Device for wrapping a cushion with a hose-shaped textile fabric

Abstract

The invention concerns a device for wrapping a cushion (1) with a hose-shaped textile fabric (2), with a wrapping section (4) configured for holding a supply of the fabric (2), for receiving the cushion (1) and for wrapping the received cushion (1) by enclosing it with the fabric (2), wherein the wrapping section (4) comprises a heating beam arrangement (5) configured to, after enclosing the received cushion (1) with the fabric (2), engage sections (20) of the fabric (2) and join the sections (20) of the fabric (2) by heating. The device is characterized in that the device comprises a dispenser apparatus (10) for applying a brazing material (11), which brazing material (11) is heated by the heating beam arrangement (5) for joining the sections (20) of the fabric (1) by brazing. The invention also concerns a method for wrapping a cushion (1) with a hose-shaped textile fabric (2).

Description

[0001] The present invention concerns a device for wrapping a cushion with a hose-shaped textile fabric with the features of the general part of claim 1 as well as a method for wrapping a cushion with a hose-shaped textile fabric with the features of the general part of claim 14.

[0002] A cushion such as a mattress body or a pillow body is easier to handle and to insert into a mattress cover or pillow cover when it is wrapped with a textile fabric. Such a wrapping also offers protection to the cushion.

[0003] Devices for wrapping cushions with textile fabrics are known from the prior art, for example from the patent DE 10 2010 064 703 B3, which is considered the closest prior art for the present invention. Here, the cushion is wrapped with a hose-shaped fabric by first pulling the cushion in order to enclose it with the fabric and then heating and sealing the fabric at the open end, thereby closing it. This sealing is effected by having two beams engage the fabric and then have at least one of the beams heat the fabric in a welding process. By heating the fabric, the fabric material melts and fuses. Thus, the fabric material itself is melted for the sealing effect.

[0004] Though this process has been found reliable and very economic compared to the solutions that were known before, it is evident that the throughput of such a device is one of the most important criteria for the economic benefit that it conveys to its operator, which throughput in turn depends on the time it takes to process each mattress. Thus, there is a need to further reduce the processing time for such devices.

[0005] The object of the invention is achieved for a device for wrapping a cushion with a hose-shaped textile fabric with the features of the general part of claim 1 through the features of the characterizing part of claim 1. With respect to the method for wrapping a cushion with a hose-shaped textile fabric with the features of the general part of claim 14, the object of the invention is achieved through the features of the characterizing part of claim 14.

[0006] The invention proceeds from the realization that a brazing material may be used for joining the textile fabric. Such brazing material permits the choice of material properties different from those of the fabric, for example a lower melting temperature. This in turn allows to conduct the heating and cooling procedure for the sealing in a shorter time.

[0007] The device according to the invention is for wrapping a cushion with a hose-shaped textile fabric. The cushion may be a mattress or a pillow and in particular a mattress core or a pillow core. The device according the invention comprises a wrapping section, which wrapping section is configured for holding a supply of the fabric, for receiving the cushion and for wrapping the received cushion by enclosing it with the fabric. The hose-shaped textile fabric may be provided in the form in the shape of a hose, which hose is closed on one end with the other end open. Thus, when the cushion is received and wrapped, the fabric wrapping the cushion is at first open on one end.

[0008] For the device according to the invention, the wrapping section comprises a heating beam arrangement configured to, after enclosing the received cushion with the fabric, engage sections of the fabric and join the sections of the fabric by heating.

[0009] The device according to the invention is characterized in that the device comprises a dispenser apparatus for applying a brazing material, which brazing material is heated by the heating beam arrangement for joining the sections of the fabric by brazing. In other words, the heating beam arrangement heats and melts the brazing material. The sections of the fabric are therefore joined at least by the melted - and subsequently solidified once again - brazing material. It may also be that parts of the sections are also melted, though that is not required. In other words, more material than just the brazing material may be melted by the heating beam arrangement and may consequently contribute to joining the sections of the fabric.

