Spring Mattress Foam Bonding Through a Permeable Reinforcing Layer
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Solution Overview
Problem
The conventional bed mattress manufacturing process is complex and costly, leading to increased labor costs and decreased productivity, with issues such as noise generation due to spring contact and reduced lifespan due to spring fatigue.
Innovation Solution
A bed mattress is manufactured using a permeable reinforcing member with fine holes and foam expansion holes, where a foaming material is integrated with the spring assembly, enhancing bonding force and preventing noise by embedding the spring assembly and foaming material together through the holes, thereby simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-layered intermediate member such as felt and non-woven fabric is laminatedly attached on the spring assembly, then the cushioning performance is improved, but the manufacturing complexity and labor cost increase
Solution Approach 1:
The patent combines the intermediate member and cushioning function into a single foam layer that is integrally formed with the spring assembly. The foam material simultaneously provides the cushioning function and acts as the intermediate member, eliminating the need for separate felt and non-woven fabric layers. This merging of functions reduces manufacturing complexity while maintaining cushioning performance.
Solution Approach 2:
The patent uses foam material as a composite structure that integrates multiple functions. The foam serves as both the intermediate member and the cushioning layer, creating a composite material solution that replaces multiple separate components. This composite approach simplifies the manufacturing process while achieving the desired cushioning effect.
2Reliability
If multiple separate components are assembled to form the bed mattress, then the functional performance is improved, but the manufacturing cost and labor cost increase
Solution Approach 1:
The patent merges the spring assembly, intermediate member, and cushioning layer into an integrally formed structure. The foam material is directly formed onto the spring assembly in a single manufacturing process, eliminating the need for separate assembly steps. This integration maintains functional performance while significantly reducing manufacturing cost and labor requirements.
Solution Approach 2:
The foam material is self-adhering and self-forming onto the spring assembly through the foaming process. The expanding foam automatically conforms to the spring structure and creates its own bonding, eliminating the need for separate attachment processes. This self-service characteristic reduces both labor cost and manufacturing complexity.
3Productivity
If the spring assembly is exposed without embedding, then the manufacturing simplicity is maintained, but noise is generated due to spring contact during use
Solution Approach 1:
The patent combines the noise reduction function with the cushioning function by using the same foam layer to both cushion and embed the spring assembly. The foam simultaneously provides comfort and prevents spring-to-spring contact that causes noise. This dual-function approach maintains manufacturing simplicity while eliminating noise generation.
Solution Approach 2:
The foam material acts as an intermediary substance that fills the spaces between springs and prevents direct contact. This intermediary layer absorbs the harmful spring-to-spring contact that generates noise, while the foam itself remains part of the integrated cushioning structure. The intermediary function is achieved without adding separate noise-reduction components.
4Manufacturing precision
If various separate processes are used for manufacturing, then the quality control is improved, but the manufacturing speed decreases
Solution Approach 1:
The patent merges multiple manufacturing processes into a single integral forming operation. The spring assembly, intermediate member, and cushioning layer are formed together in one continuous process, eliminating the need for separate lamination and assembly steps. This integration maintains quality control through consistent single-step manufacturing while dramatically increasing manufacturing speed.
Solution Approach 2:
The manufacturing process continues without interruption as the foam material is continuously formed and cured onto the spring assembly in a single operational sequence. This continuous action eliminates the start-stop nature of multiple separate processes, maintaining quality through consistent manufacturing conditions while improving production speed and efficiency.
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 reduces manufacturing costs and labor, increases the bonding force between the spring assembly and foaming material, prevents noise, and extends the lifespan of the mattress by integrating the foaming material with the spring assembly through the permeable reinforcing member's holes.
Implementation Method 1
a foaming material is disposed on the permeable reinforcing member so as to be foamed, so that the permeable reinforcing member is embedded into the foaming material and simultaneously the spring assembly and the foaming material are integrally formed with each other while the foaming material is expanded through fine holes of the permeable reinforcing member
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
Disclosed herein is a bed mattress and a method of manufacturing the same, in which a permeable reinforcing member (20) is provided at an upper portion and a lower portion of a spring assembly (10) which is one of frame constituents of the bed mattress, and a foaming material (24) is disposed on the permeable reinforcing member (20) so as to be foamed, so that the spring assembly (10) and the foaming material (24) are integrally formed while the foaming material (24) is expanded through fine holes (21) and/or foam expansion holes (22) of the permeable reinforcing member (20).