Apparatus and method for making a resilient unit
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Solution Overview
Problem
Existing methods for manufacturing resilient units, such as mattresses, lack the ability to efficiently control the positioning and variation of resilient elements during the manufacturing process, limiting the creation of customized resilient units with specific characteristics and patterns.
Innovation Solution
The apparatus and method involve multiple resilient element supply stations providing different types of springs, which are inserted between superposed sheets of material, with the sheets being joined to form pockets, allowing for varied spring configurations and patterns, including offset and absent spring locations, to create customized resilient units with specific characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple resilient element supply stations are used to provide different spring types, then the ability to create customized resilient units with specific characteristics and patterns is improved, but the device complexity increases
Solution Approach 1:
The patent employs multiple resilient element supply stations, each capable of supplying different types of resilient elements (varying in diameter, height, stiffness, material composition). This multi-functional arrangement allows a single manufacturing apparatus to produce diverse resilient unit configurations without requiring separate production lines for each spring type, thereby achieving customization capability while managing device complexity through integrated design.
Solution Approach 2:
The manufacturing apparatus is segmented into multiple independent supply stations, each dedicated to providing specific resilient element types. This segmentation allows flexible configuration where each station can be independently controlled and selected based on the desired final product characteristics, enabling precise customization of resilient units through controlled selection and arrangement of different spring types in various patterns.
2Shape
If springs of different types are inserted in a row with offset positions, then the pattern formation and aesthetic properties are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent employs conveyors that pre-position resilient elements in compressed states at designated locations before insertion into the final assembly. This preliminary positioning action ensures that springs of different types are correctly aligned and spaced in the desired offset patterns before the actual insertion process, reducing the precision demands on the insertion mechanism itself while achieving accurate final positioning and aesthetic patterns.
Solution Approach 2:
The patent introduces conveyors as intermediary devices between the supply stations and the insertion point. These conveyors maintain the compressed state of springs and precisely control their delivery timing and positioning. This intermediary system acts as a buffer that decouples the precision requirements, allowing flexible pattern formation through controlled delivery sequences while the conveyors handle the precise positioning task.
3Productivity
If resilient elements are supplied in a compressed state on a conveyor, then the space utilization and productivity are improved, but the risk of damage to resilient elements increases
Solution Approach 1:
The patent employs conveyors designed to supply resilient elements in a compressed state with controlled compression forces. The compression is applied beforehand in a controlled manner during conveyance, and the system is designed to release this compression gently at the insertion point. This beforehand cushioning approach allows efficient space utilization and high productivity while minimizing damage risk through controlled compression and release mechanisms that protect spring integrity throughout the process.
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 enables the production of resilient units with tailored characteristics and patterns, enhancing both aesthetic and functional properties, such as reduced noise and customized resilience, by using springs of different diameters, heights, and handedness, allowing for finely tuned compression characteristics and visual effects.
Implementation Method 1
joining the sheets together, for example by welding, at locations between the springs, to form pockets around the springs
Data Source
AI summary
Apparatus for forming a resilient unit comprises a conveyor and first and second spring supply stations, arranged in use to deposit respectively first and second spring types and under compression onto the conveyor. At the pocketing station the springs are urged from the conveyor into positions between upper and lower sheets, by a plurality of inserter devices that move together in a reciprocating fashion, before retracting to the position shown. Upper and lower computer-controlled welding tools come together at positions between the springs to join the sheets together. After each welding event the resilient unit is indexed forwards a distance equal to one pocket width in the direction by computer-controlled drive means. The next row of springs is then conveyed into position ready for insertion between the sheets of material, and the process is repeated.