Pocketed Spring Assembly With Sequential Fabric Welding
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Solution Overview
Problem
Existing methods for forming pocketed spring units are overly complex and costly, requiring inefficient processes for placing and welding springs between fabric layers.
Innovation Solution
A method and apparatus that compress and feed springs between conveyor belts, then position and weld them between fabric layers using a system of conveyor belts, spring inserters, and welding anvils to form discrete pockets, allowing for efficient and sequential welding of springs into pockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods are used to place and weld springs between fabric layers, then the process is complex and costly, but the springs can be positioned and welded into pockets
Solution Approach 1:
The patent combines the spring placement and welding operations into a single integrated conveyor system. Springs are compressed between conveyor belts that simultaneously position and weld them between fabric layers, eliminating the need for separate placement and welding equipment. This merging of operations directly reduces device complexity while maintaining manufacturing capability.
Solution Approach 2:
The conveyor belts serve multiple functions: they compress the springs, transport them to positioning locations, and provide the welding surface. The welding anvils are integrated into the conveyor system, allowing the same equipment to perform both positioning and welding. This multi-functionality reduces the overall number of components needed in the manufacturing system.
2Ease of manufacture
If traditional spring placement methods are used, then the process is costly, but springs can be positioned between fabric layers
Solution Approach 1:
The conveyor system enables continuous operation where springs are constantly being compressed, positioned, and welded in an unbroken sequence. The fabric layers move continuously through the system with springs being added and welded in real-time without stopping. This continuous process eliminates idle time between operations, significantly improving manufacturing efficiency while reducing per-unit costs.
Solution Approach 2:
Springs are compressed between the conveyor belts before being positioned between the fabric layers. This preliminary compression ensures springs are ready for immediate placement and welding, eliminating the need for separate compression equipment later in the process. The pre-compression step integrates seamlessly into the conveyor system, improving overall process efficiency.
3Productivity
If springs are compressed between conveyor belts and sequentially welded, then discrete pockets are formed efficiently, but the apparatus requires multiple moving components
Solution Approach 1:
The welding anvils are integrated directly into the conveyor belt system, merging the welding function with the transport and compression functions. The conveyor belts themselves serve as the positioning mechanism, eliminating the need for separate positioning equipment. This integration reduces apparatus complexity while maintaining high manufacturing efficiency through continuous operation.
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 approach simplifies the process, reduces costs, and enables the formation of pocketed spring units with unlimited length and width, improving the efficiency and cost-effectiveness of the manufacturing process.
Implementation Method 1
sequentially welding together said lengths so as to form a plurality of discrete pockets each containing a spring
Data Source
Figure 1
Figure 2A~2D
Figure 3~4
AI summary
A method and apparatus for the production of a pocketed spring unit, the method comprising the steps of compressing and feeding a plurality of springs (42) into troughs (2A, 4A) or castellations in opposed conveyor belts (2, 4) , moving said springs (42) from said troughs (2A, 4A) or casetellations to a position between upper and lower layers of fabric or other material (ISA, 18A) , step-wise advancing said material (16A, 18A) and said springs (42) in the direction of the output of the apparatus and welding together said 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) . Apparatus for carrying out the method is disclosed.