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 sizing table for sizing a layer of foam to a nominal size, the sizing table comprising:
a planar surface for supporting the foam layer; and
an adjustable rail assembly in movable communication with the sizing table configured to compress and stretch the foam layer to a nominal size, wherein the adjustable rail assembly comprises:
a pair of longitudinal rails and a pair of transverse rails to frame a periphery of the foam layer, each rail having a contact surface perpendicular to the planar surface to provide compression of the foam layer when in use; and
one or more adjustable clamps disposed on each rail having a fixed portion carried by the rail and configured to slide underneath the foam layer upon compression and an adjustable portion configured to clamp down on the foam layer to permit stretching of the compressed foam layer to a nominal size when in use.
2. The sizing table of claim 1 , wherein a selected one of the longitudinal rails and a selected one of the transverse rails intersect at a right angle at known positions on the sizing table to define a datum location of the foam layer when sized to a nominal size.
3. The sizing table of claim 1 , further comprising one or more track guides generally perpendicular to the pairs of longitudinal and transverse rails, wherein one or more of the longitudinal and transverse rails are operably coupled to track guide.
4. The sizing table of claim 3 , wherein the one or more of the longitudinal and transverse rails operably coupled to track guide comprise an arm having one end attached to the rail and another end movably coupled to the track guide.
5. The sizing table of claim 4 , further comprising a servomotor coupled to the arm to effect movement within the track guide.
6. The sizing table of claim 1 , wherein at least one of the longitudinal and transverse rails comprise multiple segments, wherein movement of each segment may be independently controlled.
7. The sizing table of claim 1 , wherein at least one of the longitudinal and transverse rails is of unitary construction.
8. The sizing table of claim 1 , wherein the planar surface comprises a plurality of perforations in fluid communication with an air source configured to provide positive or negative air flow.
9. A process for sizing a foam layer to a nominal size for precision placement onto an innercore and bucket assembly, the process comprising:
delivering a single unitary layer of foam to a sizing table having a planar surface for supporting the layer of foam, wherein the foam layer has a square or a rectangular shape;
automatically compressing sidewalls of the layer of foam and orienting the layer of foam to a specific location on the sizing table, wherein compressing the layer of foam is to less than a nominal size; and
automatically stretching the compressed layer of foam to a nominal size, wherein compressing and stretching of the foam layer comprises configuring an adjustable rail assembly about the foam layer configured to compress and stretch the foam layer to a nominal size.
10. The process of claim 9 , wherein the adjustable rail assembly comprises:
a pair of longitudinal rails and a pair of transverse rails to frame a periphery of the foam layer, each rail having a contact surface perpendicular to the planar surface to provide compression of the foam layer when in use; and
one or more adjustable clamps disposed on each rail having a fixed portion carried by the rail and configured to slide underneath the foam layer upon compression and an adjustable portion configured to clamp down on the foam layer to permit stretching of the foam layer to a nominal size when in use.
11. The process of claim 10 , wherein compressing the foam layer comprises simultaneously moving a selected one or both of the longitudinal rails towards each other and moving a selected one or both of the transverse rails towards each other.
12. The process of claim 10 , wherein stretching the foam layer comprises gripping an edge of the foam layer with each one of the longitudinal and transverse rails; and simultaneously moving a selected one or both of the longitudinal rails away from each other and moving a selected one or both of the transverse rails away from each other.
13. The process of claim 9 , further comprising defining and storing a datum location for the nominally sized foam layer.