Method and system for making pillows
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Solution Overview
Problem
Current methods for making pillows using mixed processing waste cuttings result in non-uniform padding, making it impossible to predict the bearing capacity and softness of the final product, leading to inconsistent mechanical properties across production batches.
Innovation Solution
A method and system that involves shredding and separately storing different materials like foam rubber, polyester, and polyurethane to maintain their unique characteristics, followed by precise mixing in predetermined proportions to achieve consistent mechanical properties, using an automatic mixing device and control system to ensure reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If processing waste cuttings of different materials are collected and shredded together in a single container, then production costs are reduced and sustainability is improved, but the resulting padding mixture becomes non-uniform and cannot predict bearing capacity and softness
Solution Approach 1:
The patent applies segmentation by dividing the padding production process into separate stages: different materials are shredded separately in individual containers rather than mixed together, then each shredded material is stored in separate containment volumes. This segmentation allows precise control over the composition and characteristics of the final padding mixture, resolving the contradiction between cost-effectiveness and manufacturing precision.
2Productivity
If a multiplicity of different materials are shredded together to create padding, then production efficiency is improved, but constant mechanical properties cannot be obtained for each pillow
Solution Approach 1:
The patent implements preliminary action by shredding each material separately before mixing, and by pre-storing each shredded material in dedicated containment volumes. This preliminary separation ensures that when materials are later combined, the mechanical properties of each component are preserved and可控, allowing consistent and predictable pillow characteristics across production batches.
3Adaptability or versatility
If mixed waste cuttings are used as padding material, then resource utilization is improved, but it is impossible to determine beforehand the bearing capacity and softness of the pillow
Solution Approach 1:
The patent applies feedback by implementing a controlled mixing process where predetermined quantities of each shredded material are combined based on specific proportions. This feedback mechanism ensures that the final padding mixture has predictable and controllable characteristics, allowing the bearing capacity and softness to be determined beforehand, while still utilizing diverse waste materials effectively.
Data Source
Figure 1
AI summary
Described is a method for making padded items, preferably pillows, comprising the steps of: preparing a plurality of materials suitable for being used as padding material; shredding (2) the plurality of materials, separately from each other, to obtain a plurality padding materials; mixing (4) at least two padding materials of the plurality of padding materials according to predetermined proportions to obtain a padding of the padded item; filling (6) a containment body, preferably a lining, with the padding to obtain the padded item; packaging (7) the padded item inside a wrapper.