Apparatus and method for making a resilient unit
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing resilient units, such as mattresses, lack flexibility in controlling the positioning and characteristics of springs during the manufacturing process, resulting in limited customization options for resilience and aesthetics.
Innovation Solution
An apparatus and method that supply springs in rows with varying characteristics, allowing for offset placement and different types of springs to be inserted between sheets, which are then welded together to form pockets, enabling the creation of units with specific patterns and resilience profiles, including the use of taller and wider springs to minimize noise and adjust compression characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional methods are used to manufacture resilient units, then the manufacturing process is simple, but the flexibility in controlling spring positioning and characteristics is limited
Solution Approach 1:
The manufacturing apparatus is divided into multiple independent spring supply stations, each capable of supplying springs of different types to different positions in the resilient unit. This segmentation allows flexible control over spring positioning and characteristics without requiring complete redesign of the entire manufacturing system.
Solution Approach 2:
Different spring supply stations can provide springs with different characteristics (stiffness, size, material) to specific locations in the resilient unit. This enables customization of spring properties at different positions to achieve desired comfort and support profiles while maintaining a relatively simple overall manufacturing process.
2Adaptability or versatility
If multiple types of springs are used with varying characteristics, then customization options for resilience and aesthetics are improved, but the manufacturing process complexity increases
Solution Approach 1:
The use of multiple spring supply stations allows different spring types to be supplied independently to different positions. This segmentation enables customization of resilience characteristics without requiring complex manual assembly processes, as each station can be independently configured and operated.
Solution Approach 2:
Each spring supply station is designed to handle multiple types of springs, making the manufacturing apparatus multi-functional. This universality allows the same basic manufacturing process to accommodate various spring characteristics and patterns, simplifying the overall manufacturing ease while maintaining high customization options.
3Shape
If springs are arranged in specific patterns with offset placement, then aesthetic and structural effects are enhanced, but the positioning precision requirements increase
Solution Approach 1:
Springs are pre-positioned and supplied in organized rows from dedicated supply stations before being inserted into the resilient unit. This preliminary arrangement ensures that springs are already in the correct positions and orientations, reducing the precision requirements during the final assembly process while still achieving the desired aesthetic and structural patterns.
Solution Approach 2:
The apparatus allows for asymmetric spring arrangements and offset placements between different supply stations. By designing the supply stations to accommodate asymmetric patterns, the system can create visually interesting and structurally effective designs without requiring extremely high positioning precision, as the asymmetry is built into the supply configuration rather than requiring precise adjustment during assembly.
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 production of resilient units with customizable patterns and resilience profiles, reducing noise and providing a 'soft start' compression characteristic, while allowing for varied spring characteristics and arrangements to enhance comfort and support.
Implementation Method 1
joining the sheets together, for example by welding, at locations between the springs, to form pockets around the springs
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
Apparatus for forming a resilient unit comprises a conveyor (210) and first and second spring supply stations (212 and 214), arranged in use to deposit respectively first and second spring types (216 and 218) under compression onto the conveyor. The conveyor is arranged in use to convey a row of the springs (216, 218) in a direction shown by Arrows A4 towards pocketing station (220). At the pocketing station (220) the springs are urged from the conveyor into positions between upper and lower sheets (222 and 224), by a plurality of inserter devices (226) that move together in a reciprocating fashion in the direction of arrow A5, before retracting to the position shown. After each row of springs is inserted between the sheets (222), upper and lower computer-controlled welding tools (not shown) come together at positions P between the springs to join the sheets together, forming pockets in which the springs are encased. After each welding event the resilient unit is indexed forwards a distance equal to one pocket width in the direction of Arrows A6 by computer-controlled drive means (not shown). The next row of springs is then conveyed into position ready for insertion between the sheets of material, and the process is repeated. The two spring supply stations are arranged to supply springs that differ from one another in at least one characteristic.