GB2485407A

GB2485407A - Resilient core comprising columns formed from folded pockets filled with resilient material

Info

Publication number: GB2485407A
Application number: GB201019241A
Authority: GB
Inventors: Simon Paul Spinks; David Clare
Original assignee: Harrison Spinks Beds Ltd
Current assignee: Harrison Spinks Beds Ltd
Priority date: 2010-11-12
Filing date: 2010-11-12
Publication date: 2012-05-16
Also published as: GB201019241D0

Abstract

A resilient core 20 comprises at least one elongate pocket 12; the elongate pocket being filled with pieces of resilient material; there are preferably a plurality of elongate pockets 4, 6, 8, 10, 12 that are folded to form columns within the resilient core; the elongate pockets 4, 6, 8, 10, 12 may be formed from a first web joined to a second web and the resilient material may be compressed; the core is preferably for use in a mattress and a method of forming a resilient core is also disclosed.

Description

Resilient Core The present invention relates to a resilient core and to a method of forming a resilient core. In particular, the present invention relates to a resilient core and a method of forming the same suitable for use in an article that requires a filling for padding, comfort or protection.

Mattress cores comprising spring units are well known.

For instance, WO 2005/085123 shows a spring unit wherein a plurality of coiled, helical springs are arranged to cover an area in a grid like matrix. Each spring is arranged with an axis generally perpendicular and aligned relative to the direction of pressure from a user. To increase the performance of the spring unit each spring is often encased in an individual pocket. Forming, handling and encasing the springs are complex parts of the production of the spring units. * .e

It is an object of the present invention to attempt to S.....

* overcome at least one of the above or other problems. * .

* According to the present invention there is provided a *.*..

* resilient core and a method of forming a resilient core as set forth in the appended claims. Other features of the *:*** invention will be apparent from the dependent claims, and

the description which follows.

According to the exemplary embodiments there is provided a resilient core formed from a plurality of juxtaposed, discrete resilient pockets. The pockets are elongate, having an axis which lies substantially in the plane of the resilient core. Each pocket is filled with pieces of resilient material. Advantageously, it has been found that each pocket of resilient material is able to replicate the behaviour of a spring. Two or more juxtaposed, discrete columns may be formed from a single elongate pocket folded across the pocket's elongate axis and secured in position. The juxtaposed columns may each have an axis transverse to the axis of the pocket, and aligned with the intended direction of pressure from a person using the core, such as a person lying on a mattress of which the core forms a part.

Preferably each elongate pocket is filled with compressed resilient material. Consequently, each pocket is maintained in a state of tension.

Preferably each pocket includes a plurality of folds across the elongate axis of the pocket. The elongate pocket may be fan-folded or concertinaed. The resilient core preferably comprises two or more folded, elongate en.

pockets that are arranged to be juxtaposed. Each juxtaposed pocket may be formed separately and joined together or two or more elongate pockets may be formed * .** .* * * integrally.

S..... * S

The resilient core may be suitable for a variety of applications including, but not limited to: mattresses for beds, divan beds, pillows, upholstered furniture, seats and cushions, pet beds, sports mats, protective equipment and other areas in furniture production such as in a platform beneath a seat, or an arm wrap for example.

The filling material may be of any suitable resilient material including, but not limited to: foam, latex, rubber, fabric, hemp and flax.

According to the exemplary embodiments there is provided a method of forming a resilient core, the method comprising forming an elongate pocket and filling the elongate pocket with pieces of resilient material. The method may further comprise the step of folding the elongate pocket across its elongate axis so as to form at least two juxtaposed, discrete columns.

Subsequent to folding the elongate pocket, the method may include securing the juxtaposed parts of the folded elongate pocket together.

The method preferably includes the step of forming an elongate pocket by joining two overlaying layers to form a cavity or sleeve. Suitably, the method comprises forming ** two or more spaced, parallel joins in two overlaying layers in order to form two or more cavities or sleeves.