[0010] In principle, the cushion may be fed to the wrapping section in an arbitrary way. According to a preferred embodiment of the device according to the invention, the device comprises a sliding section for supporting the cushion to be wrapped and for feeding the cushion to be wrapped to the wrapping section. For example, the sliding session may comprise rollers to slidably support the cushion. Preferably, the wrapping section comprises clamping arms for engaging the cushion. In particular, the wrapping section and in particular clamping arms may also be for pulling the cushion from the sliding section. In this case, the wrapping section may comprise a drive and in particular a clamping arm drive for pulling the cushion from the sliding section. In particular, the cushion may be pulled from the sliding section into the wrapping section.

[0011] The fabric may in principle be any kind of fabric. It is preferred that the fabric is a knitted fabric and in particular a tricot fabric.

[0012] According to a further preferred embodiment of the device according to the invention, the wrapping section is configured for pulling the cushion through the heating beam arrangement. In particular, it may be that the clamping arms are configured for pulling the cushion through the heating beam arrangement. This configuration is particularly suitable for having the heating beam arrangement join the sections of the fabric. Preferably, the heating beam arrangement forms a gate through which the cushion is pulled. Further, it is preferred that the clamping arms are configured to vertically move for engaging the cushion. Thus, the clamping arms may clamp down in the cushion supported on the sliding section. The vertical movement of the clamping arms may be combined with a movement in a further direction, e.g. horizontally.

[0013] It may be that the dispenser apparatus applies the brazing material to the sections directly. A preferred embodiment of the device according to the invention is characterized in that the dispenser apparatus is configured to apply the brazing material to the heating beam arrangement. In this way, the proper alignment between the heating beam arrangement and the brazing material is ensured. Preferably, the dispenser apparatus comprises a guide rail for driving a nozzle arrangement of the dispenser apparatus along a length of the heating beam arrangement, which nozzle arrangement is configured for applying at least one line of the brazing material. In particular, the nozzle arrangement is configured to apply the at least one line of the brazing material as the nozzle arrangement is driven along the length of the heating beam arrangement by the guide rail. It is to be noted that it may be that the nozzle arrangement is driven only along a part of a length of the heating beam arrangement.

[0014] It is preferred that the dispenser apparatus is configured to apply the brazing material, in particular to the heating beam arrangement, in a dispensing time which is less than 15 seconds. Moreover, it may also be that the dispenser apparatus is configured to apply the brazing material, in particular to the heating beam arrangement, in a dispensing time which is less than 10 seconds. In addition, it is preferred that the time for driving the nozzle arrangement along the length of the heating beam arrangement is less than 15 seconds and preferably less than 10 seconds. Shorter times for driving the nozzle arrangement and for applying the brazing material result in a higher throughput of cushions.

[0015] It may be that the nozzle arrangement has only a single nozzle. However, a further preferred embodiment of the device according to the invention is characterized in that the nozzle arrangement comprises two nozzles for applying two lines of the brazing material. These two lines of the brazing material may be arranged substantially parallel. Each nozzle of the nozzle arrangement applies a respective line of the two lines of the brazing material. Preferably, the two lines of the brazing material are applied on the heating beam arrangement. If the nozzle arrangement comprises only a single nozzle, it may also be that the dispenser apparatus is configured to drive the nozzle arrangement back and forth along the length of the heating beam arrangement to apply a single line of the brazing material for each stroke. In other words, one complete back and forth movement of the nozzle arrangement with a single nozzle results in the application of two lines of the brazing material.

[0016] According to a preferred embodiment of the device according to the invention, the heating beam arrangement comprises two beams configured for relative movement. The relative movement may be substantially vertical. Thereby, the two beams may execute a closing and opening relative movement. It may be that both beams move for their relative movement. It may also be that only one beam moves for the relative movement and the other beam remains substantially immobile. In particular, it may be that only the upper beam of the two beams moves for the relative movement.

