Bed Mesh Spring String Combination Device to Reduce Weld Count
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Solution Overview
Problem
Existing bed mesh manufacturing technologies face inefficiencies due to high costs and environmental impact from glue bonding and the need for numerous welds in ultrasonic welding, leading to lower production efficiency.
Innovation Solution
A bed mesh combination device incorporating a first loading mechanism, feeding mechanism, and combination mechanism to transport, arrange, and weld or sew first and second spring strings in a specific pattern, allowing for improved efficiency by alternating the arrangement and connection of spring strings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to cross-weld every two adjacent spring strings, then the bed mesh can be manufactured, but the number of welds increases significantly, leading to lower production efficiency
Solution Approach 1:
The patent extracts and eliminates unnecessary welds from the traditional cross-welding pattern. By removing the requirement to weld every intersection point and instead only welding specific connection points between spring strings, the design reduces the total number of welds while maintaining structural integrity through the alternating arrangement pattern.
Solution Approach 2:
The patent segments the spring strings into alternating first and second spring strings with different arrangements. This segmentation allows different connection strategies for different types of spring strings, where first spring strings are connected at multiple points while second spring strings connect fewer times, optimizing both structure and production efficiency.
2Ease of manufacture
If glue bonding is used to combine spring strings, then the bed mesh can be manufactured, but the amount of hot melt adhesive increases, leading to high cost and environmental issues
Solution Approach 1:
The patent replaces the chemical bonding method (glue bonding with hot melt adhesive) with a mechanical bonding method (ultrasonic welding). This substitution eliminates the need for large amounts of adhesive while providing strong, reliable connections between spring strings through localized welding at critical connection points.
3Device complexity
If traditional combination methods are used, then the manufacturing process is simple, but the number of connections required is high, leading to lower production efficiency
Solution Approach 1:
The patent introduces dynamic elements to the combination process through the alternating arrangement mechanism. The first and second spring strings are arranged alternately with different connection patterns, allowing the system to optimize connection points dynamically rather than using a static uniform pattern, thereby reducing total connections while maintaining structural requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device enhances production efficiency by arranging spring strings in an alternating pattern, reducing the number of connections required, thereby improving the manufacturing process.
Implementation Method 1
the magnetic assembly is arranged on the flipping frame, the flipping assembly is configured to grab a side surface of each of the first spring strings in a magnetic manner
Data Source
AI summary
A bed mesh combination device includes a first loading mechanism, a feeding mechanism, a second loading mechanism, and a combination mechanism. In a first direction, the first feeding mechanism transports the first spring strings of a set length to a first position, and the feeding mechanism transfers the first spring strings from the first position to a second position. At the second position, the first spring strings are parallel to the first direction. The second loading mechanism can reciprocate in the first direction, so as to continuously arrange the second spring string back and forth in the first direction at the second position. At the second position, there is one first spring string between two adjacent sections of the second spring string. The combination mechanism welds or sews the first spring strings at the second position and the adjacent second spring string to form a bed mesh.