PRIORITY The present invention claims priority under 35 USC section 119 based upon a provisional application with a Ser. No. 61/150,938 which was filed on Feb. 9, 2009.
BACKGROUND Steel spring recycling scrap metal value is established via a set of criteria which includes purity and measurements of the volumetric dimensions of the springs being recycled as well as a weight per unit volume of the springs being recycled. Historically, spring cutting via Guillotine shears and rotary grinders has been used to reduce the dimensions of the sets of springs to meet scrap metal criteria, and sets of springs have been encapsulated within the larger mass of other compacted material such as car compactors. Un-compacted sets of springs are often disposed of via land filling or dumping causing nuisances and/or wasting precious landfill space.
SUMMARY OF THE INVENTION The present invention provides for a spring compactor machine to compact springs, comprising: a force applied at an angle substantially between 35 degrees and 155 degrees to an at rest spring's restoring force axis with an equal and opposite restraining force applied substantially between 215 and 325 degrees to the spring's restoring force axis. Wherein when both the applied force and the restraining force substantially exceed the plastic limit of the spring, the spring deforms and the restoring force of the spring no longer returns the spring to its original shape. In a preferred aspect of the present invention, the forces are applied to the spring inside at least one compaction chamber. In an aspect of the present invention, the compaction chamber may be moved and operated sequentially or moved and operated cyclically.
A spring compactor machine comprising of a force applied at an angle substantially between 35 degrees and 155 degrees to an at rest spring's restoring force axis with an equal and opposite restraining force applied substantially between 215 and 325 degrees to the spring's restoring force axis; a spring is at rest when x=0 and the restoring force, F=0, in Hooke's law spring equation; when in combination both the applied force and the restraining force substantially exceed the plastic limit of the spring, the restoring force of the spring no longer returns the spring to its original shape. A spring compactor machine with an upward force and a downward force along or substantially parallel to the spring's restoring force axis aiding in holding the spring in its desired position during compaction.
A spring compactor machine with at least one compaction chamber which may be movable and may be operated sequentially or cyclically, or at least one fixed compaction chamber within either of said compaction chambers a force is applied at an angle substantially between 35 degrees and 155 degrees to an at rest spring's restoring force axis with an equal and opposite restraining force applied substantially between 215 and 325 degrees to the spring's restoring force axis are applied.
A spring compactor machine with at least one moveable section of the compaction chamber to apply either or both an upward and a downward force along or substantially parallel to the spring's restoring force axis aiding in holding the spring in its desired position during compaction.
A spring compactor machine wherein the moveable section's travel distance is sufficient to allow an adequate opening to load the spring set into the compaction chamber.
A spring compactor machine with a decreasing height feed shoot that applies the upward and downward forces to the spring set via height restriction as a feeding ram pushes the spring set into the compaction chamber.
A spring compactor machine with a physical support along or substantially parallel to the spring's restoring force axis aiding in holding the spring in place until initiation of the spring's compaction.
A spring compactor machine with a magnetic force field along or substantially parallel to the spring's restoring force axis aiding in holding the spring in place until initiation of the spring's compaction.
A spring compactor machine with at least one compaction chamber; wherein there is least one moveable ram to exert the applied force and at least one resistance block which may be movable to provide the restraining force.
A spring compactor machine with at least one moveable resistance block to provide the restraining force and to allow feeding of the spring set into the compaction chamber and/or to allow removal of the spring set from the compaction chamber.
A spring compactor machine with at least two compaction chambers; wherein the additional compaction chamber is used to adjust at least one volumetric dimension of the spring set.
A spring compactor machine with an additional chamber wherein at least two one movable rams ram can fold the compacted spring set around at least one fulcrum to reduce at least one volumetric dimension of the compacted set of springs.
A spring compactor machine where within an additional chamber at least one movable ram can further compact the folded spring set.
A spring compactor machine with an adjustable height and width ram, wherein the ram is adjustable to fit within the dimensions of the compaction chamber or compaction chambers through which it must pass.
A device to separate a set of springs in a box spring from the box spring frame with at least one moveable resistance frame holder which secures the frame in a fixed position.
A device to separate a set of springs in a box spring from the box spring frame with at least one movable force attached to the spring set such that when the movable force is applied it pulls the spring set away from the frame separating the frame from the spring set.
A method of weakening a manufacturer's spring set strengthening configuration which the manufacturer designed to hold a spring set within a given shape, with at least one means of countering the designed strength via physical manipulation of the strengthening configuration wherein the spring set strengthening configuration no longer is capable of moving springs out of their desired position during compaction in the spring compactor machine.
A method of weakening a manufacturer's spring set strengthening configuration with a cutting apparatus targeted at cutting the manufacturer's spring set strengthening configuration at points wherein the spring set strengthening configuration no longer is capable of moving springs out of their desired position during compaction in the spring compactor machine.
A method of weakening a manufacturer's spring set strengthening configuration with a deforming apparatus targeted at deforming the spring set strengthening configuration at points wherein the spring set strengthening configuration no longer is capable of moving springs out of their desired position during compaction in the spring compactor machine.
A spring compactor machine system wherein people buy and use mattresses and box springs and soft furniture; when people choose to discard mattresses or box springs or soft furniture, they excess them; the excessed mattress or excessed box springs or excessed soft furniture are collected; the excessed mattress or excessed box springs or excessed soft furniture are then transported to a recycling facility; at the recycling facility the excessed mattress or excessed box springs or excessed soft furniture are broken down into their component parts of which the spring or the spring set—if any—comprise one component; the spring set may be pre-treated prior to compaction to weaken the spring set strengthening configuration; the spring set may be pre-treated prior to compaction via the box spring frame machine separator; the set of springs are then loaded into the spring compactor machine; the set of springs is then compacted by the spring compactor machine; the set of springs may be post treated to further reduce their compacted size, shape or unit weight; then the set of springs is loaded into a transportation container or transportation vehicle; then the set of springs is either temporarily stored or transported to a scrap steel facility or transported to a steel recycling facility or transported to a steel mill or transported to any other scrap steel buyer.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plurality of side views of the present invention showing a single metal spring positioned to be compacted beyond its metal's yield point;
FIG. 2 is a side view of the present invention showing one embodiment of the functional components;
FIG. 3 is a perspective view of the present invention showing a horizontal embodiment with movable top section compaction chamber height adjustment;
FIG. 4 is a perspective view of the present invention showing a horizontal embodiment with width adjustment of the compaction chamber;
FIG. 5 is a perspective view of the present invention showing an adjustable height powered ram.
FIG. 6 is a perspective view of the present invention showing a decreasing height feed shoot through which a set of springs is loaded into a compaction chamber.
FIG. 7 is a top view and a side view of the present invention showing a horizontal embodiment of the compaction chamber with vertical shaft spring stabilizers;
FIG. 8 is a perspective view of the present invention showing a compaction chamber using electromagnets with associated magnetic fields to hold springs in-place;
FIG. 9 is a side view of the present invention showing a horizontal embodiment of a method of weakening a manufacturer's spring set strengthening configuration via cutting;
FIG. 10 is a side view of the present invention showing a horizontal embodiment of a method of weakening a manufacturer's spring set strengthening configuration via deformation;
FIG. 11 is a top view and a side view of the present invention showing a metal spring post compaction additional compaction chamber to adjust at least one volumetric length of a compacted spring set;
FIG. 12 is a flow diagram of the present invention showing a Spring Compactor Machine process.
FIG. 13 is a side view of a device to separate the spring set from the frame in a box springs.
DETAILED DESCRIPTION All examples given are for clarification only, and are not intended to limit the scope of the invention.
Referring to the drawings, and first to FIG. 1A, there is shown a side view of the basic embodiment which may include a hydraulic cylinder 1; a movable ram 2; a resistance block 8; a spring restoring force axis 6; and a spring 4 in its at a first rest position as defined as being no forces applied to spring 4 along its restoring force axis 6; an angle substantially between 35 degrees and 155 degrees 10 to the spring's restoring force axis 6; and an angle substantially between 215 and 325 degrees 12 to the spring's restoring force axis 6.