[0017] In principle, the two beams may have an arbitrary length. Preferably, the two beams are of substantially equal length. In particular, it may be that a respective beam length of the two beams is between 800 mm and 3000 mm or between 900 mm and 2500 mm. More precisely, a respective beam length of the two beams may be substantially 2400 mm. It is also preferred that the two beams are oriented transverse to a pulling direction of the clamping arms.

[0018] It may be that the dispenser apparatus is configured to apply the brazing material directly to the fabric. However, it is preferred that the dispenser apparatus is configured to apply the brazing material to at least one of the two beams. Preferably, at least one of the beams, in particular the at least one of the beams to which the brazing material is applied, comprises a surface material for preventing adhesion of the brazing material to the at least one beam. Preferably, the surface material is polytetrafluoroethylene (PTFE). Moreover, it is preferred that the dispenser apparatus and in particular the nozzle arrangement is configured to be switchably positioned between the two beams for applying the at least one line of brazing material. In other words, the dispenser apparatus and in particular the nozzle arrangement may be driven to a position between the two beams and then driven to a position which is not between the two beams and therefore outside the two beams.

[0019] In general, the dispenser apparatus may apply the brazing material at an arbitrary point during processing of the cushion. It is preferred that the dispenser apparatus is configured to apply the brazing material while the wrapping section pulls the cushion from the sliding section. In particular, the dispenser apparatus may be configured to apply the brazing material while the clamping arms pull the cushion from the sliding section.

[0020] In principle, nozzle arrangement may apply the brazing material to the heating beam arrangement from any distance. Preferably, the nozzle arrangement is configured to apply the brazing material to the heating beam arrangement from an application distance that is between 3 mm and 15 mm, preferably between 5 mm and 10 mm. This application distance is the distance between the nozzle arrangement and the heating beam arrangement when applying the brazing material.

[0021] According to a further preferred embodiment of the device according to the invention, the two beams are configured to be brought together for engaging the sections of the fabric. Preferably, at least one of the two beams is configured for heating the sections. It may also be that both beams are configured for heating the sections. It is further preferred that the two beams are configured to be separated for permitting the clamping arms to engage and pull the cushion. The heating beam arrangement may comprise a beam drive for selectively driving the two beams together and for separating the two beams.

[0022] A preferred embodiment of the device according to the invention is characterized in that the heating beam arrangement is configured such that the two beams engage the fabric for less than 20 seconds before the two beams are separated. Further, it may be that the heating beam arrangement is configured such that the two beams engage the fabric for less than 15 seconds or less than 10 seconds before the two beams are separated. Such a short engagement time significantly the total processing time for the cushion and consequently enables a large cushion throughput by the device.

[0023] A further preferred embodiment of the device according to the invention is characterized in that the brazing material is solidified before the two beams are separated. This solidification may occur by stopping the heating and the subsequent cooling process.

[0024] According to a preferred embodiment of the device according to the invention, the clamping arms are configured for moving at least partially through the heating beam arrangement for engaging the cushion. This means that at least a part of the clamping arms moves through the heating beam arrangement. In particular, it may be that the heating beam arrangement forms an opening through which the clamping arms at least partially move. The heating beam arrangement may be arranged in the manner of a gate to form the opening. Preferably, the clamping arms are configured for moving at least partially between the two beams for engaging the cushion. In particular, the clamping arms may be configured for moving at least partially through the heating beam arrangement when the two beams are separated for engaging the cushion.

