EP3135630B1 - Perfectionnements apportés à des ensembles à ressorts internes - Google Patents

Perfectionnements apportés à des ensembles à ressorts internes Download PDF

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Publication number
EP3135630B1
EP3135630B1 EP16185360.1A EP16185360A EP3135630B1 EP 3135630 B1 EP3135630 B1 EP 3135630B1 EP 16185360 A EP16185360 A EP 16185360A EP 3135630 B1 EP3135630 B1 EP 3135630B1
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EP
European Patent Office
Prior art keywords
coil springs
plies
operative axis
coil spring
axis
Prior art date
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EP16185360.1A
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German (de)
English (en)
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EP3135630A1 (fr
Inventor
Ian James Whitworth
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Springform Technology Ltd
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Springform Technology Ltd
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Publication of EP3135630A1 publication Critical patent/EP3135630A1/fr
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G9/00—Placing upholstery springs in pockets; Fitting springs in upholstery
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G9/00—Placing upholstery springs in pockets; Fitting springs in upholstery
    • B68G2009/005—Devices for turning the springs 90° inside the pockets

Definitions

  • the present invention relates to innerspring assemblies, and more particularly to methods and apparatus for forming innerspring assemblies comprising pocketed coil springs.
  • Pocketed coil springs which are coil springs enclosed within pockets of fabric, are widely used in the manufacture of innerspring assemblies for mattresses, cushions and the like.
  • An innerspring assembly of appropriate dimensions for a mattress can be built up by placing appropriate lengths of pocketed coil springs, commonly referred to as strings, side by side and adhering them together, eg with adhesive, such that the coil springs are arranged in a regular array, with operative axes that are substantially parallel to one another.
  • the operative axes of the coil springs are typically arranged perpendicularly to the upper surface of the innerspring assembly or mattress.
  • apparatus for manufacturing pocketed coil springs comprising a retention mechanism for retaining first and second plies of material relative to an operative axis of the apparatus, and providing relative movement between the plies of material and an insertion mechanism, along the operative axis of the apparatus, between each actuation of the insertion mechanism, and the insertion mechanism having at least a first insertion member and a second insertion member, wherein, upon each actuation of the insertion mechanism, the first insertion member inserts a first coil spring between the plies of material to a first location on a first side of the operative axis of the apparatus, and the second insertion member inserts a second coil spring between the plies of material to a second location on a second, opposite side of the operative axis of the apparatus, and at a different position on the operative axis of the apparatus relative to the first location, such that the first and second coil springs inserted by the first and second insertion members are arranged diagonally between
  • the apparatus and method of manufacture according to the present invention are advantageous principally as the coil springs that are inserted by the first and second insertion members, during actuation, are diagonally arranged between the plies of material, to each side of the operative axis.
  • successive actuations of the insertion mechanism and relative movement between the plies of material and the insertion mechanism, between each actuation of the insertion mechanism arranges the coil springs in two rows between the plies of material, either side of the operative axis.
  • more than two coil springs may be inserted in a diagonal arrangement, for example by more than two insertion members, to provide an arrangement with more than two rows of coil springs.
  • This apparatus and method of manufacture therefore enable separate insertion members to operate together, eg simultaneously, to provide two or more rows of co-axially aligned coil springs between the plies of material, without the need for either a single insertion member to insert more than one spring, or two or more insertion members to be operative along the same axis.
  • the apparatus of the present invention therefore enables efficient manufacture of innerspring assemblies comprising co-axially aligned pocketed coil springs, without the need for complex modifications of existing apparatus for manufacturing pocketed coil springs.
  • the retention mechanism and the insertion mechanism may both form part of an encapsulation section of the apparatus, in which the coil springs are inserted between the first and second plies of material, which are then joined together to form pockets about the coil springs, eg with each pocket enclosing a coil spring.
  • the apparatus for manufacturing pocketed coil springs may also comprise a coiling section in which a coil spring is formed from wire fed to the coiling section.
  • the coiling section may comprise a wire feed, and coiling elements whose position and/or orientation determines the form of the coil spring.
  • the insertion members of the insertion mechanism may each receive coil springs from the same source, eg the same coiling section.
  • at least two of the insertion members may receive coil springs from different sources, eg first and second coiling sections.
  • the first insertion member may receive coil springs from a first source, eg a first coiling section
  • the second insertion member may receive coil springs from a second source, eg a second coiling section.
  • the transfer of coil springs from different sources, eg first and second coiling sections, to the insertion members facilitates the manufacture of pocketed coil springs in which a row of coil springs have different characteristics to another row of coil springs, for example.
  • the first coil spring inserted by the first insertion member may have different characteristics relative to the second coil spring inserted by the second insertion member.
  • This may provide an innerspring assembly in which a first layer of pocketed coil springs have different characteristics to a second layer of pocketed coil springs.
  • the characteristics of the coil springs in the outer layer may be different to the characteristics of the coil springs in at least one inner layer.
  • the coil springs in each layer may be uniform, or may have different characteristics, for example in order to provide different characteristics across the innerspring assembly, eg in zones.
  • the differing characteristics of the coil springs may, for example, be any, or any combination of, pitch, number of turns, resistance to deformation or compression, material, length of the spring, diameter of the spring, diameter of the spring member, strength, direction of turn rotation about the axis of compression.
  • the apparatus may comprise a further insertion member for insertion of a further coil spring between the plies of material.
