Three-dimensional filaments-linked structure manufacturing apparatus, manufacturing method of three-dimensional filaments-linked structure, and mattress core material
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Solution Overview
Problem
Conventional manufacturing methods for three-dimensional filaments-linked structures, used as mattress core materials, are inefficient in producing customized products with optimal hardness distribution tailored to individual users' specifications, such as body shape and weight distribution.
Innovation Solution
A manufacturing apparatus and method that acquires divided weight information along a person's height axis, controlling filament density in real-time during the extrusion and cooling process to form a three-dimensional filaments-linked structure with variable hardness, using marking materials for precise cutting and indicating density changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional manufacturing methods are used to produce customized mattress core materials with optimal hardness distribution, then product customization is achieved, but manufacturing time and efficiency are excessive
Solution Approach 1:
The patent divides the weight distribution information into multiple blocks along the height axis, with each block corresponding to a specific region of the mattress core material. This segmentation allows independent control of filament density in different regions, enabling customization while maintaining efficient continuous manufacturing through automated block-based processing.
Solution Approach 2:
The patent implements local quality control by varying filament density according to divided weight information for different blocks. Each block's filament density is independently controlled to match the corresponding body region's weight distribution, achieving customized hardness distribution without requiring complete remanufacturing for each customer specification.
2Manufacturing precision
If filament density is controlled based on divided weight information, then hardness distribution is optimized for individual users, but manufacturing process complexity increases
Solution Approach 1:
The patent performs preliminary action by acquiring and dividing weight information before the extrusion process begins. The weight distribution is pre-divided into blocks and stored as reference data, allowing the manufacturing system to automatically retrieve and apply the appropriate filament density settings for each block without real-time complex calculations during production.
Solution Approach 2:
The patent replaces complex mechanical adjustment systems with an information-based control system. Instead of using complex mechanical mechanisms to adjust filament density for each block, the system uses divided weight information to control the extrusion process, substituting mechanical complexity with automated information processing and control.
3Adaptability or versatility
If made-to-order products are manufactured with tailored specifications, then customer satisfaction is improved, but manufacturing time increases significantly
Solution Approach 1:
The patent segments the manufacturing process into block-based operations corresponding to divided weight information. This segmentation allows the system to process different body regions independently and efficiently, reducing overall manufacturing time while maintaining made-to-order customization capabilities for each customer's specific weight distribution.
Solution Approach 2:
The patent maintains continuity of useful action by implementing continuous extrusion and cooling processes that operate without interruption. The divided weight information guides the continuous manufacturing process, allowing made-to-order products to be produced efficiently through uninterrupted operations rather than batch processing.
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
Enables efficient and accurate production of customized mattress core materials with tailored hardness distribution, improving user satisfaction by matching body pressure dispersion, and facilitating convenient, made-to-order manufacturing.
Implementation Method 1
a three-dimensional linked structure formation means which makes an extruder extrude a thermoplastic resin material in continuous lines via plural nozzles
Implementation Method 2
makes an extruder extrude a thermoplastic resin material in continuous lines via plural nozzles
Implementation Method 3
cools the filaments while transferring the filaments, and forms a three-dimensional filaments-linked structure
Data Source
AI summary
A manufacturing apparatus and manufacturing method for manufacturing a three-dimensional filaments-linked structure includes: divided weight information acquisition means which records divided weight information acquired by dividing weight distribution in a height direction of a person in a height axis direction, in correlation with a distance from a top of a head of the person; and three-dimensional linked structure formation means which tangles and fuses filaments of a thermoplastic resin material extruded from an extruder in a three-dimensional net shape, and forms a three-dimensional filaments-linked structure which is long in a product streaming direction, and the three-dimensional linked structure formation means includes filament density control means which controls filament density in the product streaming direction based on the divided weight information. As a result of the configuration, it is possible to promptly, reliably, and efficiently manufacture products with desired specifications for customers who request products with made-to-order specifications.