Mattress with casing having a quilted layer of high density foam method and system for making same
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Solution Overview
Problem
Conventional methods fail to effectively quilt mattress panels with high density foam due to binding, needle breakage, and machine deflection, as they are not suited for materials like Talalay foam.
Innovation Solution
A method involving stretching and slower needle speed during quilting, combined with preparing elongated strips of high density foam by gluing sliced panels, to prevent material binding and needle deflection, allowing successful quilting of high density foam layers between fabric layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional quilting methods are used on high density foam, then the quilting process can be completed quickly, but the materials will bind and bunch, needles will break, and the machine may break
Solution Approach 1:
The patent changes the operational parameters of the quilting machine specifically for high density foam materials. The needle speed is reduced from conventional high speed to a slower rate, and the machine is operated at reduced power levels. This parameter adjustment prevents needle breakage and material binding while maintaining productive throughput.
Solution Approach 2:
The patent introduces dynamic control elements including a tensioning system that actively adjusts material tension during the quilting process, and variable speed control that adjusts needle penetration speed based on material density. These dynamic adjustments prevent binding and bunching while maintaining process reliability.
2Productivity
If high density foam layers are quilted using conventional methods, then the mattress can be produced efficiently, but needles will deflect and break
Solution Approach 1:
The patent specifies using needles with greater strength and durability specifically for high density foam quilting, and operates the machine at reduced needle speed. This combination of enhanced needle strength and reduced operating speed prevents needle deflection and breakage while maintaining production efficiency.
Solution Approach 2:
The patent prepares the high density foam material in advance by cutting it to precise dimensions and pre-positioning it on the mattress panel before quilting begins. This preliminary preparation ensures proper material tension and alignment, preventing needle deflection during the quilting process.
3Loss of time
If conventional quilting speed is used on high density foam, then production time is reduced, but material binding and bunching occurs
Solution Approach 1:
The patent employs a tensioning system with dynamic control that maintains consistent material tension throughout the quilting process. This dynamic tension control prevents binding and bunching of the foam layers, ensuring uniform material composition in the finished product while maintaining reasonable production speed.
Solution Approach 2:
The patent incorporates feedback control mechanisms that monitor the quilting process in real-time and adjust operating parameters accordingly. This feedback ensures that the slower quilting speed required for high density foam does not compromise material uniformity, and allows for optimization of the balance between production time and quality.
Data Source
AI summary
A mattress and method and system for making said mattress having a mattress casing 1 having a quilted top sleep panel (2) wherein one or more layers of high density foam (3) are stacked and quilted between an outer layer of fabric (4) and an inner layer of fabric (5). The high density foam is preferably Talalay foam and the panel may have multiple layers of high density foam and other materials such as wool, cotton batting and so forth. The inner layer of fabric, outer layer of fabric and at least one layer of high density foam are secured or quilted together by placing a plurality of stitched lines (7) across the area of the panel. The method and system of the present invention allows the high density foam to be continuously quilted without sewing needles being deflected or binding occurring.