US 6,159,319 A · Method and apparatus for forming pocketed coil spring mattresses

Abstract

A method and apparatus for forming a mattress having a core formed from a plurality of elongated rows of interconnected coil spring containing fabric pockets, each row having a plurality of spaced apart pockets with a spring encased in each pocket, and having a reinforcing and/or adhesive material between adjacent rows. A first row of spring encased pockets is placed in a tray in a horizontal position and held in the tray by fingers which engage the fabric of the pockets at the ends of each spring, there being a finger at each end of each pocket. An adhesive, if necessary, may be placed on the upper surface of the row. The tray is mounted on a pivotable plate which is then rotated to a vertical position and moved linearly toward a table containing prior rows of the core to bond the row carried in the tray to the last row on the table. The fingers are thereafter removed from the row in the tray and the tray is pushed linearly a further distance to move the core on the table together with the newly bonded row further onto the table. The tray is thereafter moved linearly and rotated back to its initial position.

Claims35

Dependent claims

A method of making a spring core comprising:

encasing a plurality of coiled springs in individual fabric pockets to form a row of pocketed coil springs with opposing outwardly facing surfaces;
juxtaposing a plurality of the rows of pocketed coil springs in side-by-side fashion with longitudinal axes of the springs being generally parallel to one another;
joining the rows of pocketed coil springs together;
and
pulling the fabric of the pockets of the rows of pocketed coil springs taut around a profile of the coiled springs prior to and during joining the rows together.

2 more elements

A method of manufacturing a spring unit comprising a plurality of rows of interconnected coil spring containing fabric pockets, each row having a plurality of pockets with a coil spring encased in each pocket, each of said coil springs being coiled in a helical form about an axis of elongation and including opposed ends spaced apart along said axis, the steps comprising:

(a) disposing a first row of interconnected coil spring containing pockets within a support with said axes of said coil springs disposed generally parallel to each other and with a first surface of said row being exposed and a second surface disposed on said support;
(b) engaging the fabric of each pocket of said row with a finger to hold said row in said support and pull the fabric taut to the coil spring in the pocket;
(c) orienting said support to position said axes of said coil springs generally parallel to the axes of coil springs in another row of interconnected coil spring containing pockets;
(d) moving said support to abut said first surface to the fabric of said another row of interconnected coil spring containing pockets;
(e) joining said first row to said another row;
and
(f) thereafter disengaging the fingers from said first row to release said first row from said support.

4 more elements

A method of manufacturing a mattress having a core comprising a plurality of rows of interconnected coil spring containing fabric pockets, each row having a plurality of pockets with a coil spring encased in each pocket, each of said coil springs being coiled in a helical form about an axis of elongation and including opposed ends spaced apart along said axis, the steps comprising:

(a) disposing a first row of interconnected coil spring containing pockets within a support with said axes of said coil springs disposed in a substantially horizontal plane and with a first surface of said row facing substantially upwardly and a second surface disposed on said support;
(b) engaging the fabric of each pocket of said row at each end of a coil spring with a finger to hold said row in said support;
(c) rotating said support to position said axes of said coil springs in a substantially vertical disposition;
(d) moving said support in a substantially horizontal direction to abut said first surface to the fabric of another row of interconnected coil spring containing pockets disposed on a horizontal surface with the axes of the coil springs extending substantially vertical;
and
(e) thereafter disengaging the fingers from said first row to release said first row from said support.

3 more elements

Dependencies are inferred from the claim text.

Method and apparatus for forming pocketed coil spring mattresses

Life of this patent

Method and apparatus for forming pocketed coil spring mattresses

Life of this patent

Abstract

Claims35