* ***** * Preferably, the method comprises compressing the pieces of * resilient material within each elongate pocket. * *. ** * *** 0

According to another aspect there is provided a forming apparatus. The forming apparatus is suitable for forming a resilient core suitable for a mattress for beds, divan beds, pillows, and other articles such as upholstered furniture, seats and cushions. The forming apparatus includes a hopper for stowing pieces of resilient material and means to stow or provide upper and lower webs. The means to stow the upper and lower webs causes upper and lower webs to be arranged in an overlying state. The hopper feeds material between the upper and lower webs.

An advancement means is arranged to advance the upper and lower webs towards an outlet. A dividing means is provided to divide the pieces of resilient material into spaced lanes between the upper and lower webs. The forming apparatus includes means to secure the upper and lower webs in at least two joins, wherein a join is formed in an area either side of the spaced lanes of pieces of resilient material.

Preferably the advancement means comprises upper and lower transportation means. The upper and lower transportation means may be arranged to be inclined to each other. Thus the transportation means may compress the pieces of resilient material.

The means to divide the resilient material, such as crumbed foam or other particulate material into fl.* longitudinal lanes or strips preferably comprises a S..... . * . plurality of arms or fingers extending in the general direction of advancement of said webs, and the means to flS. U * secure said webs together so as to form said discrete * pockets will preferably be a welding or other suitable station or stations, said station(s) effecting longitudinal and/or lateral joining of said webs.

According to a further exemplary embodiment, there is provided a method of forming a resilient core suitable for a mattress for beds, divan beds, pillows, and other articles such as upholstered furniture, seats and cushions. The method comprises steps of feeding pieces of resilient material onto advancing means, advancing said material so that it lies between moving upper and lower webs, dividing said material into longitudinal lanes or strips, and securing said webs of fabric or other suitable material together so as to form a plurality of elongate pockets of web material each being filled with pieces of resilient material.

Preferably, the method comprises securing the webs together longitudinally and/or laterally so as to form a plurality of discrete pockets.

Preferably the method may comprise causing the advancing means to compress the pieces of resilient material prior to joining the webs to encapsulate the compressed material.

The method may comprise the additional step of fan-folding the resultant product in concertina fashion.

The method may include any combination of the features or limitations referred to herein, except such a combination * in which the features which are mutually exclusive.

*.** ** * * * *eoIS * For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which: Figure 1 is a perspective plan view of a partly formed mattress core according to a first embodiment; Figure 2 is a perspective side view of a portion of mattress core in accordance with the first embodiment; Figure 3 is a perspective end view of Figure 2; Figure 4 is a perspective plan view of a forming apparatus for forming a mattress core of the first embodiment; Figures 5-7 are side, rear, and plan views respectively of Figure 4; and Figure 8 is side view taken through a cross-section of Figure 4.

In an exemplary embodiment a mattress core is formed from an elongate pocket. Here the elongate pocket forms an enclosed cavity. The elongate pocket is bulk filled with pieces of a resilient material. A particular suitable material has been found to be crumbed foam. A core for a mattress comprises a single elongate pocket. A mattress S.. 4 core comprises a plurality of said filled elongate pockets arranged in a juxtaposed manner. The pockets are juxtaposed such that the elongate axes of two or more fr'S...

* elongate pockets are spaced parallel to each other. * .SS * .

*. 25 In this embodiment each elongate pocket also includes at *S * least one fold across the pocket's elongate axis, one side of the pocket being folded back on itself so that two spaced locations on the one side are arranged to lie substantially face to face. That is, each elongate pocket is folded or otherwise formed from having a single axis to having a plurality of spaced axes. The elongate pockets are secured to maintain their position. It will be appreciated that the number of folds and number of juxtaposed pockets are dependent on the size of the elongate pockets and size of the required mattress core.

Additionally or alternatively, two or more cores or mattress cores can be secured together to form the overall mattress. Consequently, there is provided a resilient mattress core, that provides an alternative to known sprung units, and that does not include springs.

A particularly suitable mattress core is further illustrated with reference to Figures 1 to 3. Referring firstly to Figure 1, there is shown a unit 2 comprising a plurality of discrete elongate pockets 4, 6, 8, 10 and 12.