A spring compaction operation is defined as a force (In this specific instance of FIG. 1A represented via the movable ram 2.) applied at an angle substantially between 35 degrees and 155 degrees to an at rest spring's 4 restoring force axis 6 with an equal and opposite restraining force applied substantially between 215 and 325 degrees to the spring's restoring force axis (In this specific instance of FIG. 1A represented via the resistance block 8.) A spring 4 is at rest when x=0 and the restoring force, F=0, in Hooke's law spring equation. The spring 4 is defined as being in its compaction position when the at rest spring 4 angle 10 to restoring force axis 6 to the applied force of the movable ram 2 is between substantially 35 degrees and 155 degrees and when the at rest spring 4 angle 12 to restoring force axis 6 to applied force of the resistance block 8 is substantially between 215 degrees and 325 degrees.
Referring to FIG. 1B, a side view of the spring 4 is shown wherein the spring 4 is in its compacted shape may further including a compacted spring 9.
In more detail, now referring to the invention of FIG. 1A and FIG. 1B, in the spring compaction operation the hydraulic cylinder 1 is activated such that the movable ram 2 applies a force at an angle substantially between 35 degrees and 155 degrees to the at rest spring's 4 restoring force axis 6 with an equal and opposite restraining force applied substantially between 215 and 325 degrees to the spring's 4 restoring force axis. In the spring compaction operation, when in combination both the ram applied force 2 and the restraining force 8 exceed the plastic limit of the spring 4 and are applied until such time as the metal in spring 4 reaches a substantial complete failure or the compressive power limit of movable ram 2 is reached or both, the total volume of space occupied by a then compacted spring 4 is less than the spring 4 initial at rest volume meaning the spring 4 has become a compacted spring 9.
The hydraulic cylinder 1 should be sized to provide both adequate stroke and power to perform the spring compaction operation. The construction details of the invention as shown in FIG. 1A are that movable ram 2 must be of adequate strength to laterally compress spring 4 beyond its bending point or elastic limit and fixed resistance block 8 should be of adequate strength to sustain the applied force of movable ram 2 at least up to where movable ram 2 compresses spring 4 beyond its bending point, more preferably resistance block 8 should be of adequate strength to sustain the lateral force of movable ram 2 up to a whole substantial complete failure of the metal in spring 4. The surface area of both movable ram 2 and fixed resistance block 8 should be adequate to hold spring 4 between them throughout the compacting process. Further, the various components of the movable ram 2 and the fixed resistance block 8 can be made of a plurality of different materials, preferably metal, more preferably metal having hardness harder than the hardness of the metal of spring 4.
In further detail, still referring to the invention of FIG. 1A, spring 4 may be a plurality of springs 4 positioned between the movable ram 2 and the resistance block 8. Further, the at rest spring's 4 restoring force axis 6 may be rotated to any angle as long as the applied force angle of the movable ram 2 and the applied force angle of the resistance block 8 are also rotated relative to the restoring force axis 6 maintain applied force angle 10 and angle 12 during the spring compaction operation.
The advantages of the present invention include, without limitation, that the spring compaction operation deforms spring 4 such that spring 4 no longer follows Hooke's law (that the force with which the spring pushes back is linearly proportional to the distance from its equilibrium length) along the restoring force axis 6 and thereby reduces the total volume of space occupied by spring 4 and increases the weight per unit volume of spring 4 to that of the compacted spring 9 which is more suitable for metal recycling and for scrap metal transporting.
In the embodiment, the invention FIG. 1A is a spring compactor machine of any shape or size and which may be operated in any position, which may be operated sequentially in plurality, or which at least one may be operated cyclically. Any movable part of the current invention may be powered hydraulically as shown or powered via an electrical, a mechanical, a brute strength, a water power, an air pressure, or any other power source.
Referring now to the invention in more detail, FIG. 1C further comprises: a surface 18; a surface 22; a force 16; and a force 24.
FIG. 1C shows a side view of one embodiment of the spring 4 being compressed between surface 18 and surface 22 via forces 16 and 24.
In further detail, referring to both FIG. 1A to FIG. 1C, the two forces 16 and 24 shown in FIG. 1C are being applied approximately parallel to the restoring force axis 6 of spring 4 which increases the spring's 4 restoring force pressure against both surfaces 18 and 22 which in turn increases the friction between both ends of spring 4 and surfaces 18 and 22. During the spring compaction operation, this increased friction acts to better hold spring 4 such that the movable ram 2 applies a force at an angle substantially between 35 degrees and 155 degrees to an at rest spring's 4 restoring force axis 6 with an equal and opposite restraining force applied substantially between 215 and 325 degrees to the spring's restoring force axis via the resistance block 8.
In FIG. 1C, where the surface 18 initially contacts the spring 4 in its at rest position is referred to as the spring 4 top and where the surface 22 initially contacts the spring 4 in its at rest position is referred to as the spring 4 base. Referring further to FIG. 1C, the surface 18 or the surface 22 may be fixed if spring 4 is compressed prior to inserting spring 4 between surfaces 18 and 22, otherwise at least one surface 18 or surface 22 should be movable to allow spring 4 to be inserted between surfaces 18 and 22 when spring 4 is in its at rest equilibrium position. Further, both surfaces 18 and 22 may be movable sections.
In further detail, now referring to FIG. 1C, the surface 18 and the surface 22 may be be constructed of material of adequate strength to withstand the spring compaction operation. The face 3 of movable ram 2 should be slightly less than the linear distance between surface 18 and surface 22 in order for the movable ram 2 to pass between the surface 18 and the surface 22. In further detail, still referring to FIG. 1C, the movable ram 2 should be of adequate power to compress spring 4 beyond the spring 4 metal's bending point or elastic limit, and more preferably the movable ram 2 should be of adequate power that it can compress spring 4 to the spring 4 metal's substantial total failure. Fixed resistance block 8 should be of adequate strength and shape to resist the pressure exerted on it via the movable ram 2 and spring 4 during the spring compaction operation.
Referring further to FIGS. 1A and 1C, the advantage of the present invention includes, without limitation, the increased probability that during the spring compaction operation the spring 4 will be held in place via the friction exerted on spring 4 by the surface 18 and the surface 22 such that the movable ram 2 force is applied at an angle substantially between 35 degrees and 155 degrees to the at rest spring 4 restoring force axis 6 with an equal and opposite restraining force applied substantially between 215 and 325 degrees to the spring's restoring force axis on spring 4 via the resistance block 8.
Referring to FIGS. 1A and 1C, The present invention may be any number of springs 4 being compressed along their restoring force axis 6 between at least two surfaces 18 and 22 to provide a frictional force to assist in holding the top and the base of spring 4 in the compaction position between any applied force and any resisting surface during the spring compaction operation.
Referring now to the invention in FIG. 1D shows a side view of one embodiment of the current invention further including a movable spring stabilizer 26; and a hydraulic cylinder 28.
In further detail, referring to FIGS. 1A and 1D, in operation the base of spring 4 rests on surface 22 and hydraulic cylinder 28 moves the top of stabilizer 26 from approximately level with the top of surface 22 up to at least a distance that reaches the height of the centroid of spring 4, or more preferably hydraulic cylinder 28 moves the top of stabilizer 26 from approximately level with the top of surface 22 up to approximately the top of spring 4. Movable ram 2 moves towards both the spring 4 and the resistance block 8. Just prior to or at the initial contact of movable ram 2 and the spring 4, hydraulic cylinder 28 pulls spring stabilizer 26 back down to where the top of spring stabilizer 26 is at or below the top of surface 22 such that ram 2 applies a force on spring 4 at an angle substantially between 35 degrees and 155 degrees to the at rest spring 4 restoring force axis 6 with an equal and opposite restraining force applied substantially between 215 and 325 degrees to the spring 4 restoring force axis 6 via the resistance block 8, compressing the spring 4 beyond its bending point or elastic limit, completing the spring compaction operation.
