Pocketed Spring Fabric Ventilation Using Removable Pin Roller Assembly
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Solution Overview
Problem
Existing pocket coil machines produce continuous strings of pocketed springs using non-woven fabrics without additional ventilation openings, making it difficult to identify the manufacturer or source of the product, and there is a need for cost-effective ventilation solutions that can pattern openings in fabrics before spring encasement.
Innovation Solution
A ventilation apparatus comprising a stationary brush roller assembly and a movable pin roller assembly that can be attached to existing pocket coil machines to create patterned ventilation openings in fabrics, allowing for improved ventilation and identification of the product or manufacturer by imprinting patterns such as letters or numbers on the fabric before it is used to make pocketed springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a non-woven fabric is used without additional ventilation openings, then the manufacturing process is simple and cost-effective, but the ventilation is insufficient and product identification is difficult
Solution Approach 1:
The ventilation openings are created in the fabric before the pocketed springs are assembled into the final product. The patterned fabric is fed into the pocket coil machine, so the openings are prepared in advance during the manufacturing process, eliminating the need for post-assembly ventilation modifications.
Solution Approach 2:
The fabric is transformed from a solid non-woven material into a porous material with a pattern of ventilation openings. The pin roller creates holes in the fabric, converting it into a porous structure that allows air flow while maintaining the fabric's structural integrity.
2Loss of information
If patterned openings are created in the fabric, then product identification and ventilation are improved, but the device complexity increases
Solution Approach 1:
The pin roller assembly serves multiple functions: it creates ventilation openings for air flow, imprints manufacturer identification patterns, and maintains fabric tension. This multi-functionality reduces the need for separate devices for each purpose, thereby limiting the increase in overall system complexity.
Solution Approach 2:
The ventilation opening creation and pattern imprinting functions are merged into a single pin roller assembly that works in conjunction with the brush roller. This combination eliminates the need for separate ventilation and branding systems, keeping the added complexity minimal.
3Reliability
If a movable pin roller assembly is used, then the ventilation openings can be created effectively, but the device complexity and maintenance requirements increase
Solution Approach 1:
The ventilation apparatus is divided into separate modular components: a stationary brush roller assembly and a movable pin roller assembly. This segmentation allows the pin roller to be easily removed, replaced, or maintained without affecting the entire pocket coil machine, thereby improving ease of repair despite the added complexity.
Solution Approach 2:
The pin roller assembly is designed to be movable rather than fixed, allowing it to be adjusted or removed as needed for maintenance. This dynamic design enables easy access to the pin roller for cleaning or replacement, offsetting the increased complexity with improved maintainability.
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 quick and cost-effective retrofitting of existing pocket coil machines for improved ventilation and allows for product or manufacturer identification through patterned openings, enhancing product differentiation and customer recognition.
Implementation Method 1
Friction between the moving fabric and the brush roller(s) causes rotation of the brush roller(s) and brush roller shaft
Data Source
AI summary
An apparatus for ventilating a web of material used in the manufacture of pocketed springs may be removably attached to a pocket coiler. The apparatus has an upper movable portion which pivots relative to a stationary portion. The stationary portion may be removably attached to the pocket coiler. Each portion has at least one roller, a web of material passing between the rollers during use. One of the rollers may have protrusions to create openings in the material before the material enters the pocket coiler.