[0025] According to a further preferred embodiment of the device according to the invention, the wrapping section is configured to hold a supply of the fabric such that the fabric is wrapped around the cushion when the wrapping section pulls the cushion through the heating beam arrangement. Thus, the pulling of the cushion happens substantially simultaneously as the wrapping of the fabric, thereby saving time. Preferably, the wrapping section is configured to hold a supply of the fabric such that the fabric is wrapped around the cushion when the clamping arms pull the cushion through the heating beam arrangement

[0026] A preferred embodiment of the device according to the invention is characterized in that the brazing material is applied by the dispenser apparatus in a liquid state. Here, it is in particular preferred that the brazing material is liquid at 20° C. Consequently, the brazing material does not need to be liquified by temperature or pressure for application by the nozzle arrangement. In particular, it may be that the brazing material is curable and liquid at 20° C in a pre-cured state. It is further preferred that the heating beam arrangement is configured to solidify the brazing material through heating. The brazing material may solidify by curing. Compared to solidification only after returning to a temperature below the melting point, this has the advantage that the process does not have to wait for the brazing material to cool off. The rate of heating up is more easily controlled and may be increased simply by feeding more energy. In contrast, the cooling process is more difficult to shorten.

[0027] Further, it is preferred that the dispenser apparatus comprises a reservoir for holding the brazing material. This reservoir may be a bag. The reservoir preferably has a holding capacity of between 10 kg and 30 kg of brazing material, in particular of substantially 20 kg of brazing material.

[0028] It is further preferred that the dispenser apparatus comprises a pump and in particular a peristaltic pump for applying the brazing material. The dispenser apparatus may apply the brazing material by ejecting the brazing material through the pump. In particular, the pump may apply a pressure of substantially 2 kPa - corresponding to 2 bar - on the brazing material for applying the brazing material.

[0029] It is preferred that the brazing material remains solid after curing at 20° C. It is further preferred that the heating beam arrangement and the brazing material are configured such that the brazing material is solidified by the heating beam arrangement during a heating period shorter than 20 seconds, preferably shorter than 15 seconds.

[0030] A further preferred embodiment of the device according to the invention is characterized in that the brazing material comprises a plastisol. Preferably, the brazing material substantially consists of a plastisol. A plastisol is liquid at room temperature, in particular 20 °C, before curing. Curing by heating solidifies the plastisol. After curing, the plastisol remains solid, in particular after cooling off to room temperature.

[0031] The method according to the invention is for wrapping a cushion with a hose-shaped textile fabric. In the method according to the invention, a wrapping section holds a supply of the fabric. Further in the method according to the invention, the wrapping section receives the cushion and wraps the received cushion by enclosing it with the fabric. Also in the method according to the invention, a heating beam arrangement of the wrapping section, after the cushion has been enclosed, engages sections of the fabric and joins the sections by heating.

[0032] The method according to the invention is characterized in that a dispenser apparatus applies a brazing material which is subsequently heated by the heating beam arrangement for joining the sections by brazing.

[0033] A preferred embodiment of the method according to the invention is characterized in that the heating beam arrangement comprises two beams which engage the sections by being brought together, preferably after the brazing material is applied, which two beams subsequently heat the sections until the brazing material is solidified. Preferably, the two beams engage the sections by being brought together after the brazing material is applied.

[0034] Features, characteristics and preferred embodiments of the device according to the invention correspond to those of the method according to the invention and vice versa.

[0035] Additional advantageous and preferred embodiments follow from the following detailed description with reference to the Figures. In the Figures showing only a single embodiment it is shown in Fig. 1a schematic illustration of an embodiment of the device according to the invention configured for executing the method according to the invention in a first stage before the wrapping is complete, Fig. 2a schematic illustration of the embodiment of Fig. 1 in a second stage after the wrapping is complete and Fig. 2a detailed schematic illustration of the heating beam arrangement and the dispenser apparatus of the embodiment of Figs. 1 and 2.

[0036] The device shown in Fig. 1 is for wrapping a cushion 1, which is here a mattress 1a, with a textile fabric 2 which is here a tricot fabric. The textile fabric 2 is hose-shaped and provided as a supply by the device in a manner described in more detail below.

