Ultrasonic Pocketed Spring Assembly Without Glue Bonds

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Solution Overview

Problem

Existing methods for constructing pocketed spring units in mattresses and cushioning assemblies often result in a 'crunchier' feel due to glue connections and can be costly, environmentally impactful, and prone to unmoored pockets and loose springs.

Innovation Solution

The use of ultrasonic welding to connect rows of pocketed spring modules without glue, employing vibrating probes and anvils to form welds in the fabric, creating stronger, more comfortable, and cost-effective cushioning units with reduced environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If glue connections are used between pocketed springs, then a crunchier feeling is achieved, but the construction becomes more costly and environmentally impactful

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the chemical bonding mechanism (glue) with an ultrasonic welding mechanism that uses mechanical vibration and heat to fuse fabric layers together. This substitution eliminates the need for adhesives while achieving strong connections between pocketed springs and fabric layers, thereby reducing manufacturing costs and environmental impact while maintaining connection reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the bonding method from chemical (glue) to physical (ultrasonic welding), altering the fundamental parameter of how connections are formed. This parameter change enables a more cost-effective and environmentally friendly construction process while achieving comparable or superior connection strength through the controlled application of ultrasonic energy and heat

Inventive Principle:

Principle #35Parameter changes

2Reliability

If glue connections are used between pocketed springs, then connection is achieved, but environmental impact increases

Engineering Contradiction:

Improveconnection strengthVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces chemical bonding (glue) with ultrasonic welding, eliminating the use of adhesives that can be harmful to the environment. The ultrasonic welding process uses mechanical vibration and heat to create strong bonds without chemical contaminants, thereby reducing environmental impact while maintaining reliable connections between pocketed springs and fabric layers

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention converts the potentially harmful effect of requiring strong connections (which might lead to using more glue or stronger adhesives) into a benefit by using ultrasonic welding. This process creates equally strong or stronger bonds without the environmental harm associated with chemical adhesives, effectively turning the challenge of achieving strong connections into an opportunity for environmentally friendly manufacturing

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If ultrasonic welding is used to connect pocketed springs, then manufacturing cost is reduced, but connection strength must be maintained

Engineering Contradiction:

Improvemanufacturing costVSAvoidconnection strength

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent employs ultrasonic welding technology that uses high-frequency mechanical vibrations to generate heat and fuse fabric layers together. This process eliminates the need for adhesives, reducing material costs and simplifying the manufacturing process while creating strong, reliable connections between pocketed springs and fabric layers through direct thermal bonding

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention optimizes the ultrasonic welding parameters (frequency, amplitude, duration, and pressure) to achieve the strongest possible bonds at minimal cost. By carefully controlling these parameters, the process creates connections that are as strong as or stronger than glue connections while significantly reducing manufacturing costs through eliminated adhesive materials and simplified processing

Inventive Principle:

Principle #35Parameter changes

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 results in more comfortable, luxurious-feeling cushioning assemblies with stronger connections, reduced weight, lower transportation costs, and a lower likelihood of unmoored pockets and loose springs, while being environmentally friendly and cost-effective.

Implementation Method 1

Rows of pocketed springs are retained in position by pins, and are transferred to corresponding rows of vibrating probes and anvils which pinch layers of fabric together and form welds using ultrasonic vibrational energy

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS9126822B2Glueless pocketed spring unit construction

Publication Date: 2015.09.08 WOLFSON MARTIN

AI summary

Methods and systems for no-glue pocketed spring unit construction. Rows of pocketed springs, preferably arranged into modules of more than two pocketed springs surrounding a central hole, are ultrasonically welded together when paired vibrating probes and anvils press layers of pocketed spring fabric from the rows of pocketed springs together and a welding pulse is transmitted to the vibrating probe.