[특허]Mattress manufacturing process and apparatus

Mattress manufacturing process and apparatus 원문보기

IPC분류정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	B32B-041/00 B65G-047/90 B25J-015/00 B68G-007/00 A47C-027/15 B25J-009/16
출원번호	US-0003936 (2016-01-22)
등록번호	US-9862553 (2018-01-09)
발명자 / 주소	Subhedar, Vinit V. Fowler, Gregory Jan, Francis
출원인 / 주소	DREAMWELL, LTD.
대리인 / 주소	Cantor Colburn LLP
인용정보	피인용 횟수 : 0 인용 특허 : 50

초록

A process and apparatus for manufacturing a mattress generally includes an automated foam layer placement apparatus for accurately securing one or more foam layers onto an innercore unit and bucket assembly.

대표청구항 ▼

1. A lifting assembly and transfer apparatus for lifting and placing a foam layer, the lifting assembly and transfer apparatus comprising: an adjustable frame assembly comprising a plurality of lifting units spaced about the adjustable frame assembly, each one of the plurality of lifting units configured to selectively engage and disengage an underlying foam layer so as to provide lifting and release of the foam layer when in use, wherein each one of the plurality of lifting units comprises a housing supporting two slides, each slide provided with one or more of the retractable angled needles, wherein the one or more retractable angled needles on one slide converge toward the one or more retractable angled needles of the other slide; anda robotic arm coupled to the adjustable frame assembly and configured to move the adjustable frame assembly from one location to another. 2. The lifting assembly and transfer apparatus of claim 1, wherein the angle of the one or more retractable needles in one slide is in a range of about 30 degrees to about 60 degrees relative to the plane of the foam layer and the angle of the one or more retractable needles in the other slide is in a range of about 120 to about 150 degrees relative to the plane of the foam layer such that the one or more retractable needles in the one slide and the other slide converge upon extension from the respective sliding. 3. The lifting assembly and transfer apparatus of claim 1, wherein the angle of the one or more retractable needles in one slide is about 45 degrees relative to the plane of the foam layer and the angle of the one or more retractable needles in the other slide is about 135 degrees relative to the plane of the foam layer such that the one or more retractable needles in the one slide and the other slide converge upon extension from the respective sliding. 4. The lifting assembly and transfer apparatus of claim 1, wherein the one or more retractable angled needles are pneumatically operated. 5. The lifting assembly and transfer apparatus of claim 1, wherein the adjustable frame assembly comprises: a pair of longitudinal beams and a pair of transverse beams coupled at respective ends to define a frame perimeter;a plurality of stationary framing beams coupled to and disposed within the frame perimeter;at least one movable longitudinal beam disposed within the frame perimeter and coupled to selected ones of the stationary framing beams and/or the frame perimeter the frame; andat least one movable transverse beam disposed within the frame perimeter and coupled to selected ones of the stationary framing beams and/or the frame perimeter the frame. 6. The lifting assembly and transfer apparatus of claim 5, wherein the at least one movable longitudinal and transverse beams coupled to selected ones of the stationary framing beams and/or the frame perimeter further comprise servomotors configured to selectively move the longitudinal and transverse beams within the frame perimeter. 7. The lifting assembly and transfer apparatus of claim 5, wherein the plurality of stationary framing beams coupled to the frame perimeter comprises a primary beam bisecting the adjustable frame assembly at about a midpoint of the pair of longitudinal beams or the pair of transverse beams. 8. The lifting assembly and transfer apparatus of claim 5, wherein the adjustable frame assembly comprises two movable longitudinal beams and one movable transverse beam. 9. The lifting assembly and transfer apparatus of claim 1, further comprising an attachment plate attached to a top surface of the adjustable frame assembly and centrally located thereon, wherein the robotic arm is coupled to the attachment plate. 10. A process for manufacturing a mattress, the process comprising: automatically lifting a foam layer at a nominal size from a sizing table while maintaining the nominal size, wherein lifting the nominally sized foam layer comprises adjusting an adjustable frame comprising a plurality of lifting units spaced about the adjustable frame assembly so as to accommodate lifting of the nominal size foam layer, each one of the plurality of lifting units configured to selectively engage and disengage the foam layer so as to provide lifting and release of the foam layer when in use; andautomatically placing the foam layer onto an innercore unit and bucket assembly, wherein placement of the foam layer comprises matching the nominally sized foam layer to a base corner datum of the innercore unit and bucket assembly. 11. The process of claim 10, wherein each one of the plurality of lifting units comprises a housing supporting two slides, each slide provided with one or more of retractable angled needles, wherein the one or more retractable angled needles on one slide face toward the one or more retractable angled needles of the other slide such that engaging the foam layer comprises extending the one or more retractable needles from the two slides. 12. The process for manufacturing the mattress of claim 10, wherein automatically lifting and placing the nominally sized foam layer onto the innercore and bucket assembly comprises: robotically moving the adjustable frame assembly over the nominally sized foam layer;lowering the adjustable frame assembly onto or in close proximity to the nominally sized foam layer;engaging the lifting units with the underlying foam layer, wherein the close proximity is at a distance effective to permit engagement of the lifting units with the underlying foam layer;robotically raising the adjustable frame assembly and the engaged foam layer;moving the adjustable frame assembly and the nominally sized foam layer to overlay the innercore and bucket assembly using the base corner datum as a reference point; andlowering the adjustable frame assembly, wherein the nominally sized foam layer contacts an upper surface of the innercore and bucket assembly;disengaging the lifting units from the foam layer; andraising the adjustable frame assembly, wherein the foam layer is in adhesive contact with the innercore and bucket assembly. 13. The process for manufacturing the mattress of claim 10, wherein engaging and disengaging the lifting units comprises inserting and retracting, respectively, retractable needles from the lifting units into the foam layer at an angle relative to a plane of the foam layer, wherein at least two of the retractable needles converge relative to one another when extended. 14. The process for manufacturing the mattress of claim 13, wherein the at least two of the retractable needles converged relative to one another when extended are at angles in a range of 30 to 60 degrees and 120 to 150 degrees, respectively, relative to a plane of the foam layer. 15. The process for manufacturing the mattress of claim 13, wherein the at least two of the retractable needles converged relative to one another when extended are at angles of about 45 and 135 degrees, respectively, relative to a plane of the foam layer.