[0037] As shown in Fig. 1, the mattress 1a is arranged on a sliding section 3 of the device adjacent to the wrapping section 4 of the device. The wrapping section 4 comprises a heating beam arrangement 5 with two horizontally aligned beams 6a, b, arranged with a relative vertical displacement, and two vertically aligned supports 7a, b for the beams 6a, b. In the process stage shown in Fig. 1, beams 6a, b are separated, thereby forming, together with the supports 7a, b, an opening 8 of the heating beam arrangement 5. The wrapping section 4 further comprises two clamping arms 9a, b which protrude through the opening 8 to engage the cushion 1.

[0038] In the process stage shown in Fig. 1, a dispenser apparatus 10 of the device applies two lines 12a, b of brazing material 11 to the upper beam 6a. The dispenser apparatus 10 is shown in more detail in Fig. 3 after the two lines 12a, b of brazing material 11 have been applied. The brazing material 11 is applied by driving a nozzle arrangement 13 with two nozzles 14a, b for applying a respective line 12a, b along a guide rail 15, which guide rail 15 runs parallel to the upper beam 6a. The nozzle arrangement 13 is positioned on an extendable nozzle support 16 such that it can be positioned between the beams 6a, b for applying the brazing material 11 and then, after application of the brazing material 11, moved out from between the beams 6a, b. The brazing material 11, which is a plastisol 18 and in a liquid state at room temperature, is held in a reservoir 17 of the dispenser apparatus 10 and ejected from the nozzles 14a, b by means of a pump 19 of the dispenser apparatus 10.

[0039] In the time between the process stage shown in Fig. 1 and the subsequent process stage shown in Fig. 2, the mattress 1a has been pulled from the sliding section 3, through the opening 8 of the heating beam arrangement 5 to the wrapping section 4 by the clamping arms 9a, b. By this pulling movement, the mattress 1a has been enclosed with the fabric 2, the supply of which is arranged in a folded manner around the clamping arms 9a, b as a hose. Moreover, the beams 6a, b have been brought together and thereby engage sections 20 of the fabric 2 to be joined.

[0040] After being brought together, the beams 6a, b are heated for a heating period which is 5 seconds long, thereby resulting in a curing and, consequently, a solidification of the plastisol 18 as brazing material 11. The solidification of the brazing material 11 results in a joining of the sections 20 and thereby also in a sealing of the so far open end of the fabric 2 wrapped around the mattress 1a. The beams 6a, b remain together for a further cooling period of 10 seconds and are separated thereafter. Because the brazing material 11 has been cured, it remains solid even after cooling down to its previous temperature and does not return to the liquid state.

[0041] After the separation of the beams 6a, b, the wrapped mattress 1a is then pulled further along and out of the wrapping section 4 and the next mattress 1a may then be pulled by the clamping arms 9a, b as new brazing material 11 is applied by the dispenser apparatus 10.

Claims

1. Device for wrapping a cushion (1) with a hose-shaped textile fabric (2), with a wrapping section (4) configured for holding a supply of the fabric (2), for receiving the cushion (1) and for wrapping the received cushion (1) by enclosing it with the fabric (2), wherein the wrapping section (4) comprises a heating beam arrangement (5) configured to, after enclosing the received cushion (1) with the fabric (2), engage sections (20) of the fabric (2) and join the sections (20) of the fabric (2) by heating, characterized in that the device comprises a dispenser apparatus (10) for applying a brazing material (11), which brazing material (11) is heated by the heating beam arrangement (5) for joining the sections (20) of the fabric (1) by brazing.

2. Device according to claim 1, characterized in that the device comprises a sliding section (3) for supporting the cushion (1) to be wrapped and for feeding the cushion (1) to be wrapped to the wrapping section (4), preferably, that the wrapping section (4) comprises clamping arms (9a, b) for engaging the cushion (1), in particular, and for pulling the cushion (1) from the sliding section (3).

3. Device according to claim 2, characterized in that, the wrapping section (4) is configured, in particular the clamping arms (9a, b) are configured, for pulling the cushion (1) through the heating beam arrangement (5), preferably, that the clamping arms (9a, b) are configured to vertically move for engaging the cushion (1).