In further detail, still referring to the invention of FIGS. 1A and 1D, the spring stabilizer 26 should be of adequate strength and shape to hold the spring 4 in its at rest position until spring 4 is engaged or just prior to being engaged by the force applied to spring 4 by the movable ram 2 such that the movable ram 2 applies its force to spring 4 while spring 4 is in the spring 4 compaction position.
The construction details of the invention as shown in FIG. 1D for the movable ram 2, the fixed resistance block 8, the surface 22, and spring stabilizer 26 may include metal or other appropriate material of adequate thickness, shape and hardness to sustain repeated spring compaction operation cycles relative to the strength of the metal in spring 4. The movable ram 2 may be constructed of wood, metal, plastic, composites thereof, or more preferably hardened steel of greater hardness than the metal of spring 4. The resistance block 8 may be constructed of wood, metal, plastic, composites thereof, concrete, or more preferably hardened steel of greater hardness than the metal of spring 4. The spring stabilizer 26 may be constructed of wood, metal, plastic, composites thereof, or more preferably hardened steel of greater hardness than the metal of spring 4. The surface 22 may be constructed of wood, metal, plastic, composites thereof, concrete, or more preferably hardened steel of greater hardness than the metal of spring 4.
The advantages of the invention as shown in FIGS. 1A and 1D include, without limitation, the increased spring compaction efficiency added via holding the spring 4 in its compaction position via the spring stabilizer 26 in preparation for the movable ram 2 to compress the spring 4 against resistance block 8 during the spring compaction operation.
In one embodiment, the present invention as shown in FIG. 1D may be of any size, may include a plurality of movable rams 2, may include a plurality of spring stabilizers 26, may include a plurality of surfaces 22 of any shape and on any or all sides, may be operated in a horizontal or vertical inclination or any angle in-between, which may be operated sequentially in plurality, or which at least one may be operated cyclically.
Referring now to the invention in more detail, FIG. 1E shows a side view of one embodiment of the invention further including an electric current supply 29; and an electromagnet 30.
In more detail, now referring to the invention of FIG. 1E, in operation the base of spring 4 sits in its at rest position on surface 22. When electric current 29 is flowing through the electro magnet 30 a magnetic field is created which holds the base of spring 4 against surface 22. During the spring compaction operation, movable ram 2 moves towards both the spring 4 and the resistance block 8 until just before or at the time movable ram 2 engages spring 4 when at that time the electric current 29 is turned off and electromagnet 30 magnetic field ceases to hold the base of spring 4 against surface 22 allowing the spring compaction operation to proceed.
In further detail, still referring to the invention of FIG. 1E, it would be obvious to one skilled in the art that the magnetic field created via the electro magnet 30 when the electric current 29 is flowing through the electro magnet 30 should be of adequate strength and shape to hold the spring 4 in its compaction position until spring 4 is engaged or just prior to spring 4 being engaged by the force applied via the movable ram 2 allowing the spring compaction operation to proceed.
The construction details of the invention as shown in FIG. 1E for the movable ram 2 and the resistance block 8 may include Metal of adequate thickness, shape and hardness to sustain repeated spring compaction operation cycles relative to the strength of the metal in spring 4. The movable ram 2 may be constructed of wood, metal, plastic, composites thereof, or more preferably hardened steel of greater hardness than the metal of spring 4. The resistance block 8 may be constructed of wood, metal, plastic, composites thereof, concrete, or more preferably hardened steel of greater hardness than the metal of spring 38. The surface 22 may be constructed of wood, non-ferrous metal, plastic, or composites thereof. The electromagnet may be constructed of ferrous metal, electrical steel, the soft magnetic alloys such as Nickel-Iron or Ferritic Stainless Steels or Iron or Silicon Iron or Iron-Cobalt or any combination thereof, or any other magnetic core material.
The advantages of the invention as shown in FIG. 1E include, without limitation, the increased spring compaction efficiency added via holding the spring 4 in its compaction position via the electro magnet 30 magnetic field in preparation for the spring compaction operation.
In one embodiment, the present invention as shown in FIG. 1E may be of any size, may comprise a plurality of movable rams 2, may comprise a plurality of electromagnet 30, may comprise a plurality of surfaces 22 being of any shape and being on any or all sides of spring 4, at least one said plurality of surfaces 22 of any shape and may be non-ferrous material, the invention may be operated in a horizontal or vertical inclination or any angle in-between, may be operated sequentially in plurality, or which at least one may be operated cyclically.
FIG. 2 is a side view of the present invention showing one embodiment of the functional components.
Referring now to the invention in FIG. 2 there is shown one embodiment of the current invention further including a side enclosed compaction chamber 32; a hydraulic cylinder 34 capable of moving the resistance block 8; and a set of springs 36 of height 35.
Referring to the invention as shown in FIG. 2, during the spring compaction operation, the hydraulic cylinder 34 moves the resistance block 8 to where it opens the end of the side enclosed compaction chamber 32 so that the set of springs 36 may be loaded via the now open end of the side enclosed compaction chamber 32. When the set of springs 36 are completely loaded into the side enclosed compaction chamber 32, the hydraulic cylinder 34 moves the resistance block 8 to where the resistance block 8 closes the end of the side enclosed compaction chamber 32. Then, the movable ram 2 moves forward through the side enclosed compaction chamber 32 towards the resistance block 8 applying the force of movable ram 2 to the set of springs 36 to complete the spring compaction operation. Then the movable ram 2 moves backward through the side enclosed compaction chamber 32 away from the resistance block 8 relieving the force of movable ram 2 applied to the resistance block 8. Then the hydraulic cylinder 34 moves the resistance block 8 to where it opens the end of the side enclosed compaction chamber 32.
Then, the movable ram 2 moves forward through the side enclosed compaction chamber 32 pushing the now compacted set of springs 36 out of open end of the side enclosed compaction chamber 32. Then the movable ram 2 moves back through the side enclosed compaction chamber 32 back to its initial position as shown in FIG. 2.
In further detail, still referring to the invention of FIG. 2, the interior dimensions of the side enclosed compaction chamber 32 may be slightly larger than the exterior dimensions of the set of springs 36 in order to enable loading the springs into the side enclosed compaction chamber 32, and the interior dimensions of the side enclosed compaction chamber 32 may be slightly larger than the exterior dimensions of the movable ram 2 to enable the movable ram 2 to pass through the side enclosed compaction chamber 32, and the height of the resistance block 8 may be slightly more than the height of the side enclosed compaction chamber 32 and the width of the resistance block 8 may be slightly wider than the width of the side enclosed compaction chamber 32 to enable the resistance block 8 to close the end of the side enclosed compaction chamber 32 during the compaction operation.
In further detail, referring to FIG. 2, the movable ram 2 and the resistance block 8 and the side enclosed compaction chamber 32 may be constructed of material of adequate strength to withstand the pressures of the spring compaction operation, preferably the material may be metal, more preferably the material may be metal harder than the metal of the springs in the set of springs 36, and more preferably the material may be machine finished metal harder than the metal of the springs in the set of springs 36. Any movable part of the current invention may be powered hydraulically as shown or powered via an electrical, a mechanical, a brute strength, or any other power source.
The advantages of the present invention shown in FIG. 2 include, without limitation, the ability to compact more than one spring at a time giving the spring compactor machine the capability of compacting a set of springs 36 into a configuration suitable for recycling in the steel market.
