Method and apparatus for forming a row of spring coils from a continuous length of wire

The method of forming a substantially flat connector segment between adjacent coils of a row of parallel coils interconnected by connector segments, said coils of said row of coils each having a pair of endmost loops, said endmost loops of each coil begin connected to an adjacent coil by a connector segment, which method comprises

• clamping endmost loops of adjacent coils at opposite ends of a connector segment between pairs of clamping dies,
• engaging the center portion of said connector segment with a forming die,
• rotating said forming die while engaged with said center portion of said connector segment and while the endmost loops of coils located at the opposite ends of said connector segment remain clamped between said pairs of clamping dies so as to create an offset center portion of said connector segment located between substantially parallel but offset opposite end portions of said connector segment.

Apparatus for forming a substantially flat connector segment between adjacent coils of a row of parallel coils interconnected by connector segments, said coils of said row of coils each having a pair of endmost loops, said endmost loops of each coil being connected to an adjacent coil by a connector segment, which apparatus comprises

• means for clamping endmost loops of adjacent coils at opposite ends of a connector segment between pairs of clamping dies,
• means for engaging a center portion of said connector segment with a forming die,
• means for rotating said forming die while engaged with said center portion of said connector segment and while the endmost loops of coils located at the opposite ends of said connector segment remain clamped between said pairs of clamping dies so as to create an offset center portion of said connector segment located between substantially parallel but offset opposite end portions of said connector segment.

A machine for production rows of coil springs, each of said rows of coil springs being formed from a single continuous piece of wire and each of said rows containing a plurality of coils interconnected by interconnecting segments, alternate ones of said interconnecting segments being disposed in spaced parallel planes, the axes of said coils being disposed perpendicular to said spaced, parallel planes, each of said coils terminating in a chordal flat bar located in a plane of said base and grid, and the chordal flat bars of adjacent coils being interconnected by said interconnecting segments, each of said interconnecting segments having substantially parallel end portions connected at the center by an offset section, said machine comprising

• conveyor means for transporting connected rows of coils through said machine,
• forming means for forming said chordal flats and said interconnecting segments between said coils, said forming means being synchronized with movement of said conveyor so as to enable said flats and interconnecting segments to formed, while said rows of coils are supported upon said conveyor.

A machine for producing rows of coil springs, each of said rows of coil springs being formed from a single continuous piece of wire and each of said rows containing a plurality of coils, each of said coils terminating in end loops, the end loops of adjacent coils being interconnected by interconnecting segments, alternate ones of said interconnecting segments being disposed in spaced parallel planes, the axes of said coils being disposed perpendicular to said spaced, parallel planes, each of said interconnecting segments having substantially parallel end portions connected by an offset portion, said machine comprising

• conveyor means for transporting connected rows of coils through said machine,
• forming means for forming said interconnecting segments within said machine and while said coils are being transported upon said conveyor, said forming means being synchronized with movement of said conveyor through said machine.

A method of forming a row of spring coils from a single continuous length of wire, said method comprising

• forming a helix of continuous length from said continuous length of wire, said helix having a longitudinal axis,
• folding said continuous length helix into a wave-like configuration so as to create a plurality of substantially parallel spring coils in a coil row, each of said coils being connected at one end by one connector segment with an adjacent coil to one side thereof and being connected at the other end with an adjacent coil at the other side thereof by another connector segment, and
• thereafter forming each of said connector segments into a substantially flat configuration by clamping opposite ends of each of said connector segments between pairs of dies and then rotating the center portion of each of said connector segments while the opposite ends of the connector segments are clamped between said dies so as to create an offset center portion of said connector segments located between substantially parallel but offset opposite end portions of said connector segments.

The method of forming a substantially flat connector segment between adjacent coils of a row of parallel coils interconnected by connector segments, said coils of said row of coils each having a pair of endmost loops, said endmost loops of each coil being connected to an adjacent coil by a connector segment, which method comprises

• clamping opposite ends of a connector segment between pairs of clamping dies,
• engaging the center portion of said connector segment with a forming die,
• rotating said forming die while engaged with said center portion of said connector segment and while the opposite ends of said connector segment remain clamped between said pair of clamping dies so as to create an offset center portion of said connector segment located between substantially parallel but offset opposite end portions of said connector segment.

A machine for producing rows of coil springs, each of said rows of coil springs being formed from a single continuous piece of wire and each of said rows containing a plurality of coils, each of said coils terminating in end loops, the end loops of adjacent coils being interconnected by interconnecting segments, alternate ones of said interconnecting segments being disposed in spaced, parallel planes, the axes of said coils being disposed perpendicular to said spaced, parallel planes, each of said interconnecting segments having substantially parallel end portions connected by an offset portion, said machine comprising

• conveyor means for transporting connected rows of coils through said machine,
• forming means for forming said interconnecting segments within said machine and while said coils are being transported upon said conveyor, said forming means being synchronized with movement of said conveyor through said machine, said forming means being operable to form said interconnecting segments by clamping opposite ends of said interconnecting segments and then rotating the center portion of said interconnecting segments.