WO2020030918A1 - Apparatus and method for manufacturing a resilient unit - Google Patents

Apparatus and method for manufacturing a resilient unit Download PDF

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Publication number
WO2020030918A1
WO2020030918A1 PCT/GB2019/052234 GB2019052234W WO2020030918A1 WO 2020030918 A1 WO2020030918 A1 WO 2020030918A1 GB 2019052234 W GB2019052234 W GB 2019052234W WO 2020030918 A1 WO2020030918 A1 WO 2020030918A1
Authority
WO
WIPO (PCT)
Prior art keywords
welding
workpiece
tools
sheets
rotatable member
Prior art date
Application number
PCT/GB2019/052234
Other languages
French (fr)
Inventor
Simon Spinks
David Clare
Richard ESSERY
Original Assignee
HS Products Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by HS Products Limited filed Critical HS Products Limited
Publication of WO2020030918A1 publication Critical patent/WO2020030918A1/en

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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06H—MARKING, INSPECTING, SEAMING OR SEVERING TEXTILE MATERIALS
    • D06H5/00—Seaming textile materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • B29C66/8362—Rollers, cylinders or drums moving relative to and tangentially to the parts to be joined
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
    • A47C27/06—Spring inlays
    • A47C27/063—Spring inlays wrapped or otherwise protected
    • A47C27/064—Pocketed springs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/085—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary sonotrode
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/433—Casing-in, i.e. enclosing an element between two sheets by an outlined seam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81433—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/086—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary anvil
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/087—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using both a rotary sonotrode and a rotary anvil
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/729—Textile or other fibrous material made from plastics
    • B29C66/7294—Non woven mats, e.g. felt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/751—Mattresses, cushions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/774—Springs
    • B29L2031/7742—Springs helical springs

Definitions

  • the present invention relates to an apparatus and a method for making a resilient unit, such as a mattress.
  • Resilient units such as mattresses, are usually made using resilient elements, such as springs of coiled wire, located inside individual pockets of material.
  • the pockets are formed around the springs by joining together leaves of pocketing material, which may, for example, comprise non-woven, spun- bonded polyester.
  • springs would be pocketed individually and then joined together to form an array.
  • several springs can be inserted between leaves of pocketing material which is then folded over the springs, before the individual pockets are established by joining the leaves of material between, and around, the springs. This is referred to as a "string" of pocketed springs.
  • the linear strings are then joined together, side by side, to form a two-dimensional array.
  • Embodiments of the present invention aim to provide an improved apparatus and method for manufacturing pocketed springs .
  • the present invention is defined in the attached independent claims, to which reference should now be made. Further, preferred features may be found in the sub-claims appended thereto .
  • a welding apparatus comprising first and second welding tools for welding together sheets of a workpiece, wherein at least one of the welding tools comprises a rotatable member arranged in use to rotate to weld a workpiece positioned between the tools.
  • the rotatable member may be arranged to rotate with respect to the workpiece in use and/or to rotate with respect to the other tool.
  • the rotatable member may comprise a wheel or a roller .
  • the welding apparatus may comprise ultrasonic welding apparatus.
  • the at least one tool may comprise an ultrasonic vibrating tool, which may be a sonotrode, or horn.
  • the at least one tool may comprise a base or anvil .
  • first and second tools may both include a rotatable member.
  • the or each rotatable member may comprise a profiled surface which may be arranged in use to impart a patterned weld to the workpiece.
  • the profiled surface of the at least one rotatable member may comprise one or more of a knurled, serrated, ridged, stepped or otherwise patterned surface.
  • a method of welding together sheets of a workpiece comprising positioning the sheets between first and second welding tools and causing a rotatable member of at least one of the tools to rotate to effect a weld.
  • the method may comprise causing the rotatable member to rotate with respect to the workpiece and/or with respect to the other tool.
  • the method may comprise a method of ultrasonic welding of sheets of a workpiece.
  • the method comprises a method of welding together thermoplastic material, more preferably non-woven material.
  • the method may comprise rolling the rotatable member over the sheet material.
  • the method comprises rolling a rotatable member over the workpiece, which rotatable member comprises a profiled surface, to impart a patterned weld to the workpiece.
  • Figure 1 shows schematically in perspective view a resilient unit made up of a plurality of coil springs encapsulated between axially spaced sheets of material, according to a prior art example
  • Figure 2 shows the unit of Figure 1 in schematic cross section taken along line 2 2 of Figure 1;
  • FIG. 3 shows schematically a welding apparatus according to an embodiment of the present invention.
  • Figure 4 is a schematic end view of a part of the apparatus of Figure 3.
  • Figures 1 and 2 show a resilient unit generally at 100, comprising an array of steel wire coil springs 110 inside individual pockets 120 formed by axially spaced sheets 130 of spun-bonded polyester that have been ultrasonically welded at points 140 between the springs and at edges of the unit 100.
  • the resilient unit would typically include more springs, i.e. be longer and wider, than is represented in the drawing.
  • FIG 3 shows an apparatus for welding a resilient unit such as is shown in Figures 1 and 2, and many other types of pocketed spring unit (not shown) .
  • the welding apparatus is shown generally at 200 and comprises a first tool, in the form of a sonotrode - or "horn" - 210 and a second tool, comprising an anvil 220. Between the welding tools 210 and 220 are located the sheets 130 of material to be welded, as a workpiece.
  • the material may be of any weldable type, but for the purpose of making pocketed spring units it is often of non-woven, spun-bonded polyester.
  • the sonotrode tool 210 comprises a bracket 210a and a rotatable wheel 210b which is arranged to rotate with respect to the stationary anvil 220.
  • an electrical current is applied to the sonotrode which causes it to vibrate at ultrasonic frequencies, typically in the region of 20 KHz. In combination with applied pressure, this causes highly localized friction in the sheets 130 which heats the material locally and welds the sheets together.
  • Figure 4 shows the tool 210 schematically from the front, from which it can be seen that the circumferential surface of the wheel 210b has a pattern P thereon.
  • the pattern can be selected from many alternatives.
  • the example shown has the sonotrode with the rotatable part 210b, and the anvil as a stationary component.
  • the stationary component could equally be the sonotrode, with the anvil including a rotatable part.
  • both welding tools include rotating parts that bear against one another - with the material sheets therebetween, to effect a weld.
  • the sheets of the workpiece could be welded together by heat sealing. This could be achieved by heating one or both of the welding tools, for example electronically. Such heat, optionally in combination with the application of pressure, could effect the weld in a similar way, by causing localised heating in the workpiece, with one or both of the welding tools having a rotatable member as described above.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

