Spring pocket, spring cushion, furniture and method of manufacturing the spring pocket
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Solution Overview
Problem
Conventional methods for manufacturing spring pockets in furniture require numerous processing steps and result in low production efficiency due to the need for multiple parts with different sizes and structures, leading to potential mismatches and reduced qualification ratios.
Innovation Solution
The method involves forming a flexible bag by overlapping and jointing two completely identical flexible sheets around a conical spring, simplifying the production process and reducing the impact of machining tolerance, thereby improving efficiency and qualification ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple parts with different sizes and structures are used to form the spring bag, then the spring pocket can accommodate the conical spring structure, but the production process becomes complex and production efficiency decreases
Solution Approach 1:
The patent merges multiple different parts into a single type of flexible sheet. Instead of using multiple parts with different sizes and structures, the invention uses one type of flexible sheet that can be positioned and jointed in different locations to form the spring bag, thereby simplifying the production process and improving efficiency while maintaining the required structural accuracy
Solution Approach 2:
The flexible sheet is designed to serve multiple functions: it can be used in different quantities and positions to accommodate various spring configurations. The same flexible sheet type can form different portions of the spring bag structure through strategic positioning and jointing, eliminating the need for multiple specialized parts
2Manufacturing precision
If multiple parts with different sizes and structures are produced individually, then each part can be optimized for its specific function, but machining tolerance causes mismatch and reduces qualification ratio
Solution Approach 1:
The invention produces only one type of flexible sheet instead of multiple different parts. This eliminates the accumulation of machining tolerances that occurs when multiple parts are assembled, as there is only one part type to manufacture. The single flexible sheet type is then positioned and jointed at specific locations to achieve the required fit accuracy without the complexity of matching multiple different parts
3Reliability
If numerous processing steps are used to manufacture spring pockets, then the spring bag can be properly formed, but production time increases and efficiency decreases
Solution Approach 1:
The patent reduces the number of processing steps by using a single flexible sheet type that can be positioned and jointed directly. Instead of requiring separate manufacturing and assembly steps for multiple different parts, the invention combines these steps into a simpler process where the same flexible sheet is used throughout, thereby maintaining quality while reducing production time
Solution Approach 2:
The flexible sheets are prepared in advance as identical pieces that can be directly positioned and jointed. This preliminary preparation of standardized flexible sheets eliminates the need for complex on-site assembly operations, reducing production time while ensuring consistent quality through standardized preparation procedures
Data Source
AI summary
A spring pocket includes a conical spring having a large-diameter end and a small-diameter end opposite to the large diameter end, and a flexible bag. The flexible bag includes an outer layer and an inner layer joined at the large-diameter end and the small-diameter end to encapsulate the conical spring in the flexible bag. The sheets for producing the flexible bag are produced in a single step. Even though the sheets have a large machining tolerance, since the two sheets are identical, they may still match each other and can be easily overlapped and joined.