Pocketed Spring Assembly Using Ultrasonic Welding Without Glue

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Solution Overview

Problem

Existing methods for constructing pocketed spring units in mattresses and cushioning assemblies often result in a 'crunchier' feel due to glue connections, which can cause a trampoline-like effect and are not cost-effective or environmentally friendly.

Innovation Solution

The use of ultrasonic welding to connect rows of pocketed spring modules without glue, employing vibrating probes and anvils to form welds in the fabric, creating stronger and more comfortable connections while reducing environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If glue connections are used between pocketed springs, then a crunchier feeling is achieved, but the construction becomes less comfortable and more environmentally harmful

Engineering Contradiction:

Improveconnection methodVSAvoidenvironmental impact

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the chemical bonding system (glue) with an ultrasonic welding system that uses mechanical vibration and heat to join fabric layers. The ultrasonic welding process applies high-frequency vibrations through a horn to generate friction heat, melting and fusing the thermoplastic fabric layers together, thereby eliminating the need for chemical adhesives and their associated environmental harm.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state and properties of the fabric layers through ultrasonic heating. The ultrasonic energy transforms mechanical vibration into thermal energy, raising the temperature of the fabric layers to their melting point, causing them to transition from a solid state to a molten state and then re-solidify into a strong weld, thus joining the layers without glue.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If glue connections are used between pocketed springs, then assembly is simplified, but comfort and luxury feel are reduced

Engineering Contradiction:

Improveassembly processVSAvoidcomfort feel

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If scrim sheets are used to connect rows of pocketed springs, then structural integrity is maintained, but a trampoline-like effect is created

Engineering Contradiction:

Improvestructural integrityVSAvoidcomfort feel

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent replaces the mechanical connection system (scrim sheets) with an ultrasonic welding system that uses high-frequency vibrations to generate friction heat. This heat melts and fuses the fabric layers at specific weld points, creating strong bonds that maintain structural integrity without the flexibility and trampoline effect associated with scrim sheet connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If glue is used for construction, then connection strength is achieved, but weight and transportation costs increase

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent extracts and eliminates the glue component from the construction process entirely. By using ultrasonic welding to join fabric layers directly, the method removes the need for separate adhesive materials, thereby reducing the overall weight of the assembled product and associated transportation costs while maintaining connection strength through mechanical welding bonds.

Inventive Principle:

Principle #2Taking out (Extraction)

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 produces a more luxurious and comfortable cushioning assembly with reduced weight and transportation costs, fewer loose springs, and increased durability, eliminating the need for glue and associated environmental issues.

Implementation Method 1

Rows of pocketed springs are retained in position by pins, and are transferred to corresponding rows of vibrating probes and anvils which pinch layers of fabric together and form welds using ultrasonic vibrational energy

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

form welds using ultrasonic vibrational energy

Methodology Applied

Scientific EffectFriction heating: Viscous Heating

Data Source

PatentUS9221671B2Glueless pocketed spring unit construction

Publication Date: 2015.12.29 WOLFSON MARTIN

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 ultrasonically welded together when paired vibrating probes and anvils press layers of pocketed spring fabric from the rows of pocketed springs together and a welding pulse is transmitted to the vibrating probe.