Foam mounting machine

Abstract

The invention relates to an device for mounting mattress foam (1), the device comprising: - an adhesive application station (2) provided with a gantry (26) connected via cylinders (21) to the longitudinal guide support (27) of the adhesive application guns; - a gantry (6) provided with: guide rails (65) for guiding the frame (68) that is movable by means of idler wheels (64) that are intended to translatably guide a carriage; a drive belt that is intended to engage with a toothed pulley mounted on the carriage of the movable conveyor (3) in order to drive it along the running rail. - a pneumatic bellows press (5) provided with a conveyor belt (544) and a transfer conveyor (53) located upstream of the press; - a conveyor (3) that is movable on the gantry (6) for positioning and gripping the peripheral surfaces of the foam.

Description

[0001] Foam mounting machine

[0002] Description

[0003] Field of invention:

[0004] The present invention relates generally to the manufacture of mattresses, and more particularly, to an apparatus for mounting the foam elements of a mattress.

[0005] Previous techniques:

[0006] Many processes are often involved in the mattress production process. Generally, when processing mattresses, an assembly line production method is preferred to provide greater precision and increase production rates.

[0007] There are several steps and mechanisms involved in the mattress production line, for example the glue spray feeding step, the mattress sub-assembly transport step, the assembly step, etc. The most critical step is spraying glue onto the mattress core, then gluing and assembling elements such as the foam side panels.

[0008] Usually, this operation involves semi-automatically transporting and applying glue, and then gluing the foam side panels, which will bring high labor intensity and low work efficiency. The long-term semi-automatic glue application and assembly operation will not only cause harm to the operators' bodies, but also limit the production capacity of the line. Therefore, developing a foam element assembly machine suitable for mattresses is preferable to improve production efficiency and operator safety.

[0009] It is known from the US patent application bearing number US2016214309 filed by DREAMWELL claiming US priority No. US201615003940, an apparatus for sizing and assembling foam elements to a nominal size comprising: a sizing table (204) having a planar surface (250) for supporting the foam layer; and an adjustable rail assembly (254) in movably communication with the sizing table (204), configured to compress and stretch the foam layer to a nominal size, characterized in that the adjustable rail assembly (254) comprises a pair of longitudinal rails (260, 264) and a pair of transverse rails (258, 262) for framing a periphery of the foam layer, each rail having a contact surface perpendicular to the planar surface (250) to provide compression of the foam layer, when in use;and one or more adjustable clamps disposed on each rail, having a fixed portion carried by the rail and configured to slide under the foam layer upon compression and an adjustable portion configured to pinch the foam to allow stretching of the compressed foam layer to a nominal size, when in use.;

[0010] Another prior art application bearing CN1 13334784 filed by Chinese mattress manufacturer HANGZHOU LUCKYKEY TECH CO LTD, wherein the invention provides a mattress manufacturing line which comprises a mattress core feeding station, a mattress core glue spraying station, a mattress core conveying table, a mattress core assembling station and a press. Said stations are sequentially arranged and the bed core feeding mechanism of which comprises a gantry and a mattress core clawing machine, bed core placing rails which are arranged on both sides of the mattress core collecting platform. The invention is also provided with a conveying table having a rotating conveying table and a conveying belt divided into an upper layer and a lower layer.

[0011] The prior art machines proposed below or involving semi-automatic operations are complicated and have high manufacturing costs. The technical problem of the invention is to obtain a mattress production system to substitute the semi-automatic operations and to provide an installation which can provide an adjustable counter-engagement surface against which the mattress elements are engaged, glued and pressed in such a way as to minimize inconsistencies or inaccuracies between the engagement of the side parts along the length, thus allowing a variety of different configurations to provide different size mattresses. DISCLOSURE OF THE INVENTION

[0012] The present invention aims to address the above-mentioned technical problems by means of a mattress assembly apparatus that allows mattress manufacturers to attach the foam border sections to each other and to the core with a high production rate while minimizing manufacturing defects. In addition, several foam-comprising surfaces can be stacked to assemble the foams on top of each other in a moving conveyor between a glue application station and a press.

