Innerspring Unit
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Solution Overview
Problem
Conventional innerspring unit manufacturing methods produce units with uniform spring characteristics and limited flexibility, particularly in edge areas, resulting in reduced stability and efficiency in mattress production.
Innovation Solution
A method and apparatus that allow for the manufacturing of innerspring units with varying spring diameters and geometries in edge areas by attaching strings of pocketed springs with different characteristics to the main body, increasing stability and enabling a fully automated production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional innerspring unit assembly machines are used to manufacture innerspring units, then the production process is automated, but the springs all have the same or very similar spring characteristics resulting in uniform spring stability across the entire innerspring unit
Solution Approach 1:
The patent applies local quality by attaching different types of pocketed springs to different regions of the innerspring main body. Specifically, edge strings with different spring characteristics (e.g., smaller diameter, different wire gauge) are attached to lateral surfaces and ends, while the center area maintains uniform springs. This allows the innerspring unit to have region-specific properties: enhanced edge stability where needed and uniform support in the center, all while maintaining automated manufacturing capability.
2Stability of the object's composition
If strings of pocketed springs with different spring characteristics are attached to lateral surfaces of the innerspring main body, then the stability in the edge area is increased, but the device complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct functional zones: a center area with uniform springs and edge regions with specialized springs of different characteristics. The apparatus is correspondingly segmented into a first station for providing the main body and a second station for attaching edge strings. This segmentation allows each station to be optimized for its specific task, managing overall system complexity while achieving enhanced edge stability.
Solution Approach 2:
The innerspring main body is prepared in advance at the first station with fleece sheets attached and dimensional accuracy established. This preliminary action allows the second station to focus solely on attaching the edge strings with different spring characteristics, simplifying the overall manufacturing process by dividing tasks into preparatory and finishing stages.
3Stability of the object's composition
If edge springs with smaller diameter are used to increase stability in edge area, then the lateral recesses become smaller resulting in more even lateral surface, but the manufacturing precision requirements increase
Solution Approach 1:
The patent changes the physical parameters of the springs used in edge areas compared to the center area. Edge springs have smaller diameter, different wire gauge, or different coil density to create smaller lateral recesses. This parameter variation achieves more even lateral surfaces and enhanced edge stability. The manufacturing apparatus is designed to accommodate these parameter changes while maintaining consistent attachment precision through specialized fixtures and positioning systems at the second station.
Data Source
AI summary
In order to manufacture an innerspring unit comprising pocketed springs and having an increased stability at its edge regions, in a first step, an innerspring main body comprising a plurality of first strings of pocketed springs is provided. In a subsequent second step, at least one second string of pocketed springs is attached to a lateral surface of the innerspring main body, so that the at least one second string of pocketed springs extends in a longitudinal direction of the innerspring main body. The springs of the at least one second string of pocketed springs have a spring characteristic or a spring geometry different from the springs of the plurality of first strings of the innerspring main body. The at least one second string of pocketed springs forms together with the innerspring main body the innerspring unit.