# US 11,109,686 B2 · Method of making a continuous string of pocketed springs

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- Number: US 11,109,686 B2
- Document ID: US11109686B2
- Status: Granted
- Kind: B2
- Application number: 16/418,041
- Filed: 2019-05-21
- Published: 2019-12-19
- Granted: 2021-09-07
- Earliest claimed: 2018-06-13
- Assignees: L&P Property Management Company
- Applicants: L&P Property Management Company
- Inventors: Guido Eigenmann; Darrell A. Richmond; Bernhard Bauer; Urs Liechti; Andreas Meier
- Web page: https://patentgrep.com/patent/US11109686B2

## CPC

- A47C 27/064: {Pocketed springs}
- A47C 27/053: {with only one layer of foamed material}
- A47C 27/062: {of different resiliencies}
- A47C 27/066: {Edge stiffeners}
- A47C 27/07: Attaching, or interconnecting of, springs in spring inlays
- B29C 65/08: using ultrasonic vibrations {(non-plastics element to plastics elements B29C65/645)}
- B29C 65/7451: {the severing tool and the welding tool being movable with respect to one-another}
- B29C 65/7841: {Holding or clamping means for handling purposes (clamping means for the purpose of applying pressure on the parts to be joined, in the area to be joined B29C66/81; work holders in general B25B; devices for holding or positioning work for welding metal B23K37/04)}
- B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)}
- B29C 66/50: {General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles}
- B29C 66/729: {Textile or other fibrous material made from plastics}
- B29C 66/73921: {characterised by the materials of both parts being thermoplastics}
- B29C 66/83221: {cooperating reciprocating tools, each tool reciprocating along one axis}
- B68G 7/00: Making upholstery (manufacturing upholstered panels B68G13/00 {; from plastics B29D99/0092}; sewing-machines D05B)
- B68G 9/00: Placing upholstery springs in pockets; Fitting springs in upholstery
- A47C 7/20: with reinforcement {in the foam layer}
- A47C 7/347: {with means for connecting springs to each other or to seat frame}
- A47C 7/35: Combinations of different types of springs; Adjustable springs; Attachment of springs to other springs or to {the base} frame {; Springs for seat parts not provided for in other groups of this subclass}
- B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)}
- B29L 2031/751: {Mattresses, cushions (upholstery B29L2031/58)}
- B29L 2031/7742: {helical springs}
- A47C: CHAIRS; SOFAS; BEDS
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B68G: METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A pocketed spring assembly comprises parallel strings, each string joined to at least one adjacent string. At least some of the strings have springs of different gauge wire and some of the pockets of the strings having springs of different gauge wire are spliced together. At least some of the strings have springs of different geometries and some of the pockets of the strings having springs of different geometries are spliced together. At least some strings may have end sections with springs different than a middle section therebetween, the springs of the end sections being firmer than the springs of the middle section.

## Claims

### Claim 1

A method of making a sectioned continuous string of pocketed springs for use in an assembler, said method comprising:
providing a welding apparatus;
cutting a string of pocketed springs to create a starting string of pocketed springs downstream of the welding apparatus and a first supply string of pocketed springs upstream of the welding apparatus, the starting string of pocketed springs having an upstream tab and the first supply string of pocketed springs having a downstream tab;
moving the first supply string of pocketed springs to an offset position using clamps;
moving a second supply string of pocketed springs to an in-line position with the starting string of pocketed springs such that the upstream tab of the starting string of pocketed springs and a downstream tab of the second supply string of pocketed springs are overlapping; and
welding the overlapping upstream tab of the starting string of pocketed springs and the downstream tab of the second supply strings of pocketed springs using the welding apparatus.

### Claim 2 (depends on 1)

The method of claim 1 wherein the springs of the first supply string of pocketed springs are different than the springs of the second supply string of pocketed springs.

### Claim 3 (depends on 1)

The method of claim 1 wherein the springs of the first supply string of pocketed springs are a different gauge than the springs of the second string of pocketed springs.

### Claim 4 (depends on 1)

The method of claim 1 wherein the springs of the first supply string of pocketed springs are a different geometry than the springs of the second string of pocketed springs.