[0013] The invention also relates to a mattress core comprehension system in the form of a padded tray. The tray is composed of four foam sides, providing edge support for persons sitting on the edge of the mattress, and containing a mattress core therein. The system is compatible with (and sized for) all standard mattress cores, e.g., coil spring, foam, foam / coil composite and all known sizes.

[0014] The present foam assembly apparatus thus consists of assembling a mattress platform with four vertical foam side walls mounted above. A standard mattress core can be placed within the confines of the moving conveyor and the assembly can then be covered with glue in a spray or glue application station.

[0015] In order to achieve the objective of the invention, the latter proposes a mattress foam mounting apparatus comprising:

[0016] - A gluing unit (2), used to spray or apply glue to the upper faces of the foam;

[0017] - A mobile conveyor (3) which allows the understanding of the vertical external surfaces of the foam elements and to move the core (7) towards the gluing unit (2) and to the bellows press (5);

[0018] - A pressing unit (5) which allows the core (7) to be pressed;

[0019] - A gantry (6) which allows the mobile conveyor (3) to be guided between the gluing unit (3) and the bellows press (5);

[0020] BRIEF DESCRIPTION OF DRAWINGS It will be understood that the drawings accompanying this description, are included to provide a better understanding of the present invention, and constitute a part of this description, illustrate various aspects, features, advantages of the present invention, and in conjunction with the following detailed description.

[0021] Furthermore, those skilled in the art will understand that, therefore, in practice, various features of the drawings are not necessarily drawn to scale, and that the dimensions of various features and elements shown or illustrated in the drawings and / or discussed in the following detailed description may be expanded,

[0022] Thus, the following figures illustrate certain illustrative embodiments of the invention in which like reference numerals designate like elements. These illustrated embodiments should be understood as illustrative of the invention and not as limiting in any way.

[0023] -Figure 1: Illustrates a perspective view of the prior art of a robotic station for transporting layers of foam between different units used in a mattress manufacturing apparatus;

[0024] -Figure 2: Illustrates a perspective view of the prior art of an apparatus for securing one or more layers of foam mattress to an inner core unit;

[0025] -Figure 3: Illustrates a perspective view of the partial prior art of a mattress element alignment unit and assembly;

[0026] -Figure 4: Illustrates a perspective view of the machine for mounting the foam elements of a mattress which is the subject of the present invention, comprising a gluing station, a mobile conveyor, and a bellows press.

[0027] -Figure 5: Illustrates a left view of the mattress assembly machine which is the subject of the present invention.

[0028] -Figure 6: Illustrates a left-hand view of the moving conveyor and the glue spraying or application station; -Figure 7: Illustrates a perspective view of the gluing station of the assembly machine;

[0029] -Figure 8: Illustrates a front view of the mobile glue spray guns and a detailed view of the transverse translation mechanism of said mobile guns (i.e. in the Y direction, i.e. the direction perpendicular to the translation direction of the mobile conveyor);

[0030] -Figure 9: Illustrates a perspective view of the translation mechanism of the mobile glue spray guns and which shows the guide elements of the guns in the longitudinal direction (i.e. in the X direction, the translation direction of the mobile conveyor);

[0031] -Figure 10: Illustrates a perspective view of the chassis of the mobile conveyor on the gantry rails and the guide and drive mechanism in the X direction, i.e. the translation direction of the mobile conveyor;

[0032] -Figure 11: Illustrates a front view of the mobile conveyor showing the actuation mechanism of the foam element comprehension elements;

[0033] -Figure 12: Illustrates a perspective view of the longitudinal understanding surface of the longitudinal foam element of the mobile conveyor mattress;

[0034] -Figure 13: Illustrates a perspective view of the transverse understanding surface of the transverse foam element of the mobile conveyor mattress;

[0035] -Figure 14: Illustrates a perspective view of the bellows press station;

