Welding apparatus and manufacturing method for multilayer pocket spring string, and manufacturing device for pocket spring mattress
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Solution Overview
Problem
Existing methods fail to effectively manufacture multilayer pocket spring strings with continuous and progressive change of intervals, as they struggle to achieve progressive separation seams in forming multilayer structures.
Innovation Solution
A welding apparatus and manufacturing method that includes a first welding module for forming separation seams, a second welding module for arranging accommodating cavities at intervals, and spring conveying mechanisms to progressively adjust the position of the seams, allowing for the creation of multilayer pocket spring strings with continuous and progressive interval changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two independent single-layer pocket spring strings are bonded and combined together through adhesive, then a two-layer pocket spring string is formed, but it is difficult to achieve an effect of progressive change of the separation seam
Solution Approach 1:
The patent replaces the adhesive bonding method with a welding method to form separation seams. The welding apparatus uses a welding element to melt and fuse the fabric at specific positions, creating precise separation seams that divide the pocket spring string into multiple layers. This mechanical/thermal process provides better control over seam position compared to adhesive bonding.
Solution Approach 2:
The patent achieves progressive change of separation seam positions by controlling the movement distance of the welding element relative to the pocket spring string. By adjusting the displacement parameters of the welding element along the fabric, different separation seam positions can be created systematically, enabling progressive change effects that cannot be achieved with fixed adhesive bonding.
2Manufacturing precision
If a welding module is used to form separation seams by welding cloth, then multilayer structures with progressive change can be achieved, but the device complexity increases
Solution Approach 1:
The welding element serves multiple functions: it welds the fabric to form separation seams, cuts the fabric along the seam lines, and potentially forms accommodating cavities. By integrating these functions into a single welding element, the patent reduces overall device complexity while maintaining precise separation seam control.
Solution Approach 2:
The patent combines the welding function and cutting function into a single welding element. The welding element not only creates the separation seam through thermal fusion but also simultaneously cuts the fabric along the seam, eliminating the need for separate cutting mechanisms and simplifying the overall apparatus structure.
3Manufacturing precision
If the first welding module moves progressively along the layer-column direction to adjust separation seam position, then continuous and progressive interval changes are achieved, but the manufacturing time increases
Solution Approach 1:
The welding element moves continuously along the pocket spring string while welding, rather than stopping at each separation seam position. This continuous movement allows the welding element to create multiple separation seams in sequence without interruption, achieving progressive interval changes while maintaining manufacturing efficiency and reducing total production time.
Solution Approach 2:
The system pre-determines the movement distances and positions of the welding element based on the desired progressive interval pattern. By calculating and setting the welding parameters in advance, the welding element can efficiently execute the progressive separation seam formation without repeated adjustments or interruptions during the manufacturing process.
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 multilayer pocket spring strings with continuous and progressive interval changes, improving production efficiency and reducing costs compared to traditional bonding methods.
Implementation Method 1
a first welding module configured for welding the cloth, so that an accommodating cavity for accommodating a spring is separated to form at least two layers of first cavities
Data Source
AI summary
Disclosed are a welding apparatus and manufacturing method for a multilayer pocket spring string, and a manufacturing device for a pocket spring mattress. The welding apparatus may include: at least one first welding module configured for welding cloth, so that an accommodating cavity for accommodating a spring is separated to form at least two layers of first cavities; at least one first driving mechanism configured for driving the first welding module to move along a layer-column direction of the first cavity; a second welding module configured for welding the cloth, so that the cloth forms the accommodating cavities arranged at intervals; and at least two spring conveying mechanisms arranged at intervals, the spring conveying mechanism is configured for clamping and conveying the spring into the corresponding first cavity.