Each pocket is suitably formed by joining a first sheet portion to a second, overlaying sheet portion along two spaced, parallel joins. The joins need not necessarily be continuous. The joins may be formed by any known method, for instance welding, stitching or other means, though ultrasonic welding has been found to be particularly suitable. Consequently, the cavity is formed by the two ns sheet portions that extend between the joins. The two overlaying sheet portions may be formed by separate sheets of fabric or other material or they may be formed by ** .* * folding over a single sheet of fabric or other material.

S.. 555 * In the latter case, one of the spaced, parallel joins is : °. 25 not required and is instead replaced by the fold in the 0S* I single sheet. * S

Each pocket is filled with pieces of resilient material such as crumbed foam or other suitable particulate material. Preferably, the material is arranged to be compressed within the pockets such that walls of the pockets are maintained in a state of tension. It will be appreciated that each pocket may be enclosed by forming end joins between the two spaced, parallel joins in order to completely maintain the resilient pieces within the pocket. This may be desirable to keep the material from spilling from the pockets during use or the further manufacturing process.

As shown in Figure 2, suitably, the pockets are juxtaposed such that the joins between overlaying sheet portions are arranged in a side-by side relationship.. Thus, whilst the pockets may be formed independently and subsequently joined in the juxtaposed arrangement, it is preferable that two or more adjacent pockets are formed from the same overlying sheet portions. For instance, it is preferable if two or more spaced parallel joins are made in order to form two or more pockets. Here the pockets are formed by longitudinally welding or otherwise securing together upper and lower layers 14 and 16 of fabric or other suitable material, the joining lines being indicated by the reference numerals 18, 20, 22, 24 and 26.

The substantially planar panel formed by the plurality of OS� elongate pockets can serve as a resilient core, for the * **.** * purposes of this invention. However, this embodiment provides further that a mattress core 20 can be formed by folding the unit 2. Referring to Figure 2, here, each elongate pocket is folded along lateral lines in concertina fashion. Here, at each lateral fold, each elongate pocket is arranged such that one side of the pocket is folded back on its self so that two spaced locations on the same layer 14, 16 are arranged to lie substantially face-to-face. The concertina fashion is achieved by alternating the layer of the pockets that lies substantially face-to-face. For instance, moving from Figure 1 to figure 2, the lower overlaying layer 16 is brought into face-to-face contact at the first lateral fold, and at the next lateral fold the upper overlaying layer 14 is brought into face-to-face contact. This is repeated for the number of lateral folds until a fan-folded mattress core 20 is formed.

Consequently as shown in Figure 3, a mattress core 20 for a mattress suitable for beds, divan beds, pillows, and other articles such as furniture, seats and cushions, is provided. Advantageously, the resulting core thus comprises a plurality of juxtaposed discrete pockets or portions which nevertheless are formed as a continuous member.

If desired, the layers 14 and 16 of the unit 2 of Figure 1, prior to the unit being folded in concertina fashion to form the mattress core 2, may be laterally welded or otherwise secured together so as to define the lines of fold. Sn.

Whilst the described embodiment of the invention specifies * *05S* * the use of a multi-pocketed elongate unit 2, it will be appreciated that the unit 2 may be a single elongate pocket filled with crumbed foam or other particulate material. * S. * * . *. .

*: The core and method of forming a core herein described may be formed by any suitable forming apparatus. However, a particularly suitable forming apparatus will now be described in relation to Figures 4 to 8. Whilst the forming apparatus is particularly suitable for forming a mattress core as herein described, it will be appreciated that the forming apparatus may be suitable for forming other products.

In an exemplary embodiment of the forming apparatus, a forming apparatus is provided to form a lower layer or web having two or more spaced lanes or strips of pieces of resilient material and overlaid by an upper layer or web.

Here, the forming apparatus includes a hopper for stowing pieces of resilient material and means to stow the upper and lower webs. A means to advance the webs and pieces of resilient material towards an outlet of the forming apparatus is also provided. The upper and lower webs are advanced so that the upper web overlies the lower web.