An apparatus for welding a resilient unit is shown generally at (200) and comprises a first tool, in the form of a sonotrode –or "horn" –(210) and a second tool, comprising an anvil (220). Between the welding tools (210) and (220) are located the sheets 130of material to be welded, as a workpiece. The material may be of any weldable type, but for the purpose of making pocketed spring units it is often of non-woven, spun- bonded polyester. The sonotrode tool (210) comprises a bracket (210a) and a rotatable wheel (210b) which is arranged to rotate with respect to the stationary anvil (220). To effect welding an electrical current is applied to the sonotrode which causes it to vibrate at ultrasonic frequencies, typically in the region of 20 KHz. In combination with applied pressure, this causes highly localized friction in the sheets (130) which heats the material locally and welds the sheets together. As the wheel moves across the sheets (130) in the direction of arrow A, whether between adjacent springs or at the edge of the unit (100), the welding tools join the sheets together.

Description

Apparatus and Method for Manufacturing a Resilient Unit
The present invention relates to an apparatus and a method for making a resilient unit, such as a mattress.
Resilient units, such as mattresses, are usually made using resilient elements, such as springs of coiled wire, located inside individual pockets of material. The pockets are formed around the springs by joining together leaves of pocketing material, which may, for example, comprise non-woven, spun- bonded polyester.
Traditionally, springs would be pocketed individually and then joined together to form an array. As a variant of this method several springs can be inserted between leaves of pocketing material which is then folded over the springs, before the individual pockets are established by joining the leaves of material between, and around, the springs. This is referred to as a "string" of pocketed springs. The linear strings are then joined together, side by side, to form a two-dimensional array.
Another manufacturing method is outlined in our UK Patent No. GB 2426926 B in which rows of springs are sequentially introduced between axially spaced sheets of material that are then joined together at positions between the sheets, and at their edges, to form an array of individually pocketed springs .
Embodiments of the present invention aim to provide an improved apparatus and method for manufacturing pocketed springs . The present invention is defined in the attached independent claims, to which reference should now be made. Further, preferred features may be found in the sub-claims appended thereto .
According to one aspect of the present invention, there is provided a welding apparatus comprising first and second welding tools for welding together sheets of a workpiece, wherein at least one of the welding tools comprises a rotatable member arranged in use to rotate to weld a workpiece positioned between the tools.
The rotatable member may be arranged to rotate with respect to the workpiece in use and/or to rotate with respect to the other tool. The rotatable member may comprise a wheel or a roller .
The welding apparatus may comprise ultrasonic welding apparatus. The at least one tool may comprise an ultrasonic vibrating tool, which may be a sonotrode, or horn. Alternatively the at least one tool may comprise a base or anvil .
In one arrangement the first and second tools may both include a rotatable member.
The or each rotatable member may comprise a profiled surface which may be arranged in use to impart a patterned weld to the workpiece. The profiled surface of the at least one rotatable member may comprise one or more of a knurled, serrated, ridged, stepped or otherwise patterned surface.
According to another aspect of the present invention, there is provided a method of welding together sheets of a workpiece, the method comprising positioning the sheets between first and second welding tools and causing a rotatable member of at least one of the tools to rotate to effect a weld.
The method may comprise causing the rotatable member to rotate with respect to the workpiece and/or with respect to the other tool.
The method may comprise a method of ultrasonic welding of sheets of a workpiece. In a preferred arrangement the method comprises a method of welding together thermoplastic material, more preferably non-woven material.
The method may comprise rolling the rotatable member over the sheet material.
In a preferred arrangement the method comprises rolling a rotatable member over the workpiece, which rotatable member comprises a profiled surface, to impart a patterned weld to the workpiece.
The invention may include any combination of the features or limitations referred to herein, except such a combination of features as are mutually exclusive, or mutually inconsistent . A preferred embodiment of the present invention will now be described, by way of example only, with reference to the accompanying diagrammatic drawings, in which:
Figure 1 shows schematically in perspective view a resilient unit made up of a plurality of coil springs encapsulated between axially spaced sheets of material, according to a prior art example;
