Pocket Spring Core Frame Gluing to Eliminate Clip Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for coupling a frame to pocket spring elements in bedding or seating products are inefficient, requiring manual or semiautomatic alignment and use of clips, which increases manufacturing costs and complexity.
Innovation Solution
A pocket spring core design where a frame element is directly glued to the pockets of the spring elements, eliminating the need for clips and allowing for automated manufacturing, using adhesives like hot melt, polyurethane, or epoxy lime adhesives that ensure durability and stability during rolling and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clips are used to couple the frame to the coil springs, then the frame can be attached to the pocket spring elements, but the positioning must be manually or semiautomatically aligned for each pocket spring element to ensure correct clipping to the spring turn, increasing manufacturing complexity and time
Solution Approach 1:
The invention extracts and eliminates the clip component from the assembly system. Instead of using clips that require precise alignment with spring turns, the frame is directly coupled to the pocketed spring elements through the nonwoven fabric pockets. This removal of the intermediary clip component simplifies the manufacturing process while maintaining secure attachment, as the frame can be positioned without needing to align with specific spring turn locations.
Solution Approach 2:
The invention merges the frame attachment function directly with the pocketed spring element structure. By coupling the frame to the nonwoven fabric that encloses the spring pockets, the attachment system becomes integrated with the existing pocket structure rather than requiring separate clips. This merging eliminates the need for separate alignment and clipping operations, reducing manufacturing complexity while ensuring reliable frame attachment.
2Reliability
If clips are used to attach the frame to the spring turns, then the frame is secured to the pocket spring elements, but the process requires precise alignment with spring turn positions, increasing manufacturing time and reducing productivity
Solution Approach 1:
The clip component is removed from the system, eliminating the time-consuming alignment and clipping operations. The frame attaches directly to the pocketed spring elements through the nonwoven fabric, allowing for faster, less precise positioning that can be more easily automated while maintaining secure attachment.
Solution Approach 2:
The mechanical clip-and-align system is replaced with a direct coupling system where the frame attaches to the nonwoven fabric pockets. This substitution eliminates the need for precise mechanical alignment with spring turns, enabling faster manufacturing processes and easier automation while maintaining attachment security through the distributed contact across multiple pockets.
3Reliability
If clips penetrate the nonwoven material to attach to spring turns, then the frame is coupled to the pocket spring elements, but additional fastening materials and components are required, increasing manufacturing cost
Solution Approach 1:
The clip fastening component is completely removed from the system. The frame couples directly to the pocketed spring elements through the nonwoven fabric pockets without requiring any additional fastening materials. This elimination of extra components reduces material costs, assembly complexity, and manufacturing expenses while maintaining reliable frame attachment.
Solution Approach 2:
The frame attachment function is merged with the existing nonwoven pocket structure. The same nonwoven fabric that encloses the spring pockets also serves as the attachment surface for the frame, eliminating the need for separate clips or fastening materials. This functional merging reduces component count and manufacturing cost while ensuring secure frame coupling through distributed contact across multiple pockets.
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
This approach reduces manufacturing costs and complexity by enabling automated assembly, maintains adhesion under various conditions, and allows for flexible frame placement without considering spring turn positions, enhancing the efficiency and stability of the pocket spring core.
Implementation Method 1
The frame element is glued to several pockets of the plurality of pocketed spring elements
Data Source
AI summary
The present invention relates to a pocket spring core (40). The pocket spring core (40) comprises a plurality of pocketed spring elements (41). Each of the plurality of pocketed spring elements (41) is formed of a pocket (42) and at least one coil spring (43) enclosed by the pocket (42). The pocket spring core (40) comprises furthermore a frame element (44) enclosing an arrangement of the plurality of pocketed spring elements (41) along a circumference of the arrangement. The frame element (44) is glued to several pockets (42) of the plurality of pocketed spring elements (41) using a hot melt adhesive, a polyurethane adhesive or an epoxy lime adhesive.