Mattress manufacturing process and apparatus
View Patent ↗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.
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; and
a 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; and
at 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; and
automatically 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; and
lowering 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; and
raising 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.