In one embodiment, the present invention shown in FIG. 2 may be oriented either vertically or horizontally or any angle in-between, it may have a plurality of movable rams 2, it may have a plurality of enclosed side compaction chambers 32, it may have a plurality of movable resistance blocks 8, and it may be configured to operate as a single unit or it may be configured to operate as a set of units in sequence, or it may be configured to operate in either a single or multiple cyclical operation. The present invention shown in FIG. 2 may be configured to compress a single spring or set of springs. In one embodiment, the invention FIG. 2 is a spring compactor of any shape which comprises at least one movable ram and at least one resistance or opposing force between which at least one spring is compacted in the spring compaction operation.
FIG. 3 is a perspective view of the present invention showing a horizontal embodiment with movable top section compaction chamber height adjustment;
Referring now to the invention in more detail, in FIG. 3 there is shown one embodiment of the current invention further including a three sided compaction chamber 38; a movable top section 40; and a hydraulic cylinder 42.
In more detail, still referring to the invention of FIG. 3, in operation the set of springs 36 is loaded into the three sided compaction chamber 38. Then hydraulic cylinder 42 lowers the movable top section 40 downward engaging the set of springs 36 such that the set of springs 36 height 35 is shortened. The movable top section 40 continues moving downward until it rests on the three sided compaction chamber 38. Lowering the movable top section 40 down to where it contacts a three sided compaction chamber 38 creates a closed sided compaction chamber including the movable top section 40 and the three sided compaction chamber 38. Then hydraulic cylinder 34 moves the resistance block 8 across the end of the three sided compaction chamber 38 and the end of the movable top section 40 hereafter referred to as the closed sided compaction chamber. During the compaction operation, hydraulic cylinder 1 moves movable ram 2 forward towards the resistance block 8 through the closed sided compaction chamber compressing the individual springs of set of springs 36 beyond their bending point or elastic limit against the resistance block 8. Then hydraulic cylinder 1 moves the movable ram 2 backward away from the resistance block 8 relieving the pressure applied on the resistance block 8 via the movable ram 2. Then the hydraulic cylinder 42 moves the resistance block 8 clear of the end of the closed sided compaction chamber. Then hydraulic cylinder 1 moves movable ram 2 forward pushing the now compacted set of springs 36 out the end of the closed sided compaction chamber. Then hydraulic cylinder 1 moves movable ram 2 backward through the closed sided compaction chamber to its original position as shown.
In further detail, referring to the invention of FIG. 3, it would be obvious to one skilled in the art that the interior dimensions of the three sided compaction chamber 38 may be slightly larger than the exterior dimensions of the set of springs 36 in order to enable loading the set of springs 36 into the three sided compaction chamber 38. The interior height of the closed sided compaction chamber created via the three sided compaction chamber 38 and the lowered movable top section 40 will be limited by the height of the movable ram 2 as the movable ram 2 must be able to move through the closed sided compaction chamber without damaging the closed sided compaction chamber. Further, the height of the resistance block 8 may be slightly more than the height of the closed sided compaction chamber and the width of the resistance block 8 may be slightly wider than the width of the closed sided compaction chamber to enable the resistance block 8 to cover the end of the closed sided compaction chamber.
In further detail, referring to FIG. 3, the movable ram 2 and the resistance block 8 and the three sided compaction chamber 38 and the movable top section 40 may be constructed of material of adequate strength to withstand the pressures of the spring compaction operation, preferably the material may be metal, more preferably the material may be metal harder than the metal of the individual springs in the set of springs 36, and more preferably the material may be machine finished metal harder than the metal of the individual springs in the set of springs 36. Any movable part of the current invention may be powered hydraulically as shown or powered via an electrical, a mechanical, a brute strength, or any other power source.
The advantages of the present invention as shown in FIG. 3 include, without limitation, the capability of compacting a set of springs 36 into a configuration suitable for recycling in the metal market. The movable top section 40 allows side loading of the set of springs 213 into the three sided compaction chamber 38 in addition to the end loading allowed by moving the resistance block 8 clear of the closed sided compaction chamber. The movable top section 40 allows the user to apply FIG. 1B forces 16 and 24 on the individual springs of the set of springs 36 increasing the friction between the individual springs in the set of springs 36 with the bottom of the three sided compaction chamber 38 and the movable top section 40 creating resistance to the individual springs overturning during the compaction operation.
In one embodiment, the present invention shown in FIG. 3 is a spring compactor machine of any shape which is capable of compacting individual springs or sets of springs and which may include At least one movable ram and at least one resistance or opposing force between which at least one spring or at least one set of springs is held in place during the spring compactor operation via the spring's restoring force, F being greater than 0 in Hooke's law spring equation, F being created by a downward vertical force applied to a set of springs via a movable section of the closed sided compaction chamber and by an upward vertical force applied to the set of springs via the opposite side of the closed sided compaction chamber. The invention of FIG. 3 may be configured to operate as a single unit or it may be configured to operate as a set of units in sequence, or it may be configured to operate in either a single or cyclical operation. Further, the present invention shown in FIG. 3 may be oriented either vertically or horizontally or any angle in-between, it may have a plurality of movable rams, it may have a plurality of enclosed side compaction chambers, it may have a plurality of movable resistance blocks.
FIG. 4 is a perspective view of the present invention showing a horizontal embodiment with width adjustment of the compaction chamber.
Referring now to the present invention according to a embodiment in FIG. 4, there is shown one embodiment of the current invention further including a movable sub-top 46; a hydraulic cylinder 48; a movable top section 50; a two sided compaction chamber 44 with a sub-component extension 58; a spring set loading area 52; a hydraulic cylinder 54; a side movable ram 56; and the resistance block 8 is now attached to the movable top section 50 such that they move as one unit.
Still referring to the invention of FIG. 4, in operation the set of springs 36 are loaded into the spring set loading area 52. Then the hydraulic cylinder 54 moves the movable side ram 56 forward pushing the set of springs 36 across the sub-component extension 58 into the two sided compaction chamber 44. When the movable side ram 56 reaches the inner edge of the two sided compaction chamber 44, the face of the movable side ram 56 becomes a third side of the compaction chamber, hereafter referred to as a three sided compaction chamber. Then the hydraulic cylinder 42 moves the movable top section 50 along with resistance block 8 downward to rest upon the top of the three sided compaction chamber. At this time, with the movable top section 50 in contact with the three sided compaction chamber, the compaction chamber becomes a closed sided compaction chamber, hereafter referred to as a closed sided compaction chamber.
The hydraulic cylinder 48 moves the movable sub-top 46 downward through the closed sided compaction chamber engaging and applying a downward force on the set of springs 36 to which according to Hooke's law the spring reacts with an equal and opposite force F along its restoring force axis resulting in an increase in friction between the spring base and the closed sided compaction chamber and in an increase in friction between the spring top and the closed sided compaction chamber. Then hydraulic cylinder 1 moves movable ram 2 forward through the closed sided compaction chamber towards the resistance block 8 completing the spring compaction operation. Then, the hydraulic cylinder 1 moves movable ram 2 backward in the closed sided compaction chamber to relieve the pressure on the resistance block 8. Then, the hydraulic cylinder 42 moves the movable top section 50 with the resistance block 8 to its original position as shown. Then, the hydraulic cylinder 48 moves the movable sub-top 46 upward to its original shown position. Then, the hydraulic cylinder 1 moves the movable ram 2 forward in the three sided compaction chamber pushing the now compacted set of springs 36 out the far end of the three sided compaction chamber. Then, hydraulic cylinder 1 moves the movable ram 2 backward in the three sided compaction chamber to its original position as shown. Then the hydraulic cylinder 54 moves the movable side ram 56 back to its original position as shown.