Figure 2 shows the unit of Figure 1 in schematic cross section taken along line 2 2 of Figure 1;
Figure 3 shows schematically a welding apparatus according to an embodiment of the present invention; and
Figure 4 is a schematic end view of a part of the apparatus of Figure 3.
Turning to Figures 1 and 2 these show a resilient unit generally at 100, comprising an array of steel wire coil springs 110 inside individual pockets 120 formed by axially spaced sheets 130 of spun-bonded polyester that have been ultrasonically welded at points 140 between the springs and at edges of the unit 100. The resilient unit would typically include more springs, i.e. be longer and wider, than is represented in the drawing.
Figure 3 shows an apparatus for welding a resilient unit such as is shown in Figures 1 and 2, and many other types of pocketed spring unit (not shown) . The welding apparatus is shown generally at 200 and comprises a first tool, in the form of a sonotrode - or "horn" - 210 and a second tool, comprising an anvil 220. Between the welding tools 210 and 220 are located the sheets 130 of material to be welded, as a workpiece. The material may be of any weldable type, but for the purpose of making pocketed spring units it is often of non-woven, spun-bonded polyester.
The sonotrode tool 210 comprises a bracket 210a and a rotatable wheel 210b which is arranged to rotate with respect to the stationary anvil 220. To effect welding an electrical current is applied to the sonotrode which causes it to vibrate at ultrasonic frequencies, typically in the region of 20 KHz. In combination with applied pressure, this causes highly localized friction in the sheets 130 which heats the material locally and welds the sheets together.
As the wheel moves across the sheets 130 in the direction of arrow A, whether between adjacent springs or at the edge of the unit 100, the welding tools join the sheets together.
Figure 4 shows the tool 210 schematically from the front, from which it can be seen that the circumferential surface of the wheel 210b has a pattern P thereon. The pattern can be selected from many alternatives. One reason why a pattern of welds is preferred to a continuous line, is that the latter might introduce a structural weakness into the unit 100. The example shown has the sonotrode with the rotatable part 210b, and the anvil as a stationary component. However, the stationary component could equally be the sonotrode, with the anvil including a rotatable part. Indeed, a more complex arrangement can be envisaged in which both welding tools include rotating parts that bear against one another - with the material sheets therebetween, to effect a weld.
One advantage of the apparatus described is the speed with which the welds can be made. Previous welding apparatus requires the tools to come together and then separate, usually under the control of a pneumatic actuator, before either moving the pair of tools or, more conveniently, indexing the sheets to a new weld position and bringing the tools together again. There are certain operational limitations that must be overcome when seeking to increase the speed of such a process. In contrast, when at least one of the welding tools is rotatable with respect to the other, and to the workpiece, it can be moved quickly and efficiently.
Although the example described above is of a stationary workpiece and a moving weld tool, it will be understood by the skilled person that the workpiece could also be moved while one or both of the tools remain in a fixed position. What is important is that there is relative movement of the material with respect to at least one of the tools. The rotatable member still rotates with respect to the material and/or with respect to the other tool. It may be useful/necessary to move the workpiece while keeping one or more of the welding tools stationary for one direction of weld and to keeping the workpiece stationary while moving one or more of the welding tools for another direction of weld. So, it will be understood that a combination of approaches might be appropriate, for example when welds are to be made in substantially different directions in the workpiece, such as directions that are of the order of 90 degrees apart.
Furthermore, while the example given above is of ultrasonic welding, it will be understood by those skilled in the art that other types of welding can be employed either alone or in combination with ultrasonic welding, whilst still remaining within the scope of the present invention. For example, the sheets of the workpiece could be welded together by heat sealing. This could be achieved by heating one or both of the welding tools, for example electronically. Such heat, optionally in combination with the application of pressure, could effect the weld in a similar way, by causing localised heating in the workpiece, with one or both of the welding tools having a rotatable member as described above.
Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance, it should be understood that the applicant claims protection in respect of any patentable feature or combination of features referred to herein, and/or shown in the drawings, whether or not particular emphasis has been placed thereon.

