Box Spring Separation Mechanism for Automated Mattress Recycling
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Solution Overview
Problem
The recycling of mattresses and box springs is labor-intensive due to the difficulty in separating metal springs from the wooden frames, leading to increased costs and environmental concerns related to landfill disposal and incineration.
Innovation Solution
A device with suppression fingers and a gripping mechanism is used to hold the wooden frame in place while pulling the metal springs upward, automating the separation process and reducing labor and time required for recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual labor is used to separate springs from the wooden frame, then the separation can be completed, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent replaces manual mechanical labor with an automated mechanical system consisting of a conveyor belt, gripping device, and suppression fingers. The gripping device automatically grasps the spring assembly while suppression fingers hold the wooden frame stationary, enabling automated separation without manual intervention.
Solution Approach 2:
The system enables the box spring itself to be separated through automated mechanical actions. The conveyor belt feeds the box spring into position, the gripping device grasps the springs, and the suppression fingers constrain the frame, allowing the process to proceed without continuous human operation.
2Ease of operation
If manual labor is used to remove staples and separate components, then separation is possible, but the time and labor required increase significantly
Solution Approach 1:
The patent replaces manual staple removal and component separation with automated mechanical systems. The conveyor belt automates feeding, the gripping device automates spring extraction, and the suppression fingers automate frame constraint, eliminating the need for manual staple removal and significantly reducing processing time.
Solution Approach 2:
The system performs preliminary positioning actions automatically. The conveyor belt pre-positions the box spring on the conveyor, and the suppression fingers pre-constrain the wooden frame before the gripping device applies the separating force, streamlining the overall process.
3Productivity
If automated devices are introduced to speed up recycling, then productivity increases, but device complexity increases
Solution Approach 1:
The patent divides the recycling system into distinct functional segments: a conveyor belt segment for feeding, a gripping device segment for spring extraction, and suppression fingers for frame constraint. This segmentation allows each component to perform a specific function independently, managing complexity through functional decomposition.
Solution Approach 2:
The conveyor belt serves multiple functions: it feeds box springs into the system, positions them for the gripping device, and potentially transports separated components. This multi-functionality reduces the need for additional dedicated devices, managing overall system complexity.
Data Source
AI summary
A device for removing a set of springs from a mattress box spring including a mattress box spring support, a pushing block support frame secured to the mattress box spring support, a pushing block supported by the pushing block support frame adjacent to the mattress box spring support, a cylinder for extending the pushing block over a mattress box spring positioned on the mattress box spring support belt, wherein the cylinder is operable to extend the pushing block transversely over the mattress box spring to separate springs attached to a frame of the mattress box spring from the frame, and wherein a plurality of forks extend in front of the pushing block transversely to the mattress box spring support for helping to prevent the springs from folding underneath a bottom of the pushing block when the pushing block is extended over the mattress box spring to separate the springs from the frame.