Pocketed Spring Unit Welding Without Glue for Mattress Comfort
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Solution Overview
Problem
Existing methods for constructing pocketed spring units in mattresses and cushioning assemblies often result in a trampoline-like effect and a 'crunchier' feel due to glue connections, which can be uncomfortable and inefficient.
Innovation Solution
The use of Joule heating to weld rows of pocketed spring modules together without glue, employing probes and anvils to pinch layers of fabric and form welds using current-heated wires, creating stronger and more comfortable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glue connections are used between pocketed springs, then a crunchier feeling is achieved, but comfort is reduced and environmental impact increases
Solution Approach 1:
The patent replaces the chemical bonding mechanism (glue) with an electrical heating mechanism (Joule heating elements) that creates thermal welds. The heating elements pass through the fabric pockets and generate heat via electrical current to melt and bond the fabric layers together, eliminating the need for adhesives while achieving strong connections without the harmful effects of glue.
Solution Approach 2:
The patent changes the bonding method from chemical (glue) to thermal (heat). By controlling parameters such as heating element resistance, electrical current magnitude, and heating duration, the fabric is heated to its melting point to create strong welds. This parameter change enables connection without glue while maintaining comfort and reducing environmental impact.
2Object-affected harmful factors
If thermal welding is used to connect pocketed springs, then comfort is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the welding system into modular components: individual heating elements are integrated into separate fabric pockets, each pocket is prepared independently with the heating element positioned within it, and welding occurs at discrete locations where pockets intersect. This segmentation simplifies the overall manufacturing process by breaking down the complex welding operation into manageable, repeatable steps.
Solution Approach 2:
The heating elements are self-contained within the fabric pockets and generate their own heat through electrical current without requiring external heating equipment. The fabric itself serves as the medium for heat transfer and bonding, eliminating the need for complex external heating systems and reducing manufacturing complexity.
3Strength
If Joule heating is used to weld fabric layers, then connection strength is improved, but energy consumption increases
Solution Approach 1:
The heating elements are positioned locally within specific fabric pockets where welding is required, rather than heating the entire fabric assembly. This localized heating approach concentrates energy only where needed to create welds, minimizing overall energy consumption while achieving strong connections at critical junction points.
Solution Approach 2:
The patent utilizes the phase transition of the fabric material from solid to molten state and back to solid during welding. The Joule heating elements raise the temperature of the fabric at the weld point to its melting point, creating a molten state that bonds the layers together, then allows cooling and solidification to form a strong weld. This phase transition enables strong bonding with controlled, localized energy input.
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 method allows for the construction of comfortable, luxurious-feeling cushioning units with reduced weight, cost, and environmental impact, while eliminating the likelihood of unmoored pockets and loose springs, and enabling unitary welds of full vertical extent.
Implementation Method 1
forming welds using current-heated wires in the probes
Implementation Method 2
form welds using current passed through heating elements on the probes
Data Source
AI summary
Methods and systems for no-glue pocketed spring unit construction. Rows of pocketed springs, preferably arranged into modules of more than two pocketed springs surrounding a central hole, are welded together when paired probes and anvils press layers of pocketed spring fabric from the rows of pocketed springs together and a welding pulse of current is transmitted through wires on the probes to heat the wire it is pressed against the fabric. Non-stick material interposed between the wires and the fabric prevents melted fabric from sticking to the wires.