The hopper feeds the pieces of particulate material onto one of the webs so that when said web is advanced, the pieces of resilient material are also advanced. The apparatus includes at least one dividing means to divide the pieces of resilient material into spaced lanes. The apparatus further includes means to secure the upper and lower webs in at least two joins, wherein a join is formed in an area either side of the spaced lanes of pieces of resilient material. The joins may be continuous or may * ***** * include gaps. *

* ** S.. * S

A particularly suitable forming apparatus 30 is further * illustrated with reference to Figures 4 to 8. Referring :.: . firstly to Figure 4, the apparatus comprises a hopper 32 for receiving pieces of resilient material such as crumbed foam or other particulate material (not shown) . The hopper is arranged to feed the pieces of resilient material in a downward direction under gravity. A positive feeding pressure may be applied if required.

Means to stow the upper and lower webs are not shown in the Figures. Suitably, however, the means may comprise upper and lower bobbins that are arranged to stow the upper and lower webs in a horizontal direction. The bobbins may be mounted to rotate about their axis such that the upper and lower webs may be unwound. The bobbins can either be mounted within the hopper or away there from. Suitably, the upper and lower webs are arranged within the hopper so that the bobbins or guides are mounted spaced from each other such that the lower bobbin or guide is spaced further from the outlet than the upper bobbin or guide. As well as being spaced further from the exit with respect to the direction of the advancing means the upper bobbin or guide may also be spaced from the lower bobbin or guide with respect to the direction of feed of the material from the hopper. So in the case where the hopper is gravity fed, the upper bobbin or guide is also spaced above the lower bobbin or guide.

The means to advance the upper and lower webs are suitably respectively upper, and lower, transportation means * *..

arranged one above the other. Here, at one end, the upper * and lower transportation means are arranged with a space there between to accommodate the lanes of material. At the other end, the upper and lower transportation means may be spaced further apart to encourage material to flow there between. As shown in the Figures the upper and lower transportation means suitably comprise endless belt sets 34 and 36 which are driven by a servo drive 38 and gearing 40. As will best be seen from Figure 5, the upper belt 34 is preferably inclined with respect to the lower belt 36 so that when the crumbed foam or other particulate material is fed from the hopper 32 it will be gradually compressed. To assist in the compression, cone-shaped members 42 may be prcvided between the belts as described below. Preferably the lower belt set 36 may be arranged substantially horizontally. Each belt set 34, 36 includes end rollers 44, 46. One of each of the end rollers 44 is arranged towards the outlet and are spaced so as to set the height of the lanes of the pieces of resilient material. The other one of each of the end rollers 46 is arranged in communication with the hcpper. The end roller 46 of the upper belt set 34 is arranged to be spaced from the end roller of the lower belt 36. As well as being spaced further from the outlet with respect to the direction of the advancing means the end roller 46 of the upper belt set 34 may also be spaced from the end roller 46 of the lower belt set 36 with respect to the direction of feed of the material from the hopper 32. It will be appreciated therefore that the end rollers 46 may also form the guides for the upper and lower webs.

Preferably, as shown in Figure 7, the dividing means divides the pieces of resilient material into spaced lanes S... part way along the advancing means. Consequently, the * S....

* upper and lower webs are continued to be advanced by the ri advancing means after the dividing means begins.

Therefore, each belt set 34, 36 suitably comprises a plurality of belts (for instance 34a, 34b, 34c etc.).

Here the dividing means is shown as two or more dividers 50. Each divider includes a finger 52 that preferably projects from the forward end of the hopper 32. The plurality of arms or fingers 54 serves to divide the crumbed foam or other particulate material into lanes or strips. The fingers 52 extend between the off-set between the end of the upper and lower transportation means (for instance between the gap in rollers 44) . However, a gap is maintained to allow the upper and lower webs to be guided either side of the fingers 52. Preferably, the dividers may also include cone-shaped members 42. The cone-shaped members are shown in Figure 7 as being formed to join parts of the dividers filling the gap between the belts in the upper belt set and parts of the dividers filling the gap between the belts in the lower belt set.

The cone-shaped members 42 are arranged to have a smaller width facing the material relative to its movement. Thus the cone-shaped members 42 encourage the material to divide into the lanes. Again, the upper and lower webs are guided either side of the cone-shaped members. It will be appreciated that the gap is kept to a minimum to force all pieces of resilient material to separate either side of the divider.

