Multi-Layer Pocket Spring Strand Assembly Using Ultrasonic Welding
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Solution Overview
Problem
The labor-intensive process of manufacturing multi-layer spring cores using pocketed springs often requires manual intervention and gluing, which can alter the characteristics of the pocket material undesirably, such as flexibility or permeability.
Innovation Solution
A machine with an alignment mechanism and welding mechanism that aligns seam portions of pocketed springs coaxially and welds them using ultrasonic welding, eliminating the need for additional materials or chemicals, allowing for efficient formation of multi-layer strands without altering the pocket material's characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual intervention and gluing are used to connect layers, then the connection between strands can be formed, but the process becomes labor-intensive and the pocket material characteristics are altered undesirably
Solution Approach 1:
The patent replaces the chemical gluing process with ultrasonic welding, which uses mechanical vibration energy to join the pocket materials. This substitution eliminates the need for chemicals while improving manufacturing efficiency through an automated welding mechanism that can process multiple layers simultaneously.
Solution Approach 2:
The patent changes the connection method from chemical bonding to mechanical bonding through ultrasonic welding. By altering the joining parameter from chemical adhesive to mechanical vibration and heat, the process achieves both automated efficiency and preservation of material characteristics.
2Extent of automation
If gluing is used to join multiple strands, then automatic joining can be achieved, but the pocket material characteristics such as flexibility and permeability are altered undesirably
Solution Approach 1:
The patent replaces chemical gluing with ultrasonic welding, substituting a chemical process with a mechanical vibration-based process. This maintains automation while preserving the natural properties of the pocket material, as no chemicals are introduced that could alter flexibility or permeability.
Solution Approach 2:
The ultrasonic welding process uses a consumable welding tip that can be replaced, eliminating the need for ongoing chemical adhesive supplies. This disposable welding tip approach maintains automation while avoiding the material-altering effects of chemicals.
3Ease of manufacture
If gluing is used to connect strands, then joining can be achieved, but additional materials or chemicals are required
Solution Approach 1:
The patent extracts and eliminates the chemical adhesive component from the joining process. By using ultrasonic welding, the connection is achieved through the pocket material's own structure without requiring any additional chemical substances, thus removing the source of material alteration.
Solution Approach 2:
The patent replaces the chemical-based joining system with a mechanical ultrasonic welding system. This substitution eliminates the need for additional chemical materials, using only mechanical energy and the pocket material itself to achieve the connection.
4Manufacturing precision
If manual alignment and connection are used, then precision can be achieved, but the process becomes labor-intensive
Solution Approach 1:
The patent incorporates preliminary alignment features in the pocket material structure, such as pre-positioned seam portions and guide elements, that automatically align strands before welding. This preliminary preparation enables both high precision and automated high-speed processing without manual intervention.
Solution Approach 2:
The patent combines the alignment and welding operations into a single integrated ultrasonic welding mechanism. The welding tool simultaneously aligns and joins the pocket materials, achieving both precision and productivity through process integration.
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
Enables the efficient and precise formation of multi-layer strands of pocketed springs, maintaining the material's characteristics and allowing for tailored spring core units with varied characteristics, which can be used in bedding or seating products.
Implementation Method 1
The welding mechanism is configured to weld the first seam portion to the second seam portion. Accordingly, a connection between the first strand and the second strand may be formed in an efficient manner by welding, without requiring additional material or chemicals to form the connection. According to an embodiment, the welding mechanism is based on welding of the first seam portion and the second seam portion between an anvil and a welding tool. For example, the welding mechanism may be based on ultrasonic welding, and the welding tool can be an ultrasonic horn.
Data Source
AI summary
For forming a multi-layer strand of pocketed springs, a first strand (11) of pocketed springs (21) and a second strand of pocketed springs (22) are connected to each other. For this purpose a first pocketed spring (21) of the first strand (11) is aligned in a coaxial manner with a second pocketed spring (22) of the second strand (12) so that a first seam portion (31) of pocket material at an end of the first pocketed spring (21) overlaps with a second seam portion (32) at an end of the second pocketed spring (22), and the first seam portion (31) is welded to the second seam portion (32), e.g., using ultrasonic welding.