Abstract:
Certain embodiments of the present invention provide systems and methods for compacting the springs of mattresses and box springs. The present invention compresses the springs in at least two, preferably three different directions. One compression is achieved through actuation of a crush chamber door. At least two of the three directions of compression are perpendicular to an axis through the springs. After the final compression is performed, the compressed springs are discharged from the crush chamber in a direction parallel to the direction of the final compression.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a divisional of and claims priority to U.S. patent application Ser. No. 12/724,320 filed Mar. 15, 2010 entitled Coil Spring Compactor, which claims priority to U.S. Provisional Application Ser. No. 61/266,143 filed Dec. 2, 2009, entitled Coil Spring Compactor and U.S. Provisional Application Ser. No. 61/160,252, filed Mar. 13, 2009, entitled Coil Spring Compactor, the contents of both of which are incorporated in their entirety herein. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This application relates to an apparatus and method for compacting springs and, more particularly, to an apparatus and method for compacting and preparing the metal components of mattresses for recycling. 
       BACKGROUND OF THE INVENTION 
       [0003]    Modern mattresses are made from various combinations of materials including: synthetic and natural fabrics, feathers, foam, plastics, wood, and arrangements of metal springs. The disposal and recycling of mattresses is a complicated process that involves both separating the various mattress materials from each other and also preparing each of the resulting materials in a bundle that meets the specific acceptance requirements of the various recyclers. For example, the metal springs of mattresses form an interconnected array of metal that occupies a relatively large area at a low density. Metal foundries, however, accept metal in relatively small volume, high-density units, for example one cubic foot units or blocks of approximately 60 to 100 pounds. Efficient systems and methods for compacting resilient springs to such densities have thus far not been developed in the field. Accordingly, there exists a need to efficiently process low-density mattress springs into high-density units accepted by typical foundries. 
       OBJECTS AND SUMMARY OF THE INVENTION 
       [0004]    The present invention addresses this need by providing systems and methods for efficiently compacting the springs of mattresses and box springs. The present invention compresses the springs in at least two, preferably three different directions. One compression is achieved through actuation of a crush chamber door. At least two of the three directions of compression being perpendicular to an axis through the springs. After the final compression is performed, the compressed springs are discharged from the crush chamber in a direction parallel to the direction of the final compression. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]    These and other aspects, features and advantages of which embodiments of the invention are capable of will be apparent and elucidated from the following description of embodiments of the present invention, reference being made to the accompanying drawings, in which 
           [0006]      FIG. 1  is a front elevation view of a spring compactor according to certain embodiments of the present invention. 
           [0007]      FIGS. 2A and 2B  are side elevation views of a spring compactor according to certain embodiments of the present invention. 
           [0008]      FIG. 3  is a front elevation view of a spring compactor according to certain embodiments of the present invention. 
           [0009]      FIGS. 4A and 4B  are side elevation views of a spring compactor according to certain embodiments of the present invention. 
           [0010]      FIG. 5  is a sectional view taken along lines A-A of  FIG. 3  of a spring compactor according to certain embodiments of the present invention. 
           [0011]      FIG. 6  is a side elevation view of a spring compactor according to certain embodiments of the present invention. 
           [0012]      FIG. 7  is a sectional view taken along lines B-B of  FIG. 1  of a spring compactor according to certain embodiments of the present invention. 
       
    
    
     DESCRIPTION OF EMBODIMENTS 
       [0013]    Specific embodiments of the invention will now be described with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements. 
         [0014]    Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. 
         [0015]    The coil spring compactor of the present invention is operable to simultaneously compact a plurality of springs from mattresses and/or box springs into a compressed unit that is of a density accepted by commercial metal foundries. For example, in a preferred embodiment, the compactor of the present invention compacts four mattress springs into a 12 inch wide by 6 inch high by 18 inch long mass of approximately 60 to 100 pounds, preferably 75 pounds. 
         [0016]    As shown in  FIGS. 1-7 , in certain embodiments of the present invention, a coil spring compactor  10  employs a six sided magazine or crush chamber  12 . The crush chamber is approximately rectangular having a height and width dimensioned so as to accept at least the springs from a king size mattress or box springs. The internal dimensions of the crush chamber  12  may, for example, be 78 inches high by 88 inches wide by 12 inches deep. 
