Mattress Layer Fastening Tool Without Adhesive Bonding
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Solution Overview
Problem
Conventional mattress manufacturing techniques using adhesives to secure multiple layers result in waste, hazardous fumes, and audible crackling sounds as adhesives age, increasing manufacturing costs and creating an unhealthy environment.
Innovation Solution
A tool for dispensing plastic fasteners with a cross-bar formed on one end of a thin filament, featuring a housing, a hollow needle, an ejection mechanism, a needle guard, and a locking member to securely fasten layers of a mattress without adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives are used to secure multiple layers of mattress, then layers can be joined together, but waste is generated and hazardous fumes are produced
Solution Approach 1:
The patent extracts and eliminates the adhesive substance from the mattress manufacturing process entirely, replacing it with a mechanical fastening system using plastic clips and fasteners that secure layers without chemical bonding agents, thereby removing the source of hazardous fumes and adhesive waste
Solution Approach 2:
The patent replaces the chemical bonding system (adhesives) with a mechanical fastening system consisting of plastic clips, fasteners, and stitching mechanisms that physically secure mattress layers together without requiring chemical substances, thus eliminating hazardous fumes and adhesive waste
2Strength
If adhesives are used to secure mattress layers, then layers are bonded together, but audible crackling sounds occur as adhesives age
Solution Approach 1:
The patent removes adhesives from the mattress construction entirely, replacing them with mechanical fastening elements that do not exhibit aging-related cracking or audible noise, thereby eliminating this harmful effect while maintaining layer bonding strength
Solution Approach 2:
The patent employs plastic clips and fasteners that are designed to remain stable throughout the product lifecycle without degrading into crackling sounds, replacing the aging adhesive materials with durable mechanical fastening components
3Strength
If adhesives are used to secure mattress layers, then layers can be joined, but manufacturing costs increase
Solution Approach 1:
The patent eliminates adhesive materials and associated disposal costs from the manufacturing process, replacing them with reusable mechanical fastening systems that reduce waste management expenses and overall manufacturing costs while maintaining layer bonding strength
Solution Approach 2:
The patent employs a fastening system where plastic clips and fasteners can be recovered and potentially reused, unlike single-use adhesives that generate waste requiring disposal, thereby reducing manufacturing costs through material recovery
Data Source
AI summary
A method for coupling together at least two layers (23, 25, 27, 29, 21-1) of a mattress includes the steps of aligning each layer in its proper position in relation to the other layers of the mattress (11) and, after the alignment step, inserting a plastic fastener (31) through the layers. A fastener dispensing tool (211) is provided for inserting plastic fasteners (31)through the layers (23, 25, 27, 29, 21-1) of the mattress(11). In one embodiment, the fastener dispensing tool (211) includes a housing (213), a hollow sharpened needle (229) fixedly coupled to the housing (213), an ejection mechanism for advancing a cross-bar of the plastic fastener through the hollow needle, a needle guard slidably coupled to the housing over a portion of the sharpened needle, and a needle guard stop slidably coupled to the housing in such a manner so that it can be releasably fixed place in either of two or more set positions.