Assembly for and Method of Automated Manufacture of Multi-Layer Foam Laminate Mattresses
AssigneeSealy Technology, LLC
InventorsVictor Covone, Micah A. Kaufman, Lisa Nowak, Ronald Buerkle, Jeff Fillers
Life of this patent
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Abstract
Present embodiments relate to assemblies for and methods of manufacturing laminate foam mattresses including, but not limited to, cushions and other mattress. More specifically, the embodiments pertain to, without limitation, a glue bridge assembly used to form laminate mattresses and the methods of using the glue bridge assembly.
Claims24
A method of applying adhesive to one or more foam layers to form a laminate mattress, comprising the steps of:
- conveying a first foam layer under a glue dispenser bridge;
- identifying a size of said first foam layer;
- determining a plurality of process characteristics for at least one of said first foam layer and at least a second foam layer;
- applying a predetermined amount of glue to said first foam layer in at least one of a predetermined density or predetermined pattern;
- applying a second foam layer on to said first foam layer;
- and,
- compressing said first foam layer and said second foam layer.
A glue bridge assembly, comprising:
- a first support and a second support spaced apart and configured to allow a substrate to pass therethrough;
- a glue dispenser bridge extending between said supports, said glue dispenser bridge having a plurality of glue dispensers;
- said plurality of glue dispensers directed downwardly to apply glue to a first foam layer which is be configured to pass below said bridge on said substrate;
- a plurality of flow meters in flow communication with said plurality of glue dispensers, said flow meters creating a closed loop signal with a processor to confirm an amount of glue dispensed by said glue dispensers on said glue dispenser bridge.
A method of applying adhesive to one or more layers to form a laminate mattress, comprising the steps of:
- conveying a first layer under a glue dispenser bridge;
- identifying a size of said first layer;
- determining a plurality of process characteristics for at least one of said first layer and at least a second layer;
- applying a predetermined amount of glue to said first layer in at least one of a predetermined density or predetermined pattern, wherein the predetermined density or predetermined pattern is determined based on the plurality of process characteristics;
- applying a second layer on to said first layer;
- and,
- compressing said at least one first layer and said at least one second layer.
Dependencies are inferred from the claim text.