Multi-Layer Pocketed Spring Strand Assembly Using Ultrasonic Welding
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Solution Overview
Problem
The laborious and often manual process of assembling multi-layered spring cores using pocketed springs, which can alter the characteristics of the pocket material when glued, leading to undesirable changes in flexibility or permeability.
Innovation Solution
A machine with an alignment mechanism and welding mechanism that aligns and welds seam portions of pocketed springs in a coaxial manner, using ultrasonic welding without additional materials or chemicals, allowing for efficient formation of multi-layer strands of pocketed springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual intervention is used to connect layers of pocketed springs, then flexibility in assembly is improved, but productivity and labor efficiency deteriorate
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated welding system that uses ultrasonic vibration to join pocketed springs. The welding mechanism includes a welding tool that applies ultrasonic vibrations to the seam portions of the springs, automatically connecting layers without manual intervention while maintaining precise control over the joining process.
Solution Approach 2:
The patent changes the physical state and properties of the pocket material through ultrasonic welding. By applying ultrasonic vibrations at specific frequencies and amplitudes, the seam portions of the pocket material are heated and fused together, creating a strong bond between layers. This parameter-based approach allows automated control while achieving reliable connections.
2Extent of automation
If gluing is used to join multiple strands of pocketed springs, then automation is improved, but the characteristics of the pocket material (flexibility, permeability) deteriorate
Solution Approach 1:
The patent substitutes chemical bonding (gluing) with physical bonding through ultrasonic welding. The welding tool applies mechanical ultrasonic vibrations directly to the seam portions of the pocketed springs, creating a thermal-mechanical bond without introducing any chemical substances. This eliminates the harmful effects of adhesives on the flexibility and permeability of the pocket material while maintaining full automation.
Solution Approach 2:
The patent uses the seam portions of the pocket material themselves as the bonding medium, eliminating the need for external adhesives. The ultrasonic welding process directly fuses the overlapping seam portions together through localized heating and pressure, using the material's own properties to create the bond without external chemical intermediaries that would alter its characteristics.
3Productivity
If welding is used to connect seam portions of pocketed springs, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent divides the welding process into distinct functional components: an alignment mechanism that positions the strands and seam portions, a welding tool that applies ultrasonic vibrations, and a pressure application system. This segmentation allows each component to be optimized independently and facilitates easier maintenance and operation, reducing the practical complexity despite the advanced functionality.
Solution Approach 2:
The welding mechanism is designed to handle multiple strands of pocketed springs simultaneously, with the ability to adjust for different spring configurations and sizes. The alignment mechanism and welding tool can accommodate various seam portion geometries, making the device universally applicable to different spring core designs while maintaining high productivity through parallel processing.
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 efficient and precise connection of pocketed springs without altering their characteristics, facilitating the production of tailored multi-layer spring cores for bedding or seating products.
Implementation Method 1
The welding mechanism may be based on ultrasonic welding, and the welding tool can be an ultrasonic horn
Data Source
Figure 1
Figure 2A~2B
Figure 3
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.