Fabric Ventilation Roller Apparatus for Pocketed Spring Manufacturing
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Solution Overview
Problem
Existing pocket coil machines produce continuous strings of pocketed springs using non-woven fabrics with no additional ventilation openings, making it difficult to identify the manufacturer or source of the product, and there is a need for cost-effective ventilation solutions that can pattern openings in fabrics before the springs are encased.
Innovation Solution
A ventilation apparatus comprising a stationary brush roller assembly and a movable pin roller assembly that can be attached to existing pocket coil machines to create patterned ventilation openings in fabrics, allowing for improved ventilation and identification of the product or manufacturer by imprinting patterns such as letters or numbers on the fabric before it is used to make pocketed springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If a non-woven fabric with natural ventilation is used in pocket coil machines, then the fabric provides basic ventilation, but it is difficult to identify the manufacturer or source of the product
Solution Approach 1:
The patent applies local quality by creating specific patterned openings (letters, numbers, or logos) in particular locations on the fabric to convey manufacturer identification information, while the rest of the fabric maintains its natural ventilation properties. This allows the fabric to serve dual purposes: ventilation and brand identification.
Solution Approach 2:
The patent uses the presence or absence of openings in specific patterns to create visual differentiation, similar to color changes. The patterned openings create distinct visual signatures that identify the manufacturer, allowing easy differentiation between products from different sources.
2Loss of information
If pre-ventilated fabric is used to identify manufacturer, then product identification is achieved, but it increases manufacturing cost
Solution Approach 1:
The patent applies preliminary action by creating the ventilation openings and manufacturer identification patterns in the fabric before the fabric enters the pocket coil machine. This allows the fabric to be prepared in advance with the desired patterns, eliminating the need for post-processing and reducing overall manufacturing costs.
Solution Approach 2:
The patent replaces complex mechanical post-processing systems with a simpler pre-treatment approach. By using a patterned roller or stamping mechanism to create openings in the fabric before it enters the main pocket coil machine, the system avoids the need for expensive post-manufacturing ventilation and branding operations.
3Object-affected harmful factors
If ventilation openings are created after springs are encased in fabric, then ventilation is provided, but it is not cost-effective
Solution Approach 1:
The patent applies preliminary action by creating all ventilation openings in the fabric before the spring encasement process. This ensures that the fabric is already optimally ventilated when it enters the pocket coil machine, eliminating the need for additional post-encasement modifications and reducing overall manufacturing costs.
4Object-affected harmful factors
If existing pocket coil machines are retrofitted for ventilation, then ventilation capability is added, but machine complexity increases
Solution Approach 1:
The patent applies the nested doll principle by integrating the ventilation creation mechanism within the existing pocket coil machine structure. The patterned roller or stamping mechanism is positioned to work in conjunction with the fabric feed system already present in the machine, nesting the new ventilation function within the existing mechanical framework.
Solution Approach 2:
The patent applies universality by designing a retrofit mechanism that can be added to existing pocket coil machines regardless of the specific manufacturer or model. The patterned roller or stamping mechanism works with the universal fabric feed system of pocket coil machines, allowing a single retrofit solution to serve multiple existing machine types.
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
Enables quick and cost-effective retrofitting of existing pocket coil machines for improved ventilation and allows for the imprinting of patterns on pocketed coil springs to identify the product or source, enhancing product differentiation and customer identification.
Implementation Method 1
Friction between the moving fabric and the brush roller(s) causes rotation of the brush roller(s) and brush roller shaft
Data Source
AI summary
An apparatus for ventilating a web of material used in the manufacture of pocketed springs may be removably attached to a pocket coiler. The apparatus has an upper movable portion which pivots relative to a stationary portion. The stationary portion may be removably attached to the pocket coiler. Each portion has at least one roller, a web of material passing between the rollers during use. One of the rollers may have protrusions to create openings in the material before the material enters the pocket coiler.