Method and apparatus for the production of a pocketed spring unit

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

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 into troughs or castellations on conveyor belts, then move them between fabric layers, using sequentially controlled welding anvils to form discrete pockets containing the springs, with optional spring formation immediately before compression and use of power-driven spring inserters and movable welding means.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional methods are used to produce pocketed spring units, then the production process is established and reliable, but the process becomes overly complicated and costly

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidprocess complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The production process is divided into distinct sequential steps: spring formation, compression, feeding into troughs, positioning between fabric layers, and welding. Each step is performed by dedicated apparatus components that work in sequence, transforming a complex monolithic process into manageable modular stages that reduce overall system complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Springs are formed and compressed before being fed into the conveyor troughs, and fabric layers are prepared and positioned in advance. The welding anvils are positioned and controlled in advance to weld at specific intervals. These preliminary actions organize materials and equipment beforehand, simplifying the main production flow and reducing on-the-fly complexity

Inventive Principle:

Principle #10Preliminary action

2Productivity

If conventional methods are used to produce pocketed spring units, then production can proceed, but the production cost becomes excessive

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The conveyor belts continuously transport springs and fabric layers through the production line without interruption. The welding anvils operate continuously at fixed intervals, welding fabric layers as they pass. This continuous operation eliminates stopping and starting, maximizing productivity while using equipment efficiently to reduce costs

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The apparatus is designed to automatically form, compress, feed, position, and weld components without manual intervention. The spring inserters automatically feed springs into troughs, and the welding anvils automatically weld fabric layers at predetermined intervals. This automation eliminates labor costs and increases productivity simultaneously

Inventive Principle:

Principle #25Self-service

3Speed

If fabric layers and springs are advanced continuously, then production speed increases, but precise positioning for welding becomes difficult

Engineering Contradiction:

Improveadvancement speedVSAvoidpositioning accuracy

Core Design Contradiction:

SpeedVSManufacturing precision

Solution Approach 1:

The welding anvils are positioned to weld fabric layers at periodic intervals as they move through the conveyor. The springs are also positioned at regular intervals within the fabric layers. This periodic arrangement allows the system to maintain continuous high-speed operation while ensuring precise positioning at each welding point, as the periodic pattern is easily controllable and repeatable

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent employs controlled advancement mechanisms that replace manual positioning with automated mechanical control. The welding anvils are positioned and actuated by controlled mechanical means that ensure precise positioning relative to the moving fabric layers, maintaining accuracy even at high speeds

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 and cost-reduces the production of pocketed spring units by enabling precise and efficient formation of discrete pockets with unlimited length and width, enhancing the manufacturing process through controlled advancement and welding.

Implementation Method 1

welding together said lengths of fabric at each said step-wise advancement by a plurality of sequentially controlled welding anvils so as to form a plurality of discrete pockets

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS10961112B2Method and apparatus for the production of a pocketed spring unit

Publication Date: 2021.03.30 HARRISON SPINKS COMPONENTS

AI summary

Disclosed are methods, apparatus, devices, and other implementations, including a method for the production of a pocketed spring unit that includes compressing a plurality of springs, moving the springs to positions between upper and lower layers of fabric or other material, step-wise advancing the material and the springs in a spring unit output direction, and welding together the lengths of fabric or other material at each step-wise advancement to produce a pattern of welds in which are formed a plurality of discrete pockets, each containing a spring.