Pocketed Spring Unit Conveying and Welding for Simpler Production
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Solution Overview
Problem
Existing methods for producing pocketed spring units are overly complicated and costly, necessitating a more efficient and cost-effective approach.
Innovation Solution
A method and apparatus that compress and feed springs between opposed conveyor belts, sequentially advancing them between fabric layers and welding to form discrete pockets, using a spring coiler and power-driven inserters with movable welding anvils to create pocketed spring units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods are used to form pocketed spring units, then the pockets can be formed with springs, but the production process becomes overly complicated and costly
Solution Approach 1:
The patent combines multiple functions into integrated components: the conveyor belts serve both as transport mechanisms and as structures that hold springs in position; the welding anvils integrate compression and welding functions; the inserters combine spring placement with positioning. This merging reduces the number of separate devices needed, simplifying the overall production process while maintaining capability to form pocketed spring units.
Solution Approach 2:
The conveyor belts are designed to perform multiple functions: they convey springs, hold them in compressed state, position them relative to fabric layers, and serve as part of the welding apparatus. The welding anvils simultaneously compress springs and perform welding operations. This multi-functionality reduces the number of dedicated devices required, thereby reducing apparatus complexity and manufacturing cost.
2Ease of manufacture
If traditional production methods are used, then pocketed spring units can be produced, but the cost of production increases
Solution Approach 1:
The patent implements continuous production through synchronized movement of conveyor belts, fabric layers, and welding anvils. Springs are continuously fed, compressed, positioned, and welded in an uninterrupted sequence. The conveyor belts run continuously, transporting springs through all stages of processing without stopping. This continuous operation increases productivity while the integrated design keeps equipment requirements manageable, controlling production costs.
Solution Approach 2:
Springs are pre-compressed before being placed into pockets, and the conveyor belts are pre-configured with troughs or castellations to receive and hold the compressed springs in the correct position. The fabric layers are pre-positioned and fed continuously through the apparatus. These preliminary actions are performed automatically as part of the continuous process, increasing productivity while avoiding the need for additional separate operations that would increase cost.
3Manufacturing precision
If springs are compressed and fed into troughs or castellations in conveyor belts, then springs can be positioned between fabric layers, but the apparatus requires coordinated movement of multiple components
Solution Approach 1:
The conveyor belts are designed with troughs or castellations that create a standardized, repeatable positioning environment for springs. Each trough or cellation provides the same geometric reference, ensuring consistent spring placement. The fabric layers are fed at a constant rate, creating a stable reference frame. This equipotential approach to positioning—where all springs encounter identical positioning conditions—achieves high precision without requiring complex individual positioning mechanisms for each spring.
Solution Approach 2:
The conveyor belts with troughs or castellations serve as an intermediary structure between the spring feeding mechanism and the fabric layers. The troughs/castellations receive compressed springs, hold them in precise position, and present them to the fabric layers. This intermediary structure simplifies the coordination between different moving components by providing a stable, standardized interface that automatically maintains positioning accuracy.
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 solution simplifies the production process, reduces costs, and allows for the formation of pocketed spring units with unlimited length and width, enhancing efficiency and versatility.
Implementation Method 1
welding means for sequentially welding together said lengths so as to form a plurality of discrete pockets each containing a spring
Data Source
AI summary
A method and apparatus for the production of a pocketed spring unit by compressing and feeding a plurality of springs (42) into troughs (2A, 4A) or castellations in opposed conveyor belts (2,4), moving the springs (42) from the troughs (2A, 4A) or castellations to a position between upper and lower layers of fabric or other material (16A, 18A), step-wise advancing the material (16A, 18A) and the springs (42) in the direction of the output of the apparatus and welding together the lengths of fabric or other material (16A, 18A) at each step-wise advancement by a plurality of sequentially controlled welding anvils (10) so as to form a plurality of discrete pockets (46) each containing a spring (42).