[0036] - Figure 15: illustrates a perspective view of the bearing surface of the bellows press conveyor;

[0037] - Figure 16: illustrates a perspective view of the structure of the bellows press conveyor;

[0038] - Figure 17: illustrates a left view of the press conveyor;

[0039] - Figure 18: illustrates a left view of the guide gantry and the frame of the mobile conveyor; - Figure 19: illustrates a bottom view of the guide gantry and the frame of the mobile conveyor;

[0040] - Figure 20: Perspective view of the foam elements constituting the mattress core

[0041] - Figure 21: bottom view of the mobile conveyor

[0042] Detailed description and embodiments of the invention:

[0043] The following detailed description is of the best modes presently contemplated for carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is better defined by the appended claims. Aspects of the description will describe by way of example and by reference the embodiments illustrated above.

[0044] Components, and other elements of the machine that may be substantially the same in one or more embodiments are identified in a coordinated manner and are described with a minimum of repetition. Thus, many specific details are described to provide a thorough understanding of the invention. However, in some instances, these well-known or conventional details are not described so as not to obscure the description. It will be noted, however, that coordinated identified elements may also differ to some extent. It will be further noted that the drawing figures included herein are schematic and generally not drawn to scale. Instead, the various drawing scales, aspect ratios, and numbers of components shown in the figures may be intentionally distorted to make certain features or relationships easier to see.

[0045] Reference in this specification to "an embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. Appearances of the phrase "in an embodiment" at various places in the description do not necessarily all refer to the same embodiment, and separate or alternative embodiments are not mutually exclusive of other embodiments. In addition, various features are described that may be exhibited by some embodiments and not by others.

[0046] The terms used in this specification generally have their ordinary meanings in the art, in the context of the disclosure, and in the specific context in which each term is used. Certain terms used to describe the information are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner regarding the description of the information.

[0047] Accordingly, alternative language and synonyms may be used for any one or more of the terms discussed herein, and no particular significance should be attached to whether or not a term is elaborated or discussed herein. The listing of one or more synonyms does not preclude the use of other synonyms. The use of examples anywhere in this description, including examples of any terms discussed herein, is illustrative only and is not intended to further limit the scope and meaning of the disclosure or any exemplified term. Likewise, the disclosure is not limited to the various embodiments given in this description.

[0048] Without intending to further limit the scope of the disclosure, examples of the mechanical elements, apparatuses, and their associated results according to embodiments of the present disclosure are given below.

[0049] A mattress foam assembly apparatus is provided that allows the mattress manufacturer to position, secure, and assemble foam side panel sections in a moving conveyor by applying glue in a glue spray station and sending them to a bellows press.

[0050] As shown in Fig.20, the mattress core (7) comprises a base (73) and four foam side panels. Said side panels are longitudinal foam panels (71) and transverse foam panels (72) which are glued together and extend along an outer perimeter of the mattress assembly (7). The base (73) is glued to the inside of the longitudinal and transverse foam panels (71 and 72) thus said panels (71-72), are glued together and to the base (73) with an adhesive. The tub defines an interior cavity (73) which is sized to receive spring packs or other elements,

[0051] Referring now to FIG. 4, a perspective view of the mattress foam mounting machine (1) is illustrated, which comprises:

[0052] - A glue station (2) having a generally parallelepiped structure and having spray guns movable transversely and longitudinally (i.e. in the X and Y direction)

[0053] - A mobile conveyor (3) provided with: a transport mechanism consisting of a wheel mounted on a carriage and pivoting freely on a horizontal roller track; a drive mechanism for driving at least one toothed belt to rotate forwards or backwards along the transport direction.

[0054] - A gantry (6) which constitutes a guide rail containing a drive belt intended to cooperate with a toothed pulley mounted on the carriage of the mobile conveyor in order to drive them along the running rail.

[0055] - A press unit comprising a bellows press (5), a conveyor and a gantry (4) which constitutes a counter-support surface of the bellows press.

