Spring Core Cord Compression to Reduce Packaging and Storage Costs
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Solution Overview
Problem
The existing methods for compressing and storing spring cores, such as vacuum packaging, are costly and prone to damage, requiring additional packaging materials and increasing storage and logistics costs due to their large volume.
Innovation Solution
A spring core is compressed using a cord or thread that forms braids and loops around the pockets, allowing for easy expansion to the non-compressed state without the need for plastic sacks, reducing costs and environmental impact, and enabling more convenient transportation and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If vacuum packaging is used to compress the spring core, then the volume is reduced for transportation and storage, but the cost increases and the risk of damage occurs
Solution Approach 1:
The spring core is divided into multiple compressed sections, each independently compressed by its own cord. This segmentation allows each section to be compressed uniformly without creating stress concentration points that could damage the springs, while also eliminating the need for a single large vacuum package.
Solution Approach 2:
The invention extracts the compression function from the vacuum packaging system and implements it directly through cords integrated with the spring core structure. The cords are woven into the non-woven material and provide compression force without requiring an external vacuum environment or plastic sacks.
2Volume of moving object
If vacuum packaging is used to compress the spring core, then the volume is reduced, but additional packaging materials are required
Solution Approach 1:
The compression cords are merged with the spring core structure itself by weaving them into the non-woven material during manufacturing. This integration eliminates the need for separate external packaging materials like plastic sacks, as the compression mechanism becomes part of the product structure.
Solution Approach 2:
The non-woven material serves multiple functions: it provides structural support, contains the springs, and integrates the compression cords directly into its fabric. This multi-functionality eliminates the need for additional dedicated packaging materials.
3Loss of time
If the spring core is compressed using vacuum packaging, then the storage cost is reduced, but the method is unsuitable for long-term storage
Solution Approach 1:
The spring core is pre-compressed during manufacturing using the cord system, and this compression state is maintained throughout storage and transportation. The cords are tensioned to hold the compressed position, and this preliminary compression action eliminates the need for continuous vacuum sealing during long-term storage.
Solution Approach 2:
The compression cords are self-contained within the spring core structure and maintain compression through their own tensile strength without requiring external vacuum equipment or monitoring. The system is self-sufficient for long-term storage, maintaining compression integrity without external intervention.
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 effectively reduces storage and transportation costs by eliminating the need for vacuum packaging, minimizing damage risks, and allowing for flexible packaging options, making it more suitable for long-term storage and circulation.
Implementation Method 1
The spring core is held in a compressed state by means of at least one cord or thread. The at least one cord is made to form braids at opposite outer ends of each row of pockets. The at least one cord passes through holes in the pockets in such a way that the at least one cord forms a number of interconnected loops on at least one side of each row of pockets.
Implementation Method 2
By pulling the cord, the compressed condition of the spring core is loosened and the springs of the pockets will return to a non-compressed state one after the other.
Data Source
AI summary
The present invention concerns a spring core (1, la, 12, 13, 17, 18) that may be used in e.g. bed mattresses, chairs or sofas. The spring core (1, 1a, 12, 13, 17, 18) comprises springs placed inside pocket (3). The pockets (3) are placed in a number of rows, which rows of pockets (3) are placed side by side. The spring core (1, 1a, 12, 13, 17, 18) is held in a compressed state by means of at least one cord (5). The at least one cord (5) is formed into braids (6) at opposite outer ends (7) of each row of pockets (3). Further, the at least one cord (4) forms a number of loops (8) on at least one side of each row of pockets (3). By pulling at one free end (10) of the at least one cord (5) the braids (6) and loops (8) are dissolved, allowing the spring core (1) to return to the non-compressed state.