In further detail, still referring to the invention of FIG. 4, the interior dimensions of the spring set loading area 52 may be larger than the exterior dimensions of the set of springs 36. The interior height of the closed sided compaction chamber including the movable sub-top 46 may be limited by the height of the movable ram 2 as the movable ram 2 must be able to move through the closed sided compaction chamber without damaging the closed sided compaction chamber or the movable sub-top 46. The width of the movable sub-top 46 may be less than the width of the three sided compaction chamber to allow the movable sub-top 46 to move up and down as needed to engage and apply a downward force to the set of springs 36. Further, the height of the resistance block 8 may be more than the interior height of the closed sided compaction chamber and the width of the resistance block 8 may be wider than the width of the interior of the closed sided compaction chamber to enable the resistance block 8 to cover the end of the closed sided compaction chamber. The hydraulic cylinder 54 would be sized to provide both adequate stroke and power to push the set of springs 36 into the two sided compaction chamber 44 and to hold the movable side ram 56 in-place during the spring compaction operation.
In further detail, referring to FIG. 4, the two sided compaction chamber 44, the movable sub-top 46, the movable top section 50, the movable side ram 56 and the sub-component extension 58, may be constructed of material of adequate strength to withstand the spring compaction operation, preferably the material may be metal, more preferably the material may be metal harder than the metal of the set of springs 36, and more preferably the material may be machine finished metal harder than the metal of the set of springs 36.
The advantages of the present invention as shown in FIG. 4 include, without limitation, the capability of compacting a set of springs into a configuration suitable for recycling in the scrap metal market. The advantage of side loading a set of springs is that a movable side ram can compress the width or length of a set of springs to comply with the scrap metal industry requirements for the width or length of scrap metal while another ram can compact the un-compacted length or width of the set of springs to comply with the scrap metal industry for a second dimensional requirement. The advantage of the movable top section is that it can adjust the third scrap metal dimension allowing the spring compactor machine to meet volumetric size requirements for the scrap metal market.
In one embodiment, the invention FIG. 4 is a spring compactor machine operated in any position in at least one of singular mode, sequential mode, or cyclical mode, including at least two movable rams and at least one resistance or opposing force between which at least one spring or one set of springs goes through the spring compactor operation. During the spring compactor operation, the spring compactor machine via its configuration controls final maximum length, width and height of the compacted spring. The face of the movable rams may be of fixed height and width or the face of the movable rams may be of an adjustable height and/or width. Any movable part of the current invention may be powered hydraulically as shown or powered via an electrical, a mechanical, a brute strength, or any other power source.
FIG. 5 is a perspective view of the present invention showing an adjustable height movable ram.
Referring now to the invention in more detail, in FIG. 5 there is shown one embodiment of the movable ram 2 further including a hydraulic cylinder 60; and a movable ram extension 62.
In more detail, still referring to the invention of FIG. 5, in operation the hydraulic cylinder 60 moves the movable ram extension 62 up and down to adjust the height of the face of the movable ram 2. The face of the movable ram 2 is defined as the surface of the movable ram 2 which contacts springs during the spring compaction operation.
In further detail, still referring to the invention of FIG. 5, the dimensions of the movable ram 2 and the movable ram extension 62 cooperate with the interior dimensions of the compaction chamber in which they will be used.
The invention as shown in FIG. 5 may be constructed of steel, more preferably constructed of steel harder than the springs to compacted.
Referring now to the invention shown in FIG. 5, via rotating the movable ram extension 62 substantially ninety degrees and placing it on the edge of the movable ram 2 along with relocating the two movable cylinders 808 and 806 or adding two additional movable cylinders, the width of the movable ram 2 may be increased in one direction. The face of the movable ram 2 may be extended on any of its sides via the addition of a plurality of movable cylinders and movable ram extensions thus the face of the movable ram 2 may be extended up, down, left or right or any combination thereof.
The advantages of the present invention shown in FIG. 5 include, without limitation, the ability to adjust the dimensions of the face of the movable ram 2 to be compatible with compaction chambers that can also alter their interior dimensions and with any other altering interior dimension configuration through which the ram must pass or fill.
In broad embodiment, the invention FIG. 5 is a metal movable ram of any shape or size which may extend at least one of its face sides to make it compatible with altering interior dimension compaction chambers or to make it compatible with any other altering interior dimension configuration through which the ram must pass or fill.
FIG. 6 is a perspective view of the present invention showing a decreasing height feed shoot through which a set of springs is loaded into a compaction chamber.
Referring to FIG. 6, there is shown one embodiment of the current invention further including a two sided compaction chamber extended top 64; and a declining height feed shoot 66.
In more detail, still referring to the invention of FIG. 6, with the addition of the two sided compaction chamber extended top 64, the two sided compaction chamber 44 becomes a three sided compaction chamber and hereafter will be referred to as a three sided compaction chamber. In operation the hydraulic cylinder 34 moves the resistance block 8 down to cover the end of the three sided compaction chamber, the set of springs 36 is placed into loading area 52 on the top of the sub-component extension 58. Then the hydraulic cylinder 60 moves the movable ram extension 62 up to a height above the top of the set of springs 36 and below the highest point of the declining height feed shoot 66. Then hydraulic cylinder 54 moves the side movable ram 56 forward towards the three sided compaction chamber pushing the set of springs 36 first under the declining height feed shoot 66 and then under the two sided compaction chamber extended top 64 and then into the three sided compaction chamber. As the set of springs 36 engages the bottom of the declining height feed shoot 66, the top of the individual springs is forced downward via the declining height feed shoot 66 applying a downward force on the set of springs 36 to which according to Hooke's law the spring reacts with an opposite force F along its restoring force axis resulting in an increase in friction between the spring base and the sub-component extension 58 an increase in friction between the spring top and the declining height feed shoot 66. Once an individual spring is pushed under the two sided compaction chamber extended top 64 the force F along its restoring force remains somewhat constant as height of the individual spring remains nearly constant as the two sided compaction chamber extended top 64 roughly parallels the sub-component extension 58. When the movable ram extension 62 engages the declining height feed shoot 66, the hydraulic cylinder 60 is used to move the movable ram extension 62 downward relative to the slope of the declining height feed shoot 66 such that the hydraulic cylinder 54 continues moving the side movable ram 56 towards the three sided compaction chamber pushing the set of springs 36 into the three sided compaction chamber.
When the movable side ram 56 reaches the inner edge of the three sided compaction chamber, the face of the movable side ram 56 becomes a fourth side of the compaction chamber, hereafter referred to as a four sided compaction chamber. Then hydraulic cylinder 1 moves movable ram 2 forward through the four sided compaction chamber towards the resistance block 8 completing the spring compaction operation. Then hydraulic cylinder 1 moves movable ram 2 backward in the four sided compaction chamber to relieve the pressure on the resistance block 8. Then the hydraulic cylinder 34 moves the resistance block 8 to its original position as shown. Then the hydraulic cylinder 1 moves the movable ram 2 forward in the four sided compaction chamber pushing the now compacted set of springs 36 out the far end of the four sided compaction chamber. Then hydraulic cylinder 1 moves the movable ram 2 backward in the four sided compaction chamber to its original position as shown. Then the hydraulic cylinder 54 moves the movable side ram 56 back to its original position as shown.
In further detail, still referring to the invention of FIG. 6, the dimensions of the spring set loading area 52 may be sized to accommodate the largest anticipated set of springs to be compacted. The highest point of the declining height feed shoot 66 above the sub-component extension 58 may be slightly higher than the tallest individual spring of the tallest anticipated set of springs to be compacted, for mattress recycling uses of the spring compactor machine. The upward slope of the declining height feed shoot 66 may be limited to a range of substantially 10 to 45 degrees. The declining height feed shoot 66 should have adequate strength to move the tops of the individual springs in the set of springs 36 downward to where they will pass under the two sided compaction chamber extended top 64. And, making the declining height feed shoot 66 movable may reduce at least one of the dimensions of the spring set loading area 52. The hydraulic cylinder 54 would be sized to provide both adequate stroke and power to push the set of springs 36 into the three sided compaction chamber and to hold the movable side ram 56 in-place during the spring compaction operation.