[0056] Referring now to Fig. 7, a perspective view of the glue application or spraying station (2) comprising: a gantry (26) connected through the jacks (21) to the support of the longitudinal guide elements (27), the latter and according to a preferred embodiment is provided with a guide rail (25); a toothed belt pulley (23) for guiding the glue spraying mechanism (22) along the Y axis (i.e. the translation direction of the mobile conveyor (3). Said jacks (21) allowing the displacement of the guide support-gun assembly vertically along the Z axis (i.e. the direction perpendicular to the translation plane of the mobile conveyor) and a fixed gun (28);

[0057] Referring now to Figure 8, which illustrates the mechanism (22) for moving and driving the guns along the X axis (i.e. the direction perpendicular to the direction of movement of the mobile conveyor (3)). Said mechanism (22) comprises:

[0058] - A guide rail (223), intended to guide the guns in translation

[0059] (221); - Sliding means (227) arranged to slide along the guide rail (223);

[0060] - Drive means arranged to drive the guns (221) in translation along the guide rail (223), the drive means comprising: a toothed drive pulley (224) mounted on the shaft of the servomotor (228) and located on the first end portion of the guide rail (223);

[0061] - A return pulley (229) mounted at the second end portion of the guide rail (223);

[0062] - A drive input belt (225) connected to the drive pulley (224) and the return pulley (229).

[0063] In one embodiment of the present invention the apparatus may be provided with an automaton for adjusting the speed of movement of the glue spray guns which allows the application rate of the glue to be adapted in order to couple the placement of the movable conveyor (3), and thus providing a volume application of the glue according to a desired pattern.

[0064] The process of transporting the foams to the glue application station and to the bellows press will be explained briefly with reference to Fig. 10 and 11, where the carriage (36) or a similar container as a load carrier is positioned on the guide rails (65) of the gantry (6) by means of the idler wheels (64) intended to guide the carriage (36) in translation relative to the gantry (6). The translation is made through drive means arranged to drive the carriage (36) in translation along the guide rail (65), said drive means comprising: a driving input pulley (67) mounted on a shaft of a servomotor in the first end of the guide rail (65); a deflection pulley (62) mounted at the second end portion of the guide rail (65); a drive belt (61) connected to the driving pulley (64) and the deflection pulley (62).

[0065] In another embodiment of the invention, the drive system of the mobile carriage may be a chain-pinion system, belt pulleys arranged with a motor or geared motor and automatons, microcontrollers connected with sensors: proximity, end of travel, or positioning.... The station for holding, positioning and understanding the sections of the foam side panels shown in Fig. 10, 11, 12, 13 and 21 comprises:

[0066] - A gantry (36) fixed on the mobile chassis (68);

[0067] - At least one conveyor belt (39); a drive shaft (37) for driving the conveyor belt (39) further provided at least one first guide roller (31), which can also be driven and can act as a drive roller to another drive roller juxtaposed and aligned with the first roller through a coupling (38). The drive device comprises a drive shaft (37), at least one set of, a return roller (39) and a drive motor (not shown)

[0068] A station for aligning and positioning foam panels in a precise, reproducible location. Said station generally comprises four reference comprehension elements (32) and (33) which collectively define a basic reference corner of the inner core unit of the mattress foams and the set of side panels when in contact with the comprehension elements (32) and (33).

[0069] The understanding elements (32) which extend along the movable carriage (3), (i.e. the Y direction generally parallel to the path of movement of the movable carriage (3) in the gantry (6). The said understanding elements (33) is transverse to the surface of the movable carriage (3) and extends along the movable carriage (3) i.e. perpendicular to the understanding elements (32) (i.e. the X direction which is perpendicular to the path of movement of the movable carriage (3)). The understanding elements (32) and (33) are in vertical contact with the external lateral surfaces of foam.