         [0017]    As shown in  FIGS. 2A ,  2 B,  4 A,  4 B, and  5 , the upper most horizontal surface of the crush chamber  12  employs one or more vertical compression plates  14 . The vertical compression plates  14  are attached to or otherwise associated with one or more vertical compression hydraulic cylinders  15  or other similar means to vertically transpose the vertical compression plate through crush chamber  12 . In embodiments employing more than one vertical compression hydraulic cylinders  15 , it will be necessary to maintain the vertical compression plate  14  level relative to the different compression hydraulic cylinders  15 . In one embodiment, the vertical compression plate  14  is maintained level by plumbing the hydraulic system from one of the vertical compression hydraulic cylinders  15  into the hydraulic system of the other vertical compression hydraulic cylinder  15 . Alternatively, the vertical compression plate  14  and the vertical compression hydraulic cylinders  15  may incorporate either a mechanical or electrical level control system. For example, the coil spring compactor  10  may employ a programmable electronic leveling system combined with fluid control valves to provide constant vertical compression plate  14  leveling. The lower most horizontal surface, the surface opposite the vertical compression plates  14 , employs a vertical compression counter surface  16 , shown in  FIGS. 5-7 . 
         [0018]    As shown in  FIGS. 1-5  and  7 , a chamber door  18  forms at least a portion of one of the large vertical sides of the crush chamber  12  when the chamber door  18  is in a closed state, shown in  FIGS. 1 ,  2 A,  3 ,  4 B, and  7 . The chamber door  18  employs a hinge  20  on a lower side  22  of the chamber door  18 , see  FIG. 5 . When the chamber door  18  is opened, shown in  FIGS. 2B ,  4 A, and  5 , the upper side  24  of the chamber door  18  is transposed in an arc-like form  19  away from the crush chamber  12  and downward. When fully opened, chamber door  18  forms an approximately horizontal surface extending approximately perpendicular from the crush chamber  12 . In the open position, the camber door  18  functions as a spring loading platform. In certain embodiments, the arc-like form  19  reflects the outline of chamber door side walls (not shown) that are employed on either side of the chamber door  12 . The chamber door side walls are attached to the crush chamber  12  such that the side walls function to guide the springs loaded onto the open chamber door  18  into the crush chamber  12  when the chamber door  18  is transitioning from the open state to the closed state. 
         [0019]    The chamber door  18  may be actuated, or opened and closed, by employing one or more chamber door hydraulic cylinders  26 . The chamber door hydraulic cylinders  26  may be anchored to the exterior sides of the crush chamber  12  and chamber door  18 , as shown in  FIGS. 1-2B , or may be anchored on a frame residing on a floor or other work surface and to central locations on an exterior surface of the chamber door  18 , as shown in  FIGS. 3-5 . The chamber door  18  may, for example, be 61 inches high by 88 inches wide. The second large vertical side of the crush chamber  12  employs a chamber door counter surface  27 , shown in  FIGS. 2A ,  2 B,  4 A,  4 B,  5  and  7 . 
         [0020]    The remaining two sides of the crush chamber  12  are the two small, vertical sides located opposite each other and form the first end surface  30  and the second end surface  32 . As shown in  FIG. 7 , the first and second end surfaces  30  and  32  extend downwards along the sides of the crush chamber  12  to a discharge door  34  and a horizontal compression plate  36 , respectively. The horizontal compression plate  36  is attached to or otherwise associated with a horizontal compression hydraulic cylinder  38  which functions to transpose the horizontal compression plate  36  horizontally through a lower portion of the crush chamber  12 . The discharge door  34 , located opposite the horizontal compression plate  36 , counters the horizontal movement of the horizontal compression plate  36 . The discharge door  34  is transposable so as to form an opening into a lower portion of the crush chamber  12 . The discharge door  34  may be actuated by employing a discharge door hydraulic cylinder  35  or other similar means of transposing. In certain embodiments of the present invention, a discharge hydraulic cylinder  35  is employed so as to transpose the discharge door  34  horizontally away from the crush chamber  12 , as shown in  FIG. 1 . In certain other embodiments, the discharge door hydraulic cylinder  35  is configured so as to transpose the discharge door  34  vertically along an exterior of the first end surface  30 , shown in  FIGS. 3 and 6 . 