In further detail, referring to FIG. 6, the two sided compaction chamber 44, the movable side ram 56 the sub-component extension 58, the two sided compaction chamber extended top 64; and the declining height feed shoot 66 may be constructed of material of adequate strength to withstand the spring compaction operation, preferably the material may be metal, more preferably the material may be metal harder than the metal of the set of springs 36, and more preferably the material may be machine finished metal harder than the metal of the set of springs 36.
The advantages of the present invention as shown in FIG. 6 include, without limitation, the capability of compacting a set of springs into a configuration suitable for recycling in the scrap metal market. The advantage of side loading a set of springs is that a movable side ram can compress the width or length of a set of springs to comply with the scrap metal industry requirements for the width or length of scrap metal while another ram can compact the un-compacted length or width of the set of springs to comply with the scrap metal industry for a second dimensional requirement. The advantage of the movable top section is that it can adjust the third scrap metal dimension allowing the spring compactor machine to meet volumetric size requirements for the scrap metal market. The advantage of the two sided compaction chamber extended top 64; and the declining height feed shoot 66 is that this configuration compresses the height of the individual springs in the set of springs 36 without using a powered movable top section.
In one embodiment, the invention of FIG. 6 is a spring compactor machine with at least one declining height feed shoot which may be movable, and is of any shape or size operated in any position in at least one of singular mode, sequential mode, or cyclical mode, including at least two movable rams and at least one resistance or opposing force between which at least one spring or at least one set of springs goes through the spring compactor operation. During said spring compactor operation the spring compactor machine via its configuration controls final maximum length, width and height of the compacted spring. The face of the movable rams may be of an adjustable height and/or width. Any movable part of the current invention may be powered hydraulically as shown or powered via an electrical, a mechanical, a brute strength, or any other power source.
FIG. 7 is a top view and a side view of the present invention showing a horizontal embodiment of the compaction chamber with vertical shaft spring stabilizers;
Referring now to the invention in more detail FIG. 7 there is shown one embodiment of the current invention wherein the hydraulic cylinder 1; the movable ram 2; the resistance block 8; the movable spring stabilizer 26; the hydraulic cylinder 28; the side enclosed compaction chamber 32; and the hydraulic cylinder 34 are configured to perform the spring compactor operation on the set of springs 36.
In more detail, still referring to the invention of FIG. 7, the side enclosed compaction chamber 32 has been modified by drilling holes in the side enclosed compaction chamber 32 as shown to allow the movable spring stabilizer 26 to move up and down and through the side enclosed compaction chamber 32. In operation the hydraulic cylinder 34 moves the resistance block 8 upward to clear the end of the side enclosed compaction chamber 32. Then the hydraulic cylinder 28 moves the movable spring stabilizer 26 downward through the side enclosed compaction chamber 32 until the top of the movable spring stabilizer 26 is at or below the top of the bottom surface of the side enclosed compaction chamber 32. Then the set of springs 36 is loaded into the side enclosed compaction chamber 32. Then the hydraulic cylinder 34 moves the resistance block 8 downward to close the end of the side enclosed compaction chamber 32. Then the hydraulic cylinder 28 moves the movable spring stabilizer 26 upward through the individual springs of the set of springs 36 inside the side enclosed compaction chamber 32 until the top of the movable spring stabilizer 26 is up to at least a distance that reaches the height of the centroid of the individual springs in the set of springs 36, or preferably hydraulic cylinder 28 moves the top of the spring stabilizer 26 up to approximately the top of the individual springs in the set of springs 36, or more preferably hydraulic cylinder 28 moves the top of stabilizer 26 up and into the drilled hole in the upper surface of the side enclosed compaction chamber 32. Then the hydraulic cylinder 1 moves the movable ram 2 forward in the side enclosed compaction chamber 32 towards the resistance block 8. As the movable ram 2 moves forward during the spring compaction operation, just prior to or at the initial contact of movable ram 2 and an individual spring in the set of springs 36 which is being held in-place via a specific movable spring stabilizer 26, hydraulic cylinder 28 pulls said specific spring stabilizer 26 back down to where the top of said specific spring stabilizer 26 is at or below the top of the drilled hole in the bottom surface of the side enclosed compaction chamber 32. When the spring compaction operation is complete, the hydraulic cylinder 1 moves the movable ram 2 backwards through the side enclosed compaction chamber 32 just enough to relieve the pressure applied the resistance block 8 via the spring compaction operation. Then the hydraulic cylinder 34 moves the resistance block 8 upward clearing the end of the side enclosed compaction chamber 32. Then the hydraulic cylinder 1 which moves the movable ram 2 forward inside the side enclosed compaction chamber 32 pushing the now compacted set of springs 36 out the end of the side enclosed compaction chamber 32. Then the hydraulic cylinder 1 which pulls the movable ram 2 backward through the side enclosed compaction chamber 32 to its initial position.
The construction details of the invention as shown in FIG. 7 include as described above for the hydraulic cylinder 1; the movable ram 2; the resistance block 8; the spring stabilizer 26; the hydraulic cylinder 28; the side enclosed compaction chamber 32; the hydraulic cylinder 34; the set of springs 36 and may be of steel, more preferably of steel harder than the steel in the set of springs 36.
The advantages of the present invention shown in FIG. 7 include, without limitation, the ability of the spring stabilizer 26 to hold individual springs in the set of springs 36 in the compaction position without regard to the interior height of the side enclosed compaction chamber 32 allowing the side enclosed compaction chamber 32 to compact sets of springs 36 of varying heights.
In one embodiment, the invention FIG. 7 is a spring compactor machine of any shape or size of a side enclosed compaction chamber and which comprises at least one movable ram and at least one resistance block or opposing force between which at least one spring of a set of springs is held in place via a spring stabilizer up until just before said spring is subjected to the spring compaction operation. The invention in FIG. 7 is shown in the horizontal position. It may be operated in a vertical position or at any angle in-between the horizontal and vertical positions, and the invention of FIG. 7 may be configured to operate as a single unit or it may be configured to operate as a set of units in sequence, or it may be configured to operate in either a single or cyclical operation. Any movable part of the current invention may be powered hydraulically as shown or powered via an electrical, a mechanical, a brute strength, or any other power source.
FIG. 8 is a perspective view of the present invention showing a compaction chamber using electro magnets with associated magnetic fields to hold springs in-place;
Referring now to the invention in more detail, FIG. 8 is perspective view showing one embodiment of the current invention wherein the hydraulic cylinder 1; the movable ram 2; the resistance block 8; the electric current supply 29; the electromagnet 30; the side enclosed compaction chamber 32; the hydraulic cylinder 34 are configured to perform the spring compactor operation on the set of springs 36.
In FIG. 8, the plurality of the electromagnet 30 are shown attached to the bottom surface the side enclosed compaction chamber 32.
In more detail, still referring to the invention of FIG. 8, in operation, the set of springs 36 is loaded into the side enclosed compaction chamber 32. Then the hydraulic cylinder 34 moves the resistance block 8 downward to close the end of the side enclosed compaction chamber 32. Then electric current 29 is turned on to flow through the electromagnet 30 creating a magnetic field which holds the base of the individual springs in the set of springs 36 against the bottom surface the side enclosed compaction chamber 32. During the spring compaction operation, movable ram 2 moves towards the resistance block 8 until just before or at the time movable ram 2 engages an individual spring of the set of springs 36 which is being held in the compaction position via a specific electromagnet's magnetic field and at that time the electric current 29 is turned off to said specific electromagnet and said specific electromagnet's magnetic field ceases to hold the base of said individual spring of the set of springs 36 against the bottom surface the side enclosed compaction chamber 32 allowing the spring compaction operation to proceed.
When the spring compaction operation is complete, the hydraulic cylinder 1 moves the movable ram 2 backwards through the side enclosed compaction chamber 32 just enough to relieve the pressure applied the resistance block 8 via the spring compaction operation. Then the hydraulic cylinder 34 moves the resistance block 8 upward clearing the end of the side enclosed compaction chamber 32. Then the hydraulic cylinder 1 moves the movable ram 2 forward inside the side enclosed compaction chamber 32 pushing the now compacted set of springs 36 out the end of the side enclosed compaction chamber 32. Then the hydraulic cylinder 1 which pulls the movable ram 2 backward through the side enclosed compaction chamber 32 to its initial position.
