Pocketed coil spring mattress cores

A method of assembling a plurality of pocketed coil strings into an innerspring coil wherein each string comprises a plurality of side-by-side pocket containing coil springs of a finite length, each pocket being formed from a nonwoven material, said method comprising:

• providing first and second continuous webs of nonwoven fabric material having a mesh netting with a heat activated adhesive on one surface;
• feeding each of said webs into engagement with a respective rotating heated roll;
• spacing said rolls apart to define a nip between said rolls of a distance less than the height of said springs;
• feeding said webs about the respective roll with the netting facing away from the respective roll and with the netting on said first web facing the netting on said second web;
• and
• feeding a pocketed coil string into the nip between said rolls to engage opposite ends of said pockets with a respective web to bond a web to each end of the pockets of said string and bond said webs to said pockets.

A method of assembling a plurality of strings of pocketed coil springs into an inner spring core wherein each string comprises a plurality of side-by-side pockets containing coil springs, said method comprising:

• providing a web having a bonding agent, wherein the bonding agent is a heat activated adhesive;
• applying the web to corresponding surfaces of a pair of strings of pocketed coil springs;
• and
• activating the bonding agent of the web to thereby join the strings of pocketed coil springs together by heating the web;
• wherein the web is passed over a heated roller to heat the web and activate the adhesive prior to the web being applied to the strings.

A method of making a spring core comprising:

• encasing a plurality of coiled springs in individual pockets to form a string of pocketed coil springs;
• juxtaposing a plurality of the strings of pocketed coil springs in side-by-side relation with longitudinal axes of the springs being generally parallel to one another;
• applying a web having a bonding agent to corresponding surfaces of the plurality of strings of pocketed coil springs, wherein the bonding agent is a heat activated adhesive;
• and
• activating the bonding agent on the web and thereby joining the strings of pocketed coil springs together by heating the web;
• wherein the web is passed over a heated roller to heat the web and activate the adhesive prior to the web being applied to the strings.

A method of making a spring core comprising:

• encasing a plurality of coiled springs in individual pockets of nonwoven material to form a string of pocketed coil springs;
• juxtaposing a plurality of the strings of pocketed coil springs in side-by-side relation with longitudinal axes of the springs being generally parallel to one another;
• applying first and second webs each having a heat activated adhesive and a reinforced netting to corresponding first and second end surfaces, respectively, of the plurality of strings of pocketed coil springs;
• and
• heating the adhesive on the webs by passing the webs over heated rollers and thereby joining the strings of pocketed coil springs together.