Spring Mattress Assembly Using Adhesive-Guided Longitudinal Members
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Solution Overview
Problem
Current methods for assembling spring mattresses are largely manual or semi-automatic, making the process complex, expensive, and prone to errors in positioning and gluing longitudinal members, which affects the stability and mechanical stress of the mattress.
Innovation Solution
A method and machine that automate the assembly of a semi-finished spring mattress product by gluing longitudinal members to a pack of springs, forming a stable single body that can be easily manipulated like a sheet, using adhesives such as acrylic water-based or hot-melt adhesives, and positioning this body within a machine for further processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual or robotized arms are used to position longitudinal members, then positioning can be achieved, but the process becomes highly complex and expensive
Solution Approach 1:
The patent replaces complex mechanical positioning systems (robotized arms) with a simplified mechanical guide system consisting of guide rails and positioning elements. The longitudinal members are guided into position using straightforward mechanical constraints rather than complex automated manipulation, achieving adequate positioning precision with much simpler equipment.
2Extent of automation
If robotized arms are used for positioning, then automation is achieved, but the equipment becomes expensive
Solution Approach 1:
The invention replaces expensive robotized arms with simple mechanical guide rails and positioning fixtures. The automation is achieved through the inherent guiding geometry of the rails and the self-aligning features of the longitudinal members, eliminating the need for costly automated manipulation systems while maintaining adequate automation for production.
3Ease of operation
If longitudinal members are positioned only on the pack of springs, then positioning is simplified, but the glued surface has reduced dimensions making pressing difficult and position variation common
Solution Approach 1:
The patent introduces a lower sheet as a separate component that provides an extended gluing surface for the longitudinal members. Instead of gluing directly to the compact spring pack, the longitudinal members are positioned on the lower sheet which has a larger, more accessible surface area, improving both the ease of positioning and the precision of gluing while maintaining the simplified positioning approach.
4Adaptability or versatility
If manual procedures are used, then flexibility is maintained, but productivity is reduced
Solution Approach 1:
The patent implements preliminary positioning actions through guide rails and positioning elements that pre-align the longitudinal members before the actual gluing operation. This preliminary mechanical alignment enables faster processing speeds by eliminating complex manual positioning steps during production, while the modular nature of the guide system maintains flexibility for different mattress configurations.
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 spring mattresses with improved structural strength and reduced mechanical stress, allowing for automated processing and the use of conventional sheet production systems, enabling variable mechanical characteristics based on associated sheets.
Implementation Method 1
applying an adhesive on a joining surface of each of the four longitudinal members 6 and/or on each of the side faces 5 of the pack 2 of springs, joining the joining surface of each of the four longitudinal members 6 to the respective side face 5 of the pack 2 of springs to glue them stably
Data Source
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AI summary
Described is a method of assembling a semi-finished product (1) for making a spring mattress (100), comprising the steps of preparing a pack (2) of springs having a substantially parallelepiped shape and having four side faces (5); preparing four longitudinal members (6) each intended to join a respective said side face (5) of said pack (2) of springs, applying an adhesive on a joining surface of each of said four longitudinal members (6) and/or on each of said side faces (5) of said pack (2) of springs, joining said approach surface of each of said four longitudinal members (6) to said respective side face (5) of said pack (2) of springs to glue them together in a stable fashion.