### Claim 5

A method of making a sectioned continuous string of springs for use in an assembler, said method comprising:
providing a welding apparatus;
providing a starting string of pocketed springs downstream of the welding apparatus, the starting string of pocketed springs having an upstream tab;
providing a first supply string of pocketed springs upstream of the welding apparatus, the first supply string of pocketed springs having a downstream tab held in place and moved with clamps, the pockets of the first supply string of pocketed springs and the pockets of the starting string of pocketed springs containing first springs;
cutting the first supply string of pocketed springs to separate the starting string of springs from the first supply string of springs;
moving the first supply string to an offset position from an in-line position with the starting string of pocketed springs;
moving a second supply string of pocketed springs upstream of the welding apparatus to an in-line position with the starting string of pocketed springs, the second supply string of pocketed springs having a downstream tab held in place and being moved with clamps, the pockets of the second supply string containing springs different than the first springs;
overlapping the upstream tab of the starting string of springs with the downstream tab of the second supply string of springs to create overlapping tabs;
welding the overlapping tabs to create a combined string of pocketed springs.

### Claim 6 (depends on 5)

The method of claim 5 wherein the pocketed springs within the first supply string of pocketed springs have a different gauge than the pocketed springs within the second supply string of pocketed springs.

### Claim 7 (depends on 5)

The method of claim 5 wherein the pocketed springs within the first supply string of pocketed springs have a different geometry than the pocketed springs within the second supply string of pocketed springs.

### Claim 8

A method of making a sectioned continuous string of springs for use in an assembler, said method comprising:
providing a starting string of pocketed springs having a starting tab;
providing a first supply string of pocketed springs containing first springs and having a first tab;
providing a second supply string of pocketed springs containing springs different than the first springs and having a second tab;
moving the first supply string of pocketed springs in-line with the starting string of pocketed springs such that the first tab overlaps the starting tab;
welding the overlapped first and starting tabs together to create a combined string of pocketed springs;
moving the combined string of springs downstream;
cutting the combined string of pocketed springs at a desired location to create a combined tab;
moving the first supply string of pocketed springs out-of-line with the combined string;
moving the second supply string in-line with the combined string of pocketed springs such that the second tab overlaps the combined tab;
welding the overlapped second and combined tabs together to create a long string of pocketed springs;
moving the long string of springs downstream;
cutting the second supply string of pocketed springs at a desired location to create a long tab.

### Claim 9 (depends on 8)

The method of claim 8 further comprising moving the second supply string of pocketed springs out-of-line with the long string of pocketed springs and moving the first supply string of pocketed springs in-line with the long string of pocketed springs to repeat the process.

### Claim 10 (depends on 8)

The method of claim 8 wherein the pocketed springs of the first supply string of pocketed springs are made of a different gauge wire than the pocketed springs of the second supply string of pocketed springs.

### Claim 11 (depends on 8)

The method of claim 8 wherein the pocketed springs within the first supply string of pocketed springs have a different geometry than the pocketed springs within the second supply string of pocketed springs.

### Claim 12

A method of making a sectioned continuous string of springs for use in an assembler, said method comprising:
providing a starting string of pocketed springs having a starting tab;
providing a first supply string of pocketed springs, each of the springs of the first supply string being first springs, the first supply string having a first tab;
providing a second supply string of pocketed springs, each of the springs of the second supply string being second springs different than the first springs, the second supply string having a second tab;
moving the first supply string of pocketed springs in-line with the starting string of pocketed springs such that the first tab overlaps the starting tab;
welding the overlapped first and starting tabs together to create a combined string of pocketed springs;
moving the combined string of springs downstream;
cutting the combined string of pocketed springs at a desired location to create a combined tab;
moving the first supply string of pocketed springs out-of-line with the combined string;
moving the second supply string in-line with the combined string of pocketed springs such that the second tab overlaps the combined tab;
welding the overlapped second and combined tabs together to create a long string of pocketed springs;
moving the long string of springs downstream;
cutting the second supply string of pocketed springs at a desired location to create a long tab.

### Claim 13 (depends on 12)

The method of claim 12 further comprising moving the second supply string of pocketed springs out-of-line with the long string of pocketed springs and moving the first supply string of pocketed springs in-line with the long string of pocketed springs to repeat the process of claim 12.

### Claim 14 (depends on 12)

The method of claim 12 wherein the pocketed springs of the first supply string of pocketed springs are made of a different gauge wire than the pocketed springs of the second supply string of pocketed springs.

