Compressed Pocketed Spring Spool for Mattress Core Storage
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Solution Overview
Problem
The mattress industry faces challenges in producing versatile and flexible pocketed spring cores with varying spring properties due to increased coiling speeds and diverse consumer preferences, leading to inefficiencies in manufacturing processes and storage requirements.
Innovation Solution
A spool of linearly wound pocketed springs in a compressed state, allowing for efficient storage and transportation, with the ability to unwind and assemble into a two-dimensional core with zones of different spring properties, reducing warehouse space and enabling faster production of customized mattress cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pocketed spring cores are produced with strings of different characteristics to create zones with different spring properties, then mattress comfort and customization are improved, but production process complexity and storage requirements increase
Solution Approach 1:
The patent divides the mattress core production into separate functional modules: string manufacturing units that produce pocketed spring strings with different characteristics, intermediate storage bins for organizing various string types, and assembly units that combine strings into final mattress cores. This segmentation allows each module to be optimized independently, managing complexity while maintaining versatility.
Solution Approach 2:
The patent implements preliminary preparation of pocketed spring strings with different characteristics (varying spring rates, pocket densities, and lengths) and stores them in intermediate bins before assembly. This advance preparation allows the assembly process to simply select and combine pre-configured strings, reducing assembly complexity while enabling customized mattress zones.
2Productivity
If spring coiling speeds are increased to improve productivity, then manufacturing efficiency is improved, but constraints on in-line processes and synchronization requirements increase
Solution Approach 1:
The patent separates the spring coiling process from the mattress assembly process into independent production lines. High-speed coiling machines produce strings that are then stored in intermediate bins, allowing the assembly process to proceed at its own pace without being constrained by coiling speed variations. This decoupling eliminates synchronization requirements while maintaining high productivity.
Solution Approach 2:
The patent introduces intermediate storage bins as buffer zones between the spring coiling process and the mattress assembly process. These bins act as intermediaries that absorb speed variations and allow independent optimization of each process stage, eliminating the need for complex synchronization mechanisms while maintaining high overall productivity.
3Adaptability or versatility
If intermediate storage of pocketed spring strings is increased to accommodate diverse mattress types, then production flexibility is improved, but warehouse space requirements increase
Solution Approach 1:
The patent nests multiple pocketed spring strings vertically within compact intermediate storage bins, maximizing the use of vertical space. This nested arrangement allows diverse string types to be stored in a minimal footprint, providing high production flexibility without proportionally increasing warehouse space requirements.
Solution Approach 2:
The patent transitions from horizontal storage arrangements to vertical stacking of intermediate bins, utilizing the vertical dimension to increase storage capacity without expanding the warehouse footprint. This dimensional change allows diverse pocketed spring strings to be accommodated in compact spaces while maintaining easy access for assembly operations.
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
This approach minimizes permanent deformation of springs, reduces storage volume, and allows for efficient assembly of cores with varying characteristics, enhancing manufacturing flexibility and cost-effectiveness.
Implementation Method 1
The linear string of pocketed springs is present in the spool spirally wound and in a compressed state such that the pocketed springs can expand upon unwinding the string of pocketed springs from the spool
Data Source
Figure 1~4
Figure 5
AI summary
A spool (100) of a linear string (110, 210, 310, 410) of pocketed springs is disclosed. The linear string of pocketed springs comprises springs (212, 312, 412) each provided in a textile pocket (214, 314, 414). The springs (212, 312, 412) comprise helically coiled steel wire springs. The textile pockets (214, 314, 414) are assembled to each other in linear direction. The linear string (110, 210, 310, 410) has a width of one textile pocket (214, 314, 414). The string (110, 210, 310, 410) of pocketed springs is present in the spool (100) spirally wound and in a compressed state such that the pocketed springs (212, 312, 412) can expand upon unwinding the string (110, 210, 310, 410) of pocketed springs from the spool (100).