[0070] The pairs of understanding elements (32) are symmetrical with respect to the longitudinal median plane of the mobile carriage (3) (i.e. in the X direction), likewise the pairs of understanding elements (33) are symmetrical with respect to the transverse median plane of the mobile carriage (3) (i.e. in the Y direction)

[0071] According to one embodiment of the invention, the understanding elements (32) can be mounted controllably at the first end of the gantry (36) parallel to the path of movement of the mobile carriage (3) and the understanding elements (33) can be pivotally mounted at a second end of the carriage (36) generally perpendicular to the path of movement of the mobile carriage (3). According to one embodiment of the invention, the understanding elements (32) can be actuated vertically relative to the upper surface of the conveyor belt (39) via an actuator controlled by, for example, a pneumatic cylinder (35) mounted on the crosspieces of the gantry (36) and the axis of actuation of which is vertical to the contact surfaces of the understanding elements (32) with the foams.

[0072] According to another embodiment of the invention and with reference to Figure 12, the understanding elements (33) are mounted on the first upper end of the membrane (30) in an L shape and pivoting relative to an axis of rotation on the second end of the membrane (30). The understanding elements (33) are driven by jacks (34) arranged horizontally inside the membrane (30);

[0073] During the transport process to the glue application station, the grasping elements (33) and (32) remain in the retracted position as shown in Figure 4. However, during the transfer to the bellows press, the grasping elements remain in the open position so as to allow the assembled foams to move unhindered towards the bellows press conveyor.

[0074] In one embodiment of the invention and with reference to Figure 15, the movable transfer surface (39) is not intended to be limited to a particular type and may comprise a plurality of roller conveyors and / or a rotating belt driven in rotation by a motor to automatically move the foam core unit to the bellows press or the glue application station.

[0075] The bellows press unit (5) shown in Fig. 14 to 17 comprises:

[0076] - A conveyor belt (544) and a drive shaft for driving a first drive roller (542), a second guide roller (545), a drive shaft and a geared motor (51).

[0077] - A table (543) having a generally planar bearing surface configured to compress the foams against the upper surface of the gantry (44). The support surface (543) is held by longitudinal cross members.

[0078] - A transfer table (53) of the mattress foam core from the movable conveyor (3) to the bellows press (5), which is not intended to be limited to a particular type and may comprise a plurality of rollers. Said transfer table (53) is located upstream of the bellows press and its first end is pivotable relative to a parallel axis of the second guide roller (545) through a jack (52) mounted on the gantry (4) and whose rod is pivotally mounted with the transfer table (53).

[0079] - a pneumatic bellows press (42), comprising an upper mold and a lower mold for shaping a pneumatic bellows, and pressing heads which move linearly by means of horizontal pushing elements positioned on the table (543), of which the first vertical pushing element is embedded with the crosspiece (41) and the second pushing element is embedded with the table (543).

[0080] The above description has been provided to enable those skilled in the art to make the best use of various aspects of the exemplary embodiments described herein. This exemplary description is not intended to be exhaustive or to be limited to any specific form disclosed. Numerous modifications and variations are possible without departing from the spirit and scope of this description. The embodiments described herein should be considered in all respects as illustrative and not limiting. Reference should be made to the appended claims and their equivalents to determine the scope of this disclosure.

[0081] Unless otherwise indicated, the terms "unit" and "station" (and their derivatives), as used in the description and claims, are to be interpreted as both enabling a technical effect to be generated (i.e., via other elements or components). In addition, the terms "a" or "an", as used in the description and claims, are to be interpreted as meaning "at least one of". Finally, for ease of use, the terms "comprising" and "having" (and their derivatives), as used in the description and claims, are interchangeable and have the same meaning as the word "comprising".

[0082] Furthermore, the terms "transverse" or "longitudinal", as used in the description and claims, should be interpreted as meaning the transverse or longitudinal direction of the mattress, i.e., respectively: the X direction perpendicular to the direction of movement of the movable carriage and the Y direction parallel to the direction of movement of the movable carriage.