In further detail, still referring to the invention of FIG. 8, it would be obvious to one skilled in the art that the plurality and strengths of the electromagnets 30 should be used to determine the number and spacing thereof required to hold individual springs of the set of springs 36 in their compaction position against the bottom surface the side enclosed compaction chamber 32 in preparation for the compaction operation.
The construction details of the invention as shown in FIG. 8 with the exception of the bottom surface of the side enclosed compaction chamber 32 are as specified above for the hydraulic cylinder 1; the movable ram 2; the resistance block 8; the electromagnet 30; the side enclosed compaction chamber 32; and the hydraulic cylinder 34 and may be of steel, preferably of steel harder than the steel in the set of springs 36. The bottom surface the side enclosed compaction chamber 32 may be constructed of a non-ferrous material so that the electromagnets 30 may function properly. In addition, in order to protect this non-ferrous material a non-abrasive strip may need to be added to any moving parts within the side enclosed compaction chamber 32, i.e. the bottom of any movable ram passing through the chamber may have a non-abrasive strip on any portion which contacts the bottom surface the side enclosed compaction chamber 32.
The advantages of the present invention shown in FIG. 8 include, without limitation, the ability of the invention to hold individual springs in the set of springs 36 in the compaction position without regard to the interior height of the side enclosed compaction chamber 32 allowing the side enclosed compaction chamber 32 to compact sets of springs 36 of varying heights.
In one embodiment, the invention FIG. 8 is a spring compactor machine of any shape or size of a side enclosed compaction chamber and which includes at least one movable ram and at least one resistance block or opposing force between which at least one spring of a set of springs is held in place via a magnetic field up until just before said spring is subjected to the spring compaction operation. The invention in FIG. 8 is shown in the horizontal position. It may be operated in a vertical position or at any angle in-between the horizontal and vertical positions, and the invention of FIG. 8 may be configured to operate as a single unit or it may be configured to operate as a set of units in sequence, or it may be configured to operate in either a single or cyclical operation. Any movable part of the current invention may be powered hydraulically as shown or powered via an electrical, a mechanical, a brute strength, or any other power source.
FIG. 9 is a side view of the present invention showing a horizontal embodiment of a method of weakening a spring set strengthening configuration via cutting;
In more detail, referring to the invention of FIG. 9, there is a side view of one embodiment of the set of springs 36 preparation for the compaction operation further comprising: a hydraulic cylinder 69; a cutting shear 70; and a slotted cutting base 72.
In operation the set of springs 36 is placed on the slotted cutting base 72 aligned under the cutting shear 70 such that when the cutting shear 70 engages the set of springs 36 that the cutting shear 70 will be in contact with the set of springs 36 manufacturer's stiffening framework. The stiffening framework is defined as the a system of keeping the set of springs 36 in their built positions during the life cycle of the set of springs 36. The stiffening framework holds the set of springs 36 together. The hydraulic cylinder 69 moves the cutting shear 70 downward towards the slotted cutting base 72 cutting through the stiffening framework. Then the hydraulic cylinder 69 moves the cutting shear 70 upwards to its original position as shown.
In further detail, still referring to the invention of FIG. 9, the cutting shear 70 includes suitable material and strength and sharpness to cut the wires in the set of springs 36 between the cutting shear 70 and the edges of the slots in the slotted cutting base 72. The hydraulic cylinder 69 includes adequate power and stroke to power the cutting shear 70 to cut through the stiffening framework. Further, the length of the stroke of the hydraulic cylinder 69 should be enough to move the cutting shear 70 far enough above the slotted cutting base 72 to allow positioning of the set of springs 36 on the slotted cutting base 72. The slotted cutting base 72 may be made of metal, preferably steel, more preferably steel hard enough to to maintain a smooth slot edge against which the cutting shear 70 cuts through the stiffening framework.
The advantages of the present invention shown in FIG. 9 include, without limitation, via cutting through the stiffening framework in the set of springs 36, the ability of the stiffening framework to move the individual springs of the spring set 36 out of their compaction position is greatly reduced. This results in a more efficient spring compaction operation. The spring compactor machine may determine the location and number of cuts to optimize the performance of said unique spring compactor machine.
In one embodiment, the invention shown in FIG. 9, may use cutting shears, cutting wheels, lasers, cutting torches, bolt cutters, or any other device capable of cutting through the manufacturer's stiffening framework to cut the stiffening framework.
FIG. 10 is a side view of the present invention showing a horizontal embodiment of a method of weakening a spring set strengthening configuration via deformation;
In more detail, referring to the invention of FIG. 10, there is a end view FIG. 10A and a side view FIG. 10B of one embodiment of the set of springs 36 preparation for the compaction operation further including a vertical support 74; a crimping head 76; a hydraulic cylinder 78; a top of the stiffening framework 79; a movable crimping form 80; a hydraulic cylinder 78; a bottom of the stiffening framework 81; and a crimping base 82.
In operation the bottom of the stiffening framework 81 of the set of springs 36 is placed on the crimping base 82 aligned under the crimping head 76 and under the movable crimping form 80 and the top of the stiffening framework 79 of the set of springs 36 is placed between the movable crimping form 80 and the crimping head 76, such that when the hydraulic cylinder 78 moves the crimping head 76 downward it engages the top of the stiffening framework 79, then the crimping head 76 pushes the top of the stiffening framework 79 down to where the top of the stiffening framework 79 engages the movable crimping form 80 which moves downward engaging the bottom of the stiffening framework 81 and continues pushing downward until the bottom of the stiffening framework 81 engages the crimping base 82. At this time the crimping base 82 resists further downward motion providing an upward force that causes the top of the stiffening framework 79 to be deformed between the crimping head 76 and the movable crimping form 80, and the bottom of the stiffening framework 81 to be deformed between the movable crimping form 80 and the crimping base 82. The hydraulic cylinder 78 then moves the crimping head 76 upward which then allows the removal of the now deformed set of springs 36 from the crimping base 82. The vertical support 74 holds the movable crimping form 80 in-place.
The construction details of the invention as shown in FIG. 10 may be made of metal, preferably made of steel, more preferably made of steel harder than the steel in the set of springs 36.
The advantages of the present invention shown in FIG. 10 include, without limitation, the points where set of springs 36 is deformed weakens the stiffening framework and thereby creates bending points in the stiffening framework which can assist in controlling where the stiffening framework bends during the spring compaction operation which may make the spring compaction operation more efficient. Further, it would be obvious to one skilled in the art that the ability to control bending points in the stiffening framework may allow the stiffening framework to serve as a banding material in the spring compaction operation.
In broad embodiment, the invention of FIG. 10, may be of any size or any shape and the pattern of a crimping head, a moving crimping form, and a crimping base may be of any design wherein the crimping parts work together to deform the stiffening framework. The device is shown in the horizontal position, it can be operated in a vertical position or in any angle between a horizontal and a vertical position. Any movable part of the current invention may be powered hydraulically as shown or powered via an electrical, a mechanical, a brute strength, or any other power source.
FIG. 11 is a top view and a side view of the present invention showing a spring post compaction additional compaction chamber to adjust at least one volumetric length of a compacted spring set;
Referring now to the invention in more detail, in FIG. 11 there is shown a side view of one embodiment of a post spring compaction operation for the current invention further including a ram foot 86; a hydraulic cylinder 88, a set of compacted springs 90; and a bending form 92.