### Claim 15 (depends on 12)

The method of claim 12 wherein the pocketed springs within the first supply string of pocketed springs have a different geometry than the pocketed springs within the second supply string of pocketed springs.

### Claim 16

A method of making a sectioned continuous string of springs for use in an assembler, said method comprising:
cutting a starting string of pocketed springs to create a first supply string of pocketed springs containing first springs from a first coiler;
providing a second supply string of pocketed springs containing second springs different than the first springs from a second coiler;
moving the first supply string of pocketed springs from an in-line position aligned with the starting string of pocketed springs to an off-line position;
moving the second supply string of pocketed springs to an in-line position with the starting string of pocketed springs;
welding overlapped tabs from the second supply string of pocketed springs and the starting string of pocketed springs together to create a combined string of pocketed springs;
moving the combined string of springs downstream;
cutting the combined string of pocketed springs at a desired location;
moving the second supply string of pocketed springs out-of-line with the combined string;
moving the first supply string in-line with the combined string of pocketed springs; and;
welding tabs from the first supply string and combined string together.

### Claim 17 (depends on 16)

The method of claim 16 wherein the pocketed springs of the first supply string of pocketed springs are made of a different gauge wire than the pocketed springs of the second supply string of pocketed springs.

### Claim 18 (depends on 16)

The method of claim 16 wherein the pocketed springs within the first supply string of pocketed springs have a different geometry than the pocketed springs within the second supply string of pocketed springs.

### Claim 19

A method of making a pocketed spring assembly, said method comprising:
providing a first supply string of pocketed springs containing first springs;
cutting the first supply string of pocketed springs to a desired length;
providing a second supply string of pocketed springs containing springs different than the first springs;
cutting the second supply string of pocketed springs to a desired length; and
securing overlapping tabs of the first and second supply strings of pocketed springs together to create a sectioned continuous string of springs, the tabs of the first and second supply strings of pocketed springs extending the entire height of the first and second supply strings of pocketed springs; and
passing the sectioned continuous string of springs to an assembler for assembly into the pocketed spring assembly.

### Claim 20 (depends on 19)

The method of claim 19 wherein the pocketed springs within the first supply string of pocketed springs have a different gauge than the pocketed springs within the second supply string of pocketed springs.

### Claim 21 (depends on 19)

The method of claim 19 wherein the pocketed springs within the first supply string of pocketed springs have a different geometry than the pocketed springs within the second supply string of pocketed springs.

### Claim 22

A method of making a sectioned continuous string of pocketed springs for use in an assembler, said method comprising:
cutting a continuous string of pocketed springs to create a starting string of pocketed springs downstream of a welding apparatus and a first supply string of pocketed springs upstream of the welding apparatus, the starting string of pocketed springs having an upstream tab and the first supply string of pocketed springs having an downstream tab;
moving the first supply string of pocketed springs to an offset position;
moving a second supply string of pocketed springs to an in-line position with the starting string of pocketed springs such that the upstream tab of the starting string of pocketed springs and an downstream tab of the second supply string of pocketed springs are overlapping; and
welding the overlapping upstream tab of the starting string of pocketed springs and the downstream tab of the second supply strings of pocketed springs using the welding apparatus to create a combined string of pocketed springs.

### Claim 23 (depends on 22)

The method of claim 22 further comprising moving the combined string of pocketed springs downstream and cutting the combined string of pocketed springs.

### Claim 24 (depends on 23)

The method of claim 23 further comprising, after cutting the combined string of pocketed springs, moving the portion of the combined string of pocketed springs upstream of the welding apparatus away from the welding apparatus.

### Claim 25 (depends on 24)

The method of claim 24 further comprising moving another portion of the first supply string of pocketed springs in-line with the portion of the combined string of pocketed springs downstream of the welding apparatus and using the welding apparatus to weld them together to create a sectioned continuous string of pocketed springs.

### Claim 26 (depends on 25)

The method of claim 25 wherein the sectioned continuous string of pocketed springs comprises a first section of springs from a first coiler from the starting string of pocketed springs, a second section of springs from the second supply string of pocketed springs and a third section of springs from the first supply string of pocketed springs.

### Claim 27 (depends on 25)

The method of claim 25 wherein the sectioned continuous string of pocketed springs comprises a first section of springs comprising springs from a first coiler, a second section of springs comprising springs from a second coiler and a third section of springs comprising springs from the first coiler.