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Goldston Roland H. (Box 771 Darlington SC 29532), Cart for transporting mattress or the like.
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Ellis, Bruce G., Foldable and width adjustable pallet jack.
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Borrmann, Hans-Peter, Fork-lift truck and kit for truck.
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Della Polla, Michael, Furniture and mattress dolly.
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Stumpf Walter (Dunwoody GA) Dillon Paul (Dunwoody GA), Independent block assembly of springs.
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Suenens Albert J. (St.-P.-Leeuw BEX) Ghysels Marcel (St.-P.-Leeuw BEX), Innerspring construction for mattresses, cushions, and the like and process for manufacturing said construction.
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Francis ; Jr. George W. (Saginaw MI), Latch assembly for containerized baggage trailer.
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St. Clair Albert R. (Lilburn GA), Method and apparatus for providing improved pocketed innerspring constructions.
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St. Clair Albert R. (Lilburn GA), Method for forming strings of pocketed springs.
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Mossbeck Niels S., Method of packaging a bedding product.
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Davies David J. (Everett WA), Modular system for quick conversion of aircraft passenger compartments to cargo baggage/compartments.
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Starr, David; McFadden, Kevin; Chiu, Jeffrey; Smith, Erin; Mault, Sarah, Movable support device.
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IPC	Description
A	생활필수품
A62	인명구조; 소방(사다리 E06C)
A62B	인명구조용의 기구, 장치 또는 방법(특히 의료용에 사용되는 밸브 A61M 39/00; 특히 물에서 쓰이는 인명구조 장치 또는 방법 B63C 9/00; 잠수장비 B63C 11/00; 특히 항공기에 쓰는 것, 예. 낙하산, 투출좌석 B64D; 특히 광산에서 쓰이는 구조장치 E21F 11/00)
A62B-1/08	.. 윈치 또는 풀리에 제동기구가 있는 것

내보내기 구분	파일저장 인쇄 메일전송
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저장형식	Text(ASCII format) Excel format PIAS분석(.xls)
메일정보	받는사람 (필수) @ 보내는사람 (선택) @ 제목 내용 KISTI 검색결과 이메일 서비스
안내	총 건의 자료가 검색되었습니다. 다운받으실 자료의 인덱스를 입력하세요. (1-10,000) 검색결과의 순서대로 최대 10,000건 까지 다운로드가 가능합니다. 데이타가 많을 경우 속도가 느려질 수 있습니다.(최대 2~3분 소요) 다운로드 파일은 UTF-8 형태로 저장됩니다. 파일의 내용이 제대로 보이지 않을실 때는 웹브라우저 상단의 보기 -> 인코딩 -> 자동선택 여부를 확인하십시오. ~ Text(ASCII format) Excel format

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Mattress manufacturing process and apparatus 원문보기

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