Claims

Demands 1 - A mattress foam mounting device (1) comprising: - A glue application station (2), equipped with: a gantry (26) connected via cylinders (21) to the longitudinal guide support (27) of the glue application guns, said guide support (27) is equipped with a guide rail (25); a fixed gun (28); mobile glue application guns (221); a toothed pulley-belt (23) to drive the glue spraying mechanism (22) in the Y direction, i.e., the direction of translation of the mobile conveyor (3); - A gantry (6) equipped with: guide rails (65) for the mobile chassis (68) by means of idler wheels (64) intended to guide the carriage (36) in translation; a drive belt intended to cooperate with a toothed pulley mounted on the carriage (36) of the mobile conveyor in order to drive them along the running rail. - A pneumatic bellows press (5) equipped with a conveyor belt (544) and a transfer conveyor (53) is located upstream of the press; - A mobile conveyor (3) on the gantry (6) for positioning and understanding the peripheral surfaces of the foams. Characterized in that the mobile conveyor (3) comprises: a gantry (36) fixed on the mobile chassis (68); at least one conveyor belt (39); a first pair of longitudinal comprehension elements (32) actuated by the cylinder (35) and extending along the mobile carriage (3) and a second pair of transverse comprehension elements (33) actuated by the cylinders (34) and perpendicular to the first longitudinal comprehension elements (32). 2- A mattress foam mounting device (1) according to claim 1 characterized in that the mobile conveyor (3) comprises a gantry (36) fixed to the mobile frame (68); at least one conveyor belt (39); a drive shaft (37) to drive the conveyor belt (39) further provided at least one first guide roller (31) driven in rotation and can act as a drive roller to another drive roller juxtaposed and aligned with the first roller through a coupling (38); a return roller (39) and a drive motor. 3- A mattress foam mounting device (1) according to claim 2 characterized in that the comprehension elements (32) are actuated by a pneumatic cylinder (35) such that the comprehension element (32) performs a partial rotational movement relative to the conveyor belt 39 and whose axis of rotation is parallel to the direction of translation of the mobile conveyor (3). 4- A mattress foam mounting device (1) according to claim 3 characterized in that the understanding elements (33) are mounted on the first upper end of the L-shaped membrane (30) and are actuated by the cylinders (34) such that the understanding element (33) performs a partial rotational movement relative to the conveyor belt 39 and whose axis of rotation is perpendicular to the direction of translation of the mobile conveyor (3). 5- A mattress foam mounting device (1) according to claim 4 characterized in that the glue application mechanism (22) comprises: A guide rail (223), intended to guide the guns (221) in translation; sliding means (227) arranged to slide along the guide rail (223); drive means arranged to drive the guns (221) in translation along the guide rail (223), drive means provided with: a toothed drive pulley (224) mounted on the shaft of the servomotor (228) and a return pulley (229) mounted on the second end portion of the guide rail; a drive input belt (225) connected to the drive pulley (224) and to the return pulley (229). 6- A mattress foam mounting apparatus (1) according to any one of the preceding claims characterized in that the bellows press (5) further comprises: a conveyor belt (544) upstream of the bellows press; a table (543) having a generally flat bearing surface configured to compress the foams against the upper surface of the gantry (44), a pneumatic bellows press (42) the first pushing element of which is embedded with the cross member (41) and the second pushing element is embedded with the table (543). 7- A mattress foam mounting device (1) according to claim 6 characterized in that the translation of the mobile conveyor (3) is made through drive means arranged to drive the carriage (36) in translation along the guide rail (65), said drive means comprising: a drive input pulley (67) mounted on a shaft coupled with a servomotor in the first end of the guide rail (65); A return pulley (62) mounted at the second end portion of the guide rail (65); a drive belt (61) connected to the drive pulley (64) and to the return pulley (62). 8- A mattress foam assembly device (1) according to claim 7 characterized in that the glue application station (2), the gantry (6), the pneumatic bellows press (5) and the mobile conveyor (3) are arranged in a straight configuration.

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