In operation, pieces of resilient material such as crumbed foam or other particulate material is fed into the hopper 2 and the belts 4 and 6 are set in motion which, in addition to feeding the crumbed foam or other material in the direction of arrow X in Figure 5, also feeds the upper * and lower webs of fabric or other suitable material in the same direction. Thus the upper and lower webs are between the belts 4 and 6, the crumbed foam or other particulate material lies between the upper and lower webs.

Continued advancement of the webs and crumbed foam or other particulate material in the direction of arrow X causes the foam or other material to be compressed. In this compressed state, the webs and foam or other material encounter the arms or fingers 14, so that, as they continue in the direction of arrow X, the foam or other particulate material is divided into strips or lanes and the webs are separated laterally -the webs retaining their integrity -so that there is formed a plurality of strips of crumbed foam lying between the upper and lower webs.

Continued advancement moves the webs and foam or other material along a bed or table (not shown) and towards a welding or other suitable station or stations where the webs are secured together. The webs are secured longitudinally and may also be secured laterally so as to form a plurality of discrete pockets each containing an amount of the pieces of resilient material.

Where the resultant product is to be used as a core for a mattress or other upholstered unit, the product may be fan-folded in concertina fashion (as herein described) prior to being incorporated into the mattress or other unit.

Although preferred embodiment(s) of the present invention have been shown and described, it will be appreciated by * ** * ** * those skilled in the art that changes may be made without departing from the scope of the invention as defined in 2 h SI.... * S

Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance, it should be understood that the applicant claims protection in respect of any patentable feature or combination of features referred to herein, and/or shown in the drawings, whether or not particular emphasis has been placed thereon.

Claims

Claims 1. A resilient core, the core comprising at least one elongate pocket substantially filled with pieces of resilient material.
2. A resilient core according to Claim 1 comprising a plurality of juxtaposed, discrete columns, wherein two or more of the columns are formed from a single filled, elongate pocket folded across the pocket's elongate axis and secured in position.
3. A core according to Claim 1 or Claim 2, wherein the pieces of resilient material are maintained in a compressed form.
4 A core according to any of Claims 1 to 3, wherein each elongate pocket is formed from a first web joined to a second web.
5. A core according to Claim 4, wherein two or more * parallel pockets are formed by the first web joined to the * second web in at least two spaced, parallel locations. * *
6. A core according to any preceding claim wherein the pocket is folded in a plurality of lateral folds so that the filled, elongate pocket is fan-folded.S..... * .
7. A core according to any preceding claim wherein one or more separate, filled and folded elongate pockets are secured together.
8. A core according to Claim 2, wherein the juxtaposed columns have first and second ends, and wherein at least the first ends are arranged in a common plane
9. A core according to Claim 8, wherein the second ends are arranged in a common, second plane that is spaced from the first common plane.
10. A method of forming a resilient core, the method comprising forming an elongate pocket and filling the elongate pocket with pieces of resilient material.
11. A method according to Claim 10 wherein the method comprises the step of folding the elongate pocket in a lateral fold to form two juxtaposed columns of pieces of resilient material.
12. A method according to Claim 11, wherein the method comprises the step of compressing the pieces of resilient material and encapsulating the resilient material whilst still in a compressed state.* ***** *
13. A method according to Claim 11 or 12, wherein the method comprises forming the elongate pocket by joining a first web to a second overlying web.
14. A method according to Claim 13 wherein the method comprises forming two or more parallel elongate pockets by forming two or more spaced, parallel joins between the webs.
15. A method according to any of Claims 11 to 14, wherein the method comprises fan-folding each elongate pocket by forming two or more lateral folds.
16. The method of any of Claims 11 to 15 wherein the method comprises securing two or more filled and folded elongate pockets together.
17. A resilient core or method of forming a resilient core substantially as herein described with reference to the Figures. 0s** * S ****S* *5* SI * SS*.ISe. * *SSSSSSS * S * 55 5* 5 S.* SSS S