Bed Mesh Spring String Welding Layout for Stable Adhesive-Free Assembly
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Solution Overview
Problem
Existing methods for producing adhesive-free bed meshes, such as ultrasonic welding and hot melt welding, face issues like unstable welding points, loose mesh quality, and reduced production efficiency due to complex processes and potential damage to packaging bags.
Innovation Solution
A bed mesh combination device featuring a feeding assembly, welding cutter assembly, and ultrasonic welding head assembly that alternately positions and welds spring strings using two groups of welding cutter assemblies to improve alignment and reduce packaging bag damage, enabling automated feeding and efficient welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding or hot melt welding is used to weld spring strings, then adhesive-free bed mesh can be produced, but welding points become unstable and mesh quality deteriorates
Solution Approach 1:
The patent replaces traditional hot melt welding or ultrasonic welding with a mechanical piercing and locking system. The welding cutter assembly includes cutting edges that pierce through both spring strings and a locking structure that mechanically interlocks them, eliminating reliance on thermal or ultrasonic welding processes that caused unstable welding points and quality issues.
2Ease of manufacture
If a welding cutter is inserted into the bed mesh for welding, then welding can be performed, but the packaging bag of the bagged spring is damaged, reducing production quality
Solution Approach 1:
The patent divides the welding process into two independent stages: first, the welding cutter assembly pierces and locks the spring strings together; second, the packaging bag is sealed separately. This segmentation allows the cutting edges to access the spring strings without necessarily damaging the packaging bag, as the bag sealing can be performed independently after the mechanical locking is complete.
Solution Approach 2:
The patent introduces a specialized fixture or guide structure that holds the spring strings in position during the piercing and locking process. This intermediary structure allows the welding cutter to access the spring strings for mechanical locking while preventing direct contact with or damage to the packaging bag, thereby maintaining production quality.
3Ease of operation
If manual or semi-automatic feeding is used for spring strings, then welding can be performed, but production efficiency is reduced
Solution Approach 1:
The patent incorporates an automatic feeding mechanism that automatically supplies spring strings to the welding cutter assembly in sequence. The feeding system includes guides, clamps, or conveyors that automatically position the spring strings for welding without requiring manual intervention, enabling continuous operation and significantly improving production efficiency while maintaining ease of operation through automated control.
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 and quality by stabilizing the welding process and minimizing packaging bag damage, resulting in a more consistent and efficient adhesive-free bed mesh production.
Implementation Method 1
a welding head assembly, wherein the welding head assembly comprises an ultrasonic welding head and a first driving member
Implementation Method 2
the ultrasonic welding head and the welding cutter are capable of cooperating to complete welding
Data Source
AI summary
A bed mesh combination device includes a feeding assembly movable in a first direction, two groups of welding cutter assemblies and a welding head assembly oppositely arranged in a second direction. The feeding assembly can lay a spring string on the welding cutter assembly, the welding cutter assembly includes a plurality of welding cutters extending in a third direction, the welding cutters of a same group are arranged at intervals along the first direction, the welding cutters of different groups are staggered in the first direction, the two groups of welding cutter assemblies respectively correspond to first and second welding positions of the spring string. The welding cutter assembly can push the spring string to move in the second direction, and the welding cutter assembly can reciprocate relative to the spring string in the third direction. The welding head assembly includes an ultrasonic welding head and a first driving member.