Inverting conveyor system for flexible articles of manufacture

Solution Overview

Problem

Manual inversion of large, flexible cushioning elements made from elastomeric gels is difficult, time-consuming, and potentially dangerous due to their size, weight, and flexible nature, which is required for processing and assembly with other mattress components.

Innovation Solution

An inverting apparatus comprising multiple conveyors that progressively invert the cushioning elements by moving them in opposing directions, allowing for automated flipping and elongation to reduce gathering or compression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual inversion is used, then the cushioning element can be flipped for processing, but the process is difficult, time-consuming, and potentially dangerous

Engineering Contradiction:

Improveease of inversionVSAvoidinversion time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent replaces the manual mechanical inversion process with an automated conveyor system. The first conveyor transports the cushioning element to the inversion point, and the second conveyor receives and inverts it by moving in the opposite direction. This substitution eliminates manual handling difficulties and reduces inversion time significantly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The inversion mechanism works by having the second conveyor move in the opposite direction to the first conveyor. As the cushioning element transitions from the first conveyor to the second, the reverse motion of the second conveyor naturally inverts the element. This uses the principle of inversion in the conveyor motion itself to achieve the desired flipping action.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of operation

If manual inversion is used, then the cushioning element can be flipped, but it may be dangerous due to size and weight

Engineering Contradiction:

Improvesafety during inversionVSAvoidconveyor system complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces the manual mechanical inversion process with an automated conveyor system. The first conveyor transports the cushioning element to the inversion point, and the second conveyor receives and inverts it by moving in the opposite direction. This substitution eliminates manual handling difficulties and reduces inversion time significantly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The inversion system is divided into separate functional segments: the first conveyor for transport, the inversion zone where direction changes occur, and the second conveyor for receiving and further transport. This segmentation allows each component to be optimized for its specific function while working together as an integrated system.

Inventive Principle:

Principle #1Segmentation

3Ease of operation

If the second conveyor moves in opposite direction to invert the article, then inversion is achieved, but gathering or compression may occur

Engineering Contradiction:

Improveinversion effectivenessVSAvoidarticle smoothness

Core Design Contradiction:

Ease of operationVSShape

Solution Approach 1:

The inversion mechanism works by having the second conveyor move in the opposite direction to the first conveyor. As the cushioning element transitions from the first conveyor to the second, the reverse motion of the second conveyor naturally inverts the element. This uses the principle of inversion in the conveyor motion itself to achieve the desired flipping action.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The conveyors are designed to move at coordinated speeds and the transition zone is configured to allow gradual inversion. By controlling the timing and speed of the conveyors, the system performs preliminary actions to prevent excessive gathering or compression before the inversion is complete, maintaining the article's smoothness.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12515890B2Inverting conveyor system for flexible articles of manufacture

Publication Date: 2026.01.06 PURPLE INNOVATION LLC

AI summary

An inverting conveyor system includes a series of conveyors that can invert a flexible article of manufacture, such as a cushioning element (e.g., a cushioning element of a mattress, etc.) formed from an elastomeric gel. The inverting conveyor system includes a first conveyor, a second conveyor, and an optional third conveyor. The first conveyor receives the flexible article of manufacture in an inverted orientation. The second conveyor is associated with the first conveyor in a manner that enables inversion of the flexible article of manufacture from the inverted orientation to an upright orientation. The optional third conveyor receives the flexible article of manufacture from the second conveyor and transports it to a desired destination. Methods for inserting flexible articles of manufacture are also disclosed.