring strings 100. Compared with existing processes, this effectively solves the problem of difficulty in precisely controlling the spacing, resulting in more standardized and stable overall dimensions of the finished spring pads and improving product quality. This method employs highly automated production equipment and processes, such as automatic stacking robots and laser welding equipment, enabling rapid and accurate assembly and welding of pocket spring packs, significantly improving production efficiency, shortening the production cycle, and reducing production costs. Furthermore, the welded portion 400 formed by ultrasonic welding or laser welding has high strength and firmness, firmly fixing multiple rows of pocket spring strings 100 into a single unit, enhancing the overall structural stability of the pocket spring pack. During use, it effectively prevents spring strings from shifting or deforming, ensuring the performance and service life of the spring pads. Furthermore, the production method of the present invention is applicable to pocket springs 110, connecting cloths, and spacers 500 of different specifications and materials. It can flexibly adjust the production process parameters according to actual needs to produce various types of pocket spring bags, meet the needs of different customers, and has strong market adaptability.

[0039] In step S200, the material selection process for the spacer 500 employs a multi-material compatibility system, including but not limited to metal spacers 500, thermosetting plastic spacers 500, or high-melting-point plastic spacers 500. The material of the spacer 500 cannot be welded by subsequent welding processes. Specifically, when selecting the material for the spacer 500, it is necessary to ensure that it can effectively block welding energy in subsequent welding processes, preventing the fabric bag of the bag spring string 100 from being accidentally welded together. Specifically, if a metal material is selected, its high thermal conductivity and high strength can completely block ultrasonic vibration energy and withstand welding pressure; if a thermosetting plastic is selected, its non-melting property when heated can provide the same isolation effect; if a high-melting-point plastic is selected, its melting point is much higher than the instantaneous high temperature generated during welding, ensuring its own morphological stability and thus serving as a reliable physical barrier.

[0040] In some embodiments, for high-end medical mattress production lines, 304 stainless steel spacers 500 or 6061-T6 aluminum alloy spacers 500 can be used instead of traditional plastic spacers 500. Specific implementation: First, in the spring string arrangement stage: the spring strings pre-compressed to the design height are arranged in a 12-row × 18-column matrix. The metal spacers 500 are precisely inserted into the gaps between adjacent springs, with the error controlled within ±0.1mm. 15kHz ultrasonic welding is used, the welding head pressure is increased to 1.2MPa, and the welding time is extended to 0.8 seconds. Finally, laser three-dimensional scanning detection shows that the standard deviation of the spacing between adjacent spring strings is reduced to 0.25mm, improving accuracy by 40% compared to the plastic spacer 500 solution.

[0041] By limiting the use of the aforementioned specific types of materials for the spacer 500, the functionality and reliability of the spacer 500 during the welding process are fundamentally guaranteed. These materials can effectively resist the high temperatures and mechanical vibrations during welding, ensuring that it continuously and stably acts as a "welding stop," thereby completely avoiding the risk of the bag spring string 100 being welded through due to the failure of the spacer 500, and ensuring the independent springing performance of each spring in the final product.

[0042] Furthermore, during the conveying of the upper connecting fabric 200 and the lower connecting fabric 300, they are passed through at least one set of power-driven feed rollers coated with elastic materials such as rubber or polyurethane. By controlling the driving speed and conveying resistance of this set of feed rollers, or by using a dedicated tension control mechanism, a precise and constant tensile force is applied to and maintained on the connecting fabric passing through them; this is the preset tension. This embodiment ensures that the connecting fabric is in a flat and taut ideal state when it enters the welding station by actively and controllably tensioning the connecting fabric. This not only eliminates the adverse effects of fabric wrinkles on welding quality, but more importantly, by precisely controlling the relative position and spacing between each row of bagged spring strings 100 through tension, it directly determines the overall dimensional accuracy and shape stability of the finished spring pad, achieving precise control over the finished product's dimensions.

[0043] Optionally, the welding device employs ultrasonic welding technology. Its core components include an ultrasonic generator that produces high-frequency electrical signals, a transducer that converts the electrical signals into mechanical vibrations, and upper and lower welding heads that ultimately transmit the vibrational energy. These two welding heads are located above and below the materials to be welded, respectively, and can move precisely in opposite directions or away from each other under the drive of a cylinder or servo motor to achieve the pressing and separation of the materials. The ultrasonic welding device and its opposing welding head design enable fast, clean, and efficient energy connection. The opposing movement of the upper and lower welding heads precisely applies the required welding pressure to the laminated materials, while concentrating ultrasonic energy on a very small welding area to achieve localized instantaneous heating and fusion. This method requires no chemical adhesives, is environmentally friendly and pollution-free, and offers fast welding speed, high strength, and a clean appearance, making it particularly suitable for efficient bonding between textiles.

[0044] Furthermore, during the welding process, the control system drives the upper and lower ultrasonic welding heads to accurately move to the corresponding coordinates based on the placement position of the spacer 500. Subsequently, the two welding heads move towards each other, tightly clamping the already stacked upper connecting fabric 200, bagged spring string 100, and lower connecting fabric 300 between the welding head end faces. While maintaining the clamping pressure, ultrasonic vibration is activated, and energy is directly applied to the clamped local area through the welding head to complete the welding. It can be understood that this implementation method ensures precise coordination between the welding action and the positioning of the spacer 500. By clamping and welding at the corresponding position of the spacer 500, the spacer 500 can fully exert its welding resistance function, while ensuring that the welding energy is concentrated on fusing the connecting fabric, thereby perfectly protecting the bagged spring string 100 below from damage while forming a strong welded part 400. This "precise clamping and spot welding" method is key to ensuring consistent welding quality and product reliability.

