Spring Bed Mesh Sewing Layout for Adhesive-Free Automated Assembly

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Solution Overview

Problem

Existing spring bed mesh manufacturing methods using glue bonding result in high pollution and high costs, while ultrasonic welding is limited to specific materials, and manual stitching is inefficient and inconsistent.

Innovation Solution

A spring bed mesh sewing device and method that uses sewing assemblies to automate the assembly of spring strings without adhesive, allowing for the production of adhesive-free spring bed meshes made of natural fibers, improving efficiency and quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If glue bonding is used to combine spring strings, then the spring bed mesh can be manufactured, but it results in large amount of hot melt adhesive, high cost, and non-environmental protection

Engineering Contradiction:

Improvemanufacturability of spring bed meshVSAvoidpollution from hot melt adhesive

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the chemical bonding method (glue bonding) with a mechanical bonding method (sewing). The sewing device uses a needle and thread to mechanically stitch spring strings together, eliminating the need for hot melt adhesive and its associated environmental pollution while maintaining the manufacturability of spring bed mesh

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and removes the harmful element (hot melt adhesive) from the manufacturing process. By eliminating the glue bonding step entirely and replacing it with sewing, the harmful chemical substance is completely taken out of the system, resolving the environmental pollution issue

Inventive Principle:

Principle #2Taking out (Extraction)

2Object-affected harmful factors

If ultrasonic welding is used to combine spring strings, then the environmental protection level is improved, but it is only suitable for fusible materials such as nonwoven fabrics made of polyester or polyester fibers

Engineering Contradiction:

Improveenvironmental protection levelVSAvoidmaterial compatibility

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The patent creates a universal bonding method (sewing) that can accommodate multiple material types. Unlike ultrasonic welding which is limited to fusible materials, the sewing device can join various materials including natural fibers, synthetic fibers, and mixed materials, greatly enhancing material compatibility and versatility

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If manual stitching is used to manufacture spring bed mesh, then adhesive-free natural fiber spring bed mesh can be produced, but it is characterized by low production efficiency, high production costs, and inconsistent product quality

Engineering Contradiction:

Improveadhesive-free productionVSAvoidproduction efficiency

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The patent transforms the manual stitching process into an automated self-service system. The sewing device automatically feeds spring strings, positions them, performs stitching operations, and advances to the next position without human intervention, thereby maintaining the adhesive-free benefit while dramatically improving production efficiency and consistency

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent incorporates preliminary actions in the automated sewing process, including pre-positioning of spring strings by the feeding assembly, pre-alignment of sewing positions, and pre-tensioning of threads before the actual stitching occurs. This ensures consistent product quality and high efficiency while maintaining the adhesive-free characteristic

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12540427B2Spring bed mesh sewing device and spring bed mesh sewing method

Publication Date: 2026.02.03 GUANGZHOU LIANROU MACHINERY & EQUIPMENT CO LTD

AI summary

A spring bed mesh sewing device includes a feeding assembly, sewing assemblies, and cloth pressing assemblies. The feeding assembly can lay spring strings in the transverse direction. Each of the spring strings to be sewn in even rows is sewn on a respective previous spring string through the first sewing positions, each of the spring strings to be sewn in odd rows is sewn on a respective previous spring string through the second sewing positions. The sewing assemblies are arranged at intervals in the transverse direction and are movable in the vertical direction. Each sewing assembly includes a sewing head and a base with a sewing channel extending in the vertical direction. The sewing head can sew two adjacent rows of spring strings along the sewing channel. The cloth pressing assemblies are arranged at intervals in the transverse direction and correspond to the sewing assemblies in the longitudinal direction.