In more detail, still referring to the invention of FIG. 11, in operation the set of compacted springs 90 is placed on the bending form 92. Then the hydraulic cylinder 88 moves at least two of the ram foot 86 downward engaging the set of compacted springs 90 on opposite sides of the bending form 92. As the hydraulic cylinder 88 continues to move the ram foot 86 downward, the set of compacted springs 90 is bent over the bending form 92. Then the hydraulic cylinder 88 moves the ram foot 86 upward disengaging the set of compacted springs 90. The now bent set of compacted springs 90 is then removed off the bending form 92. Then the now bent set of compacted springs 90 may again be run through the spring compaction operation.
The construction details of the invention as shown in FIG. 11 are “as shown” and “may be” made of metal, preferably steel, more preferably steel harder than the steel in the set of compacted springs 90. This operation may be completed inside of a compaction chamber. A plurality of the bending form 92 and a plurality of both the hydraulic cylinder 88 and the ram foot 86 may result in multiple bending points in the set of compacted springs 90. And, at least one ram foot 86 may be replaced by adding an additional bending form 92 or other fixed bending point. The width of the ram foot 86 may be longer than the width of the set of compacted springs 90.
The advantages of the present invention shown in FIG. 11 include, without limitation, the ability to control the length of the compacted set of springs 90 to optimize market sales price based upon length and width measurements of scrap metal. Whenever the efficiency of the spring compaction operation falls below one-hundred percent, recycling a bent set of compacted springs through the compaction operation may result in a compacted set of springs suitable for the scrap steel market.
In broad embodiment, the invention FIG. 11 is a spring compactor machine post spring compaction operation of any shape or any size with the ability to fold at least once a compacted set of springs within or without a compaction chamber and which comprises at least one movable ram and at least one ram foot and at least one bending form.
FIG. 12 is a flow diagram of the present invention showing a Spring Compactor Machine process. FIG. 9 is a side view of the present invention showing a horizontal embodiment of a method of weakening a manufacturer's spring set strengthening configuration via cutting;
When the phrase “mattress or box springs” or the phrase “mattress springs” is used, it further means the springs or any other metal coming from any soft or padded furniture as well as any metal coming from the mattress or from the box springs.
Referring now to the invention in more detail, in FIG. 12 there is shown a flow chart of one embodiment of the process of the current invention including a standard bed with mattress and box springs 100; an excess mattress or box springs 102; a collection and transporting of excess mattresses or box springs 104; a storage, sorting and tear down facility for mattresses or box springs or soft furniture 106; a sale of mattresses or box springs or soft furniture in the secondary furniture market 107; a set of springs 108; a set of prepared springs 110; a loading of the prepared set of springs into a compaction chamber 112; a spring compaction operation on a set of springs 114; a removal and post processing of a set of springs from the compaction chamber 116; a transporting of the compacted springs 118; a steel recycling center or steel mill 120; a loading and transporting of reusable soft materials from the mattress tear down 122; a soft materials recycling or reuse facility 124; a loading and transporting of wood products resulting from the tear down of box springs 126; and a wood recycling or dimensional lumber reseller or user or pulp wood processing facility 128.
In more detail, still referring to the invention of FIG. 12, in operation people buy and sleep in a standard bed with mattress and box springs 100, and when people choose to discard mattresses or box springs they excess the excess mattress or box springs 102. The excess mattresses and box springs are then collected at a single or various locations and then transported to a mattress recycling facility the collection and transporting of excess mattresses or box springs 104. At the mattress recycling facility the mattress and box springs are sorted into their reusable parts or recyclable components the storage, sorting and tear down facility for mattresses or box springs or soft furniture 106. In the broadest sense, the storage, sorting and tear down facility for mattresses or box springs or soft furniture 106 generates four basic process streams.
The first basic process stream is the total removal from the recycling process and direct sale of yet useable mattresses, box springs or other soft furniture as the sale of mattresses or box springs or soft furniture in the secondary furniture market 107.
Once the first basic process stream useable mattresses, box springs or other soft furniture have been removed, the remaining non-useable mattresses, box springs or other soft furniture are torn down into their component parts and these component parts are separated and sorted.
The second basic process stream is the recycling of the metal from the springs, frames, the stiffening framework, connectors, ties, mechanical devices, supports, etc. which are used to construct the mattress or box springs or was later inserted to repair the mattress or box springs. When all material other than metal has been removed from the mattress springs the set of springs 108 is ready to enter the spring compaction operation process. The set of springs 108 may be pre-treated to become the set of prepared springs 110 prior to spring compaction operation. FIG. 9 and FIG. 10 along with their associated detailed descriptions define how a set of mattress springs becomes the set of prepared springs 110. The set of springs is then loaded into a compaction chamber which is described in FIG. 12 as the loading of the prepared set of springs into a compaction chamber 112. Then the spring compaction operation on a set of springs 114 is completed. Then the removal and post processing of a set of springs from the compaction chamber 116 takes place. FIG. 11 along with its associated detailed descriptions defines what the post processing of a set of compacted springs may be. If necessary after post processing, a compacted set of springs may be sent back to the loading of the prepared set of springs into a compaction chamber 112 as indicated by the dotted line. Then the compacted set of springs is loaded and then the transporting of the compacted springs 118 to a steel recycling center or steel mill 120 is completed.
The third basic process stream may be at least one of the soft materials such as cotton, foam, ticking, quilting and others which came from mattresses and box springs at the storage, sorting and tear down facility for mattresses or box springs or soft furniture 106. These soft materials are normally baled and then the loading and transporting of reusable soft materials from the mattress tear down 122 to a soft materials recycling or reuse facility 124 takes place.
The fourth basic process stream is the wood generated from the tear down of the box springs at the storage, sorting and tear down facility for mattresses or box springs or soft furniture 106. This wood may be dimensional lumber or scrap pieces of lumber. The dimensional lumber or the scrap pieces of lumber are loaded and transported, the loading and transporting of wood products resulting from the tear down of box springs 126 to a wood recycling or dimensional lumber reseller or user or pulp wood processing facility 128.
In further detail, still referring to the flow chart of FIG. 12, the efficiency of the process is greatly enhanced when located near large population centers, and the transportation costs may be reduced via using transportation methods rail and waterways.
The advantages of the present invention shown include, without limitation, the added value of reusing and recycling various forms of soft furniture to specifically include mattresses and box springs to put their component parts to good use and keeps various forms of soft furniture out of the dwindling available landfill space.
In broad embodiment, the process flow chart shown in FIG. 12 may be used to recycle almost any man made soft furniture via breaking down the soft furniture into its component parts and then recycling or reusing those parts.
While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed.
FIG. 13 is a side view of a device to separate the spring set from the frame in a box springs.
Referring now to the invention in more detail, in FIG. 13 there is shown a side view of one embodiment of a device to separate the spring set from the frame in a box springs comprising;
A box springs frame 132, at least one resistance frame holder 134, a strengthening configuration 136, at least one movable force 138, and a set of springs 139 which contacts the frame securing the frame in a fixed position.
In more detail, still referring to the device of FIG. 13, in operation the resistance frame holder 134 is placed under the box springs frame 132 such that box springs frame 132 is held in a stationary position and the resistance frame holder 134 is touching the box springs frame 132. Then the movable force 138 is hooked over the strengthening configuration 136. Then the movable force 138 is activated pulling downward until the set of springs 139 separates from the box springs frame 132.
The construction details of the invention as shown in FIG. 13 are “as shown” and may be made of metal, preferably steel, more preferably steel harder than the steel in the set of compacted springs 90. This operation may be completed as shown so that any staples or other connectors holding the set of springs 139 to the box springs frame 132 fall to the floor below. A plurality of both the resistance frame holder 134 and the movable force 138 would serve to smooth out this separation process.
The advantages of the present device shown in FIG. 13 include, without limitation, the ability to separate non-metallic frames from the set of springs 139 before the set of springs 139 are placed in the spring compactor machine.
The device shown in FIG. 13 is a device to separate the spring set from the frame in a box springs of any shape or any size with the ability to separate the spring set from the frame in a box springs or any other piece of soft furniture having a frame and springs.
