Glueless Pocketed Spring Assembly Without Crunchy Glue Joints

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Solution Overview

Problem

Existing methods for constructing pocketed spring units in mattresses and cushioning assemblies often result in a 'crunchier' feel due to glue connections and can be costly, environmentally impactful, and prone to unmoored pockets and loose springs.

Innovation Solution

The use of ultrasonic welding to connect rows of pocketed spring modules without glue, employing vibrating probes and anvils to weld layers of flexible material, forming strong, comfortable, and cost-effective cushioning units with reduced environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If glue connections are used to connect pocketed springs, then the connection strength is improved, but the comfort feel deteriorates (crunchier feeling)

Engineering Contradiction:

Improveconnection strengthVSAvoidcomfort feel

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the chemical bonding mechanism of glue with an ultrasonic welding mechanism that uses mechanical vibration and heat to fuse fabric layers. The ultrasonic welding probe generates high-frequency vibrations that melt and bond the fabric pockets together, eliminating the need for adhesive chemicals while maintaining connection strength and improving comfort by avoiding the crunchier feel associated with glue.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If scrim sheets are used to connect rows of pocketed springs, then the structural stability is improved, but the comfort feel deteriorates (trampoline-like effect)

Engineering Contradiction:

Improvestructural stabilityVSAvoidcomfort feel

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent removes the scrim sheet component entirely from the construction process. Instead of using a separate scrim sheet to connect rows of pocketed springs, the invention directly ultrasonically welds adjacent rows together through their fabric pockets, eliminating the intermediate scrim layer that causes the trampoline-like effect while maintaining structural stability through direct fabric-to-fabric welding.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent creates asymmetric connection points by welding at specific locations on the fabric pockets rather than using a uniform scrim sheet across the entire surface. This localized welding approach at strategic positions provides structural stability without creating the uniform rigid connections that cause the trampoline effect associated with scrim sheets.

Inventive Principle:

Principle #4Asymmetry

3Ease of manufacture

If glue is used in construction, then the manufacturing process is simplified, but environmental impact worsens

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidenvironmental impact

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent replaces chemical adhesive processes with mechanical ultrasonic welding. This substitution eliminates the need for glue application, drying, and curing steps while maintaining manufacturing efficiency. The ultrasonic welding process is environmentally friendly as it uses only mechanical energy and heat generated by vibration, producing no chemical waste or volatile organic compounds associated with glue-based constructions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If traditional construction methods are used, then the manufacturing cost is reduced, but weight increases

Engineering Contradiction:

Improvemanufacturing costVSAvoidunit weight

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The patent eliminates excess material such as scrim sheets and glue layers that add weight to the final product. By using direct ultrasonic welding of fabric pockets without intermediate components, the construction achieves lighter weight while maintaining structural integrity. The removal of non-essential materials reduces both weight and manufacturing complexity, countering the assumption that traditional methods are always more cost-effective.

Inventive Principle:

Principle #2Taking out (Extraction)

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 eliminates glue connections, enhances comfort and luxury feel, reduces weight and transportation costs, and minimizes the likelihood of unmoored pockets and loose springs, while being more environmentally friendly and cost-effective.

Implementation Method 1

Rows of pocketed springs are retained in position by pins, and are transferred to corresponding rows of vibrating probes and anvils which pinch layers of fabric together and form welds using ultrasonic vibrational energy.

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS9221670B2Glueless pocketed spring unit construction

Publication Date: 2015.12.29 WOLFSON MARTIN

AI summary

Methods and systems for no-glue pocketed spring unit construction. Rows of pocketed springs, preferably arranged into modules of more than two pocketed springs surrounding a central hole, are ultrasonically welded together when paired vibrating probes and anvils press layers of pocketed spring fabric from the rows of pocketed springs together and a welding pulse is transmitted to the vibrating probe.