[0045] It should be noted that the position of the welded portion 400 formed in step S500 is offset from the position of the springs in the bag spring string 100. Specifically, during process planning, a distribution pattern of welding points is set to ensure that each welded portion 400 falls within the gap area between two adjacent springs in the bag spring string 100, i.e., the springless area of ​​the bag. During equipment execution, a precise positioning control system ensures that the welding mechanism's movements strictly follow this preset pattern, thereby guaranteeing that all the welded portions 400 formed ultimately avoid the projection area of ​​the spring body in physical space. It is understandable that placing the welded portion 400 in the gap between the springs has the most direct and important benefit of completely avoiding any possible impact of the welding process on the springs themselves. The heat, pressure, or material melting generated during welding is confined to the springless area, ensuring that each spring can bounce freely and fully within its independent bag space, ensuring that the overall support performance, responsiveness, and service life of the bag spring pack are not damaged by the welding process.

[0046] In some embodiments, multiple independent welding units are integrated into the welding apparatus, each unit comprising a complete ultrasonic transducer, amplitude transformer, and welding head. These welding units can be arranged according to a predetermined welding dot matrix layout. Within a single welding cycle, all welding units receive the same command and start synchronously, causing multiple welding heads to press down and emit ultrasonic waves simultaneously, thereby forming multiple welded sections 400 at different positions in a single welding action. This configuration of multiple transducers working in parallel significantly improves production efficiency and welding consistency. It eliminates the sequential movement and multiple welding times required for single-head welding, shortening the welding cycle by several times. Simultaneously, since all welded sections 400 are formed at the same instant under the same process parameters, their welding quality and strength have a high degree of consistency, avoiding parameter fluctuations that may occur due to multiple welding operations, ensuring the uniformity and robustness of the overall product structure, making it particularly suitable for large-scale industrial production.

[0047] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A pocketed spring package, characterized in that, The bagged spring package comprises multiple rows of bagged spring strings arranged in parallel, each row of the bagged spring strings is composed of multiple independent bagged springs connected head to tail by cloth bags outside the bagged springs; upper and lower connecting cloths are respectively covered and connected above and below the multiple rows of bagged spring strings, wherein the upper connecting cloth and the lower connecting cloth are directly combined by welding at the gap corresponding to the bagged spring between the adjacent two rows of bagged spring strings, the welding part is formed by ultrasonic welding, so as to fix the multiple rows of bagged spring strings as a whole and accurately limit the spacing between the adjacent bagged spring strings.

2. The bagged spring pack of claim 1, wherein, The cloth bag of the bagged spring string is made of non-woven fabric or knitted fabric.

3. The bagged spring pack of claim 1, wherein, The upper and lower connecting cloths are polyester oxford cloth.

4. A method of producing a bagged spring pack, characterized by, The method for producing the bagged spring package as claimed in any one of claims 1 to 3, the bagged spring package comprises multiple rows of bagged spring strings arranged in parallel, each row of the bagged spring strings is composed of multiple independent bagged springs connected head to tail by cloth bags outside the bagged springs; upper and lower connecting cloths are respectively covered and connected above and below the multiple rows of bagged spring strings, wherein the upper connecting cloth and the lower connecting cloth are directly combined by welding at the gap corresponding to the bagged spring between the adjacent two rows of bagged spring strings, the welding part is formed by ultrasonic welding, so as to fix the multiple rows of bagged spring strings as a whole and accurately limit the spacing between the adjacent bagged spring strings, the method comprises the following steps: S100: providing multiple rows of bagged spring strings filled with springs; S200: placing a spacer in the cloth bag between adjacent bagged springs in each row of the bagged spring strings; S300: tensioning and guiding the upper and lower connecting cloths to the upper and lower sides of the multiple rows of bagged spring strings respectively; S400: superimposing the upper connecting cloth, the multiple rows of bagged spring strings and the lower connecting cloth, and welding at the position corresponding to the spacer by using a welding device; S500: the spacer prevents the upper and lower surfaces of the cloth bag of the bagged spring string at the position from being welded together, while the upper connecting cloth at the position is welded to the adjacent upper cloth, and the lower connecting cloth is welded to the adjacent lower cloth, forming a welding part, so as to connect the multiple rows of bagged spring strings into a whole spring pad.

5. The method of producing a bagged spring package of claim 4, wherein, In the step S200, the material of the spacer is metal, thermosetting plastic or high-melting-point plastic.

6. The method of producing a bagged spring pack of claim 4, wherein, In the step S300, the upper and lower connecting cloths are tensioned to a preset tension by at least one set of rubber-coated cloth rollers.

7. The method of producing a bagged spring package of claim 4, wherein, In the step S400, the welding device is an ultrasonic welding device, which has upper and lower ultrasonic welding heads arranged correspondingly and movable towards each other.

8. The method of producing a bagged spring package of claim 7, wherein, The upper and lower ultrasonic welding heads clamp and weld the superimposed materials at the position corresponding to the spacer.

9. The method of producing a bagged spring package of claim 4, wherein, In the step S500, the position of the welding part formed is staggered with the position of the spring in the bagged spring string.

10. The method of producing a bagged spring package of claim 4, wherein, In the step S500, the welding device is provided with two or more sets of ultrasonic transducers to synchronously generate multiple welding parts.

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