Flat-packing machine for innerspring units

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Solution Overview

Problem

The process of flat-packing innerspring units is laborious and poses health risks due to the manual compression required, necessitating a more efficient and precise method for producing compressed packages.

Innovation Solution

A flat-packing machine with a press device featuring multiple drives and interchangeable pressing tools that compress innerspring units in an interleaved manner, assisted by a feed mechanism for automated feeding and packaging materials, allowing for precise control and reduced manual labor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If manual compression is used to flat-pack innerspring units, then the process is simple in terms of equipment, but it requires significant manpower and poses health risks to personnel

Engineering Contradiction:

Improveequipment simplicityVSAvoidmanpower efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent replaces manual mechanical compression with an automated press device that uses mechanical drives (first drive, second drive, third drive, fourth drive) to compress innerspring units. The pressing tools are mechanically actuated to apply compression force, eliminating the need for manual labor while maintaining controlled compression capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The press device is designed to automatically perform the compression cycle without continuous human intervention. The pressing tools automatically compress, hold, and release the innerspring units through the coordinated action of multiple drives, making the system self-sufficient for the compression task.

Inventive Principle:

Principle #25Self-service

2Device complexity

If manual compression is used to flat-pack innerspring units, then the equipment requirements are minimal, but it poses health risks due to significant forces exerted

Engineering Contradiction:

Improveequipment simplicityVSAvoidhealth risks to personnel

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If multiple pressing tools are used to compress innerspring units in an interleaved manner, then compression precision and control are improved, but device complexity increases

Engineering Contradiction:

Improvecompression control precisionVSAvoidpress device complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent divides the compression task into multiple independent pressing tools (first pressing tool, second pressing tool), each controlled by its own drive system. This segmentation allows each tool to independently compress and hold innerspring units, enabling precise control over the compression process while distributing the functional complexity across separate components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements dynamic control where pressing tools can independently move along the compression direction and retraction direction. The first and second drives control compression motion, while the third and fourth drives control retraction, allowing flexible and precise coordination of multiple pressing tools throughout the compression cycle.

Inventive Principle:

Principle #15Dynamics

4Productivity

If pressing tools are withdrawn from the stack after each compression, then they become available for further compression, but the process time increases

Engineering Contradiction:

Improvecompression throughputVSAvoidcycle time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent maintains continuous useful action by having multiple pressing tools operate in an interleaved manner. While one pressing tool is being retracted, another pressing tool can begin compressing the next innerspring unit. This overlapping operation ensures that compression activity continues without interruption, maximizing throughput while minimizing idle time.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The pressing tools are designed to be pre-positioned and ready to compress the next innerspring unit as soon as the previous compression is complete. The retraction and positioning actions are prepared in advance, allowing seamless transition between compression cycles without significant delays.

Inventive Principle:

Principle #10Preliminary action

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 machine enables efficient and precise compression of multiple innerspring units, reducing manpower needs and health risks while improving the stability and efficiency of the packaging process.

Implementation Method 1

The press device is configured to compress an innerspring unit between the first pressing tool and the second pressing tool

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS11203484B2Flat-packing machine for innerspring units

Publication Date: 2021.12.21 L& P SWISS HLDG AG

AI summary

A flat-packing machine for producing a package of compressed innerspring units (10) comprises a press device having a first pressing tool (210) and a second pressing tool (220). The press device is configured to compress an innerspring unit (10) between the first pressing tool (210) and the second pressing tool (220) while one of the first pressing tool (210) and the second pressing tool (220) holds one or more further previously compressed innerspring units (10) in a compressed state.