         [0021]    It will be appreciated by those of skill in the art that interior surfaces of the crush chamber  12  will be subjected to significant resistance and subsequent wear during operation. In order to improve the longevity of the interior surfaces, in certain embodiments of the present invention, the interior surfaces of the crush chamber  12  employ, for example, abrasive resistant steel plates. In certain other embodiments, the interior surfaces of the crush chamber  12  are designed such that the individual components may be rotated, reversed, or interchanged with other interior surface components such that specific portions of the surfaces subject to disproportional wear may be moved to areas of less wear are without altering the operability of the coil spring compactor  10 . For example, the wear plates forming the first end surface  30  and the second end surface  32  may be substantially identical and therefore interchangeable. If, for example, the first end surface  30  is worn more extensively than the second end surface  32 , the two surfaces can be interchanged so as to maximize the use of both surfaces. Furthermore, the individual surfaces may be designed such that the surface, for example the chamber door counter surface  26 , can be rotated  180  degrees and remounted with the same surface forming the interior surface or may be reversed such that the interior and exterior surfaces are reversed. In order to facilitate these features the interior surfaces of the crush chamber  12  may have symmetrical shapes, such as rectangular shapes, and symmetrical mounting means, for example equally spaced threaded holes. 
         [0022]    In operation, the springs from dismantled mattresses are placed horizontally onto an elevated planar surface formed by an open chamber door  18 , shown in  FIGS. 2A ,  2 B,  4 A,  4 B, and  5 . The chamber door  18  is then closed to form at least a portion of one side of the crush chamber  12 . Closing the chamber door  18  positions the mattress springs approximately vertically upon their long sides within the crush chamber  12 . Depending on the number of springs loaded on to the open chamber door  18 , closing of the chamber door  18 , provides the first compression of the springs in a direction parallel to an axis formed through the springs. 
         [0023]    A second compression of the springs initiates with displacement of the vertical compression plates  14  in a downward direction by the vertical compression hydraulic cylinders  15 . A downward displacement of the vertical compression plates  14  results in a decrease in the height of the crush chamber  12  and a first compression of the springs in a direction approximately perpendicular to an axis formed through the springs. Upon displacement of the vertical compression plates  14  to a desired height above the vertical compression counter surface  16 , for example a height of 6 inches above the vertical compression counter surface  16 , vertical compression ceases. 
         [0024]    While maintaining the vertical compression plates  14  at the desired height above the vertical compression counter surface  16 , the horizontal compression plate  36  is transposed horizontally through the bottom portion of the crush chamber  12  so as to compress the springs in a third direction. It will be understood that the third compression compresses the springs in a direction approximately perpendicular to an axis formed through the springs and in a direction approximately perpendicular to the direction of the second compression. Horizontal compression ceases once a desired hydraulic pressure in the horizontal compression hydraulic cylinder  38  is achieved. 
         [0025]    The compressed mattress springs are then discharged from the crush chamber  12  by retracting, lifting, or otherwise displacing of the discharge door  34  so as to form an opening at one side of the lower crush chamber  12 . The compressed mattress springs are discharged from the crush chamber  12  by additional horizontal displacement of the horizontal compression plate  36  towards the opening formed by the now retracted discharge door  34 . The compressed springs can be discharged from the crush chamber  12  on to a cart, conveyor belt, truck or other means for facilitating the transportation of the compressed springs to a foundry. 
         [0026]    In certain embodiments of the present invention, the compressed mattress springs may be bundled or otherwise confined such that the compressed springs better maintain their compressed state and/or to facilitate handling and transport of the compressed springs. 
         [0027]    In certain embodiments of the present invention, compression of the mattress springs is facilitated through hydraulic displacement of certain interior surfaces of the crush chamber  12 . In a preferred embodiment, the hydraulic displacement is achieved by employing a motor  40 , for example, an electric motor of ten horsepower. However, it is noted that other suitable manners of achieving displacement of the surfaces of the crush chamber  12  and other suitable means for powering such displacement are well known in the art and may also be employed to achieve similar results. 
         [0028]    In certain other embodiments of the present invention, the spring compactor  10  may be operated manually through the use of valve controls  42 , shown in  FIG. 3 . Alternatively, operation may be automated such that after loading the springs on to the open chamber door  18 , an operator need only actuate a button of lever to begin an automated compression cycle that results in the discharge of a mass of compressed metal springs of a density accepted by metal foundries. 
         [0029]    Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.