4. Device according to one of claims 1 to 3, characterized in that the dispenser apparatus (10) is configured to apply the brazing material (11) to the heating beam arrangement (5), preferably, that the dispenser apparatus (10) comprises a guide rail (15) for driving a nozzle arrangement (13) of the dispenser apparatus (10) along a length of the heating beam arrangement (5), which nozzle arrangement (13) is configured for applying at least one line (11a, b) of the brazing material (11).

5. Device according to claim 4, characterized in that the nozzle arrangement (13) comprises two nozzles (14a, b) for applying two, in particular substantially parallel, lines (11a, b) of the brazing material (11), preferably on the heating beam arrangement (5).

6. Device according to one of claims 1 to 5, characterized in that the heating beam arrangement (5) comprises two beams (6a, b) configured for relative, in particular substantially vertical, movement, preferably, that the dispenser apparatus (10), in particular the nozzle arrangement (13), is configured to be switchably positioned between the two beams (6a, b) for applying the at least one line (11a, b) of brazing material (11).

7. Device according to claim 6, characterized in that the two beams (6a, b) are configured to be brought together for engaging the sections (20) of the fabric (2), in particular, that at least one of the two beams (6a, b) is configured for heating the sections (20), preferably, that the two beams (6a, b) are configured to be separated for permitting the clamping arms (9a, b) to engage and pull the cushion (1).

8. Device according to claim 7, characterized in that the heating beam arrangement (5) is configured such that the two beams (6a, b) engage the fabric (2) for less than 20 seconds, preferably for less than 15 seconds before the two beams (6a, b) are separated.

9. Device according to claim 8, characterized in that the brazing material (11) is solidified before the two beams (6a, b) are separated.

10. Device according to claim 8 or 9, characterized in that the clamping arms (9a, b) are configured for moving at least partially through the heating beam arrangement (5), preferably for moving at least partially between the two beams (6a, b), for engaging the cushion (1), further preferably, that the clamping arms (9a, b) are configured for moving at least partially through the heating beam arrangement (5) when the two beams (6a, b) are separated.

11. Device according to one of claims 7 to 10, characterized in that the wrapping section (4) is configured to hold a supply of the fabric (2) such that the fabric (2) is wrapped around the cushion (1) when the wrapping section (4) pulls the cushion (1) through the heating beam arrangement (5).

12. Device according to one of claims 1 to 11, characterized in that the brazing material (11) is applied by the dispenser apparatus (10) in a liquid state, preferably, that the heating beam arrangement (5) is configured to solidify the brazing material (11) through heating, preferably, that the heating beam arrangement (5) and the brazing material (11) are configured such that the brazing material (11) is solidified by the heating beam arrangement (5) during a heating period shorter than 20 seconds, preferably shorter than 15 seconds.

13. Device according to claim 11 or 12, characterized in that the brazing material (11) comprises a plastisol (18), preferably, that the brazing material (11) substantially consists of a plastisol (18).

14. Method for wrapping a cushion (1) with a hose-shaped textile fabric (2), wherein a wrapping section (4) holds a supply of the fabric (2), wherein the wrapping section (4) receives the cushion (1) and wraps the received cushion (1) by enclosing it with the fabric (2), wherein a heating beam arrangement (5) of the wrapping section (4), after the cushion (1) has been enclosed, engages sections (20) of the fabric (2) and joins the sections (20) by heating, characterized in that, a dispenser apparatus (10) applies a brazing material (11) which is subsequently heated by the heating beam arrangement (5) for joining the sections (20) by brazing.

15. Method according to claim 14, characterized in that the heating beam arrangement (5) comprises two beams (6a, b) which engage the sections (20) by being brought together, preferably after the brazing material (11) is applied, which two beams (6a, b) subsequently heat the sections (20) until the brazing material (11) is solidified.

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