Claims

1. A welding apparatus comprising first and second welding tools for welding together sheets of a workpiece, wherein at least one of the welding tools comprises a rotatable member arranged in use to rotate to weld a workpiece positioned between the tools.
2. A welding apparatus according to Claim 1, wherein the rotatable member is arranged to rotate with respect to the workpiece in use and/or to rotate with respect to the other tool.
3. A welding apparatus according to Claim 1 or 2, wherein the rotatable member comprises a wheel or a roller.
4. A welding apparatus according to any of the preceding claims, wherein the welding apparatus comprises ultrasonic welding apparatus.
5. A welding apparatus according to Claim 4, wherein the at least one tool comprises an ultrasonic vibrating tool, such as a sonotrode, or horn.
6. A welding apparatus according to Claim 4, wherein the at least one tool comprises a base or anvil.
7. A welding apparatus according to any of the preceding claims, wherein the first and second tools both include a rotatable member.
8. A welding apparatus according to any of the preceding claims, wherein the or each rotatable member comprises a profiled surface arranged in use to impart a patterned weld to the workpiece.
9. A welding apparatus according to any of the preceding claims, wherein the apparatus is arranged to effect at least one first weld in a first direction by moving the workpiece while keeping one or more of the welding tools stationary, and at least one second weld in a second direction by keeping the workpiece stationary while moving one or more of the welding tools.
10. A method of welding together sheets of a workpiece, the method comprising positioning the sheets between first and second welding tools and causing a rotatable member of at least one of the tools to rotate to effect a weld.
11. A method according to Claim 10, wherein the method comprises causing the rotatable member to rotate with respect to the workpiece and/or with respect to the other tool.
12. A method according to Claim 10 or 11, wherein the method comprises a method of ultrasonic welding of sheets of a workpiece.
13. A method according to any of Claims 10 12, wherein the method comprises a method of welding together thermoplastic material, more preferably non-woven material .
14. A method according to any of Claims 10-13, wherein the method comprises rolling a rotatable member over the workpiece, which rotatable member comprises a profiled surface, to impart a patterned weld to the workpiece.
15. A method according to any of Claims 10-14, wherein at least one first weld is effected in a first direction by moving the workpiece while keeping one or more of the welding tools stationary, and at least one second weld is effected in a second direction by keeping the workpiece stationary while moving one or more of the welding tools.
PCT/GB2019/052234 2018-08-10 2019-08-08 Apparatus and method for manufacturing a resilient unit WO2020030918A1 (en)

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GB1813122.7 2018-08-10
GB1813122.7A GB2576215A (en) 2018-08-10 2018-08-10 Apparatus and method for manufacturing a resilient unit

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