  • the further coil spring may be inserted on an opposite side of a further operative axis of the apparatus relative to the first and/or second coil spring, and may be inserted at a different position on the operative axis of the apparatus relative to the first location and or second location, such that the first, second and third coil springs inserted by the first, second, and third insertion members are arranged diagonally between the plies of material relative to the operative axes of the apparatus.
  • the insertion mechanism may comprise an insertion member for each coil spring to be inserted between the first and second plies of material in each actuation of the insertion mechanism. For example, where three coil springs are to be inserted in each actuation of the insertion mechanism, the insertion mechanism may comprise three insertion members.
  • the apparatus may be configured to move coil springs from the coiling section to the encapsulation section.
  • the coil springs may be loaded onto successive radial arms of a rotating wheel.
  • the apparatus may be configured to compress the coil springs as they are being transported from the coiling section to the encapsulation section.
  • the coil springs may be substantially fully compressed when inserted between the plies of material.
  • the first and second plies of material may be held in juxtaposed relation by the retaining mechanism.
  • the first and second plies of material may be retained substantially parallel to each other.
  • the first and second plies may be generally rectangular in shape, and may have central longitudinal axes and/or longitudinal edges that are parallel to the operative axis of the apparatus. Where two rows of coil springs are inserted between the first and second plies of material, the operative axis of the apparatus may have substantially the same transverse position as the central longitudinal axes of the first and second plies of material.
  • the first and second plies of material may be formed by folding of a single sheet of material.
  • the folded sheet of material may therefore define an entrance, between the first and second plies of material, through which the coil springs are inserted.
  • the material may be any appropriate material, for example any type of fabric.
  • the material may be either a non-woven or woven fabric.
  • the pockets in the fabric may be formed by any suitable means. Such means include stitching, but it is preferred to form the pockets by thermal welding of the two sheets of material.
  • the material may be a fabric that is thermoplastic, and in particular it may be a non-woven thermoplastic material.
  • One suitable material is a non-woven polypropylene.
  • the relative movement between the plies of material and the insertion mechanism, between each actuation of the insertion mechanism, may be a pre-determined distance.
  • the pre-determined distance may correspond substantially to the width of material that will form each pocket, eg around 1.5 times the largest diameter of the coil springs.
  • the first and second plies of material may be movable relative to the insertion members, eg by use of feed rollers, such that the insertion members have a fixed position on the operative axis.
  • This arrangement may be cheaper and/or less complex than an arrangement in which the insertion members are movable relative to fixed first and second plies of material, primarily as less control of the insertion means is required, and the apparatus may be smaller than the string of pocketed coil springs being manufactured.
  • the material may drawn through the encapsulation section by means of feed rollers.
  • the material may pass between a pair of horizontally disposed rollers, one of which is driven by a servo motor.
  • the rollers may have rubberised surfaces to improve engagement of the rollers with the fabric.
  • the retention mechanism may index the first and second plies of material forward a distance equal to one pocket.
  • the next two springs may then be encapsulated, and so on, so as to form a continuous string of pocketed coil springs.
  • Each insertion member may be configured to receive a single coil spring at a time. This may reduce the cost and complexity of the apparatus, principally as only a single coil spring needs to be fed to an insertion member at any one time. Each insertion member may be configured to insert a single coil spring at a time between the first and second plies of material.
  • the insertion members may be orientated generally perpendicularly relative to the operative axis of the apparatus and/or a longitudinal axis of the first and second plies of material.
  • the insertion members may be movable relative to the operative axis of the apparatus and/or the first and second plies of material. This movement of the insertion members may be at an oblique angle relative to operative axis of the apparatus, eg in a substantially transverse direction. This movement may be effected by a servo motor or the like.
  • Each insertion member may be movable with a reciprocating action, eg between a retracted position in which a coil spring is received, and an extended position in which a coil spring is released.
  • Each of the insertion members may include retaining formations for retaining respective coil springs in a position appropriate to insert the coil springs to their respective locations relative to the operative axis and/or further operative axis of the apparatus. This may be achieved by means of insertion members of the same or similar length, with retaining formations that are located at different positions on the insertion members, eg at different transverse positions relative to the operative axis of the apparatus. Alternatively, the insertion members may extend transversely relative to the operative axis of the apparatus by different distances.
  • the insertion members may be separated, in the direction of the operative axis of the apparatus, such that the coil springs are inserted to their respective locations.
  • Each insertion member may be adapted to retain a coil spring in a compressed configuration during insertion of the coil spring into the open pocket of material.
  • the insertion member may therefore comprise retention formations, between which the compressed coil spring is held.
  • the resilient action of the coil spring on the retention formations may be sufficient to retain the coil spring.
  • the insertion member may be generally tubular in form, with the retention formations being formed by the interior surfaces of the walls of the insertion member.
  • the insertion member may therefore have the form of a cassette.
  • the coil spring may be engaged with the insertion member by an engagement member that may push the coil spring into engagement with the insertion member, or that may extend through the coil spring and carry the coil spring into engagement with the insertion member.
  • the insertion member may include an opening, eg a slot, though which the engagement member may move, in order to facilitate engagement of the coil spring with the insertion member.
  • the apparatus may include means for separating the coil spring from the insertion member, once the coil spring has been inserted between the first and second plies of material, which may take the form of a separation mechanism.
  • the separation mechanism may comprise a capture member, which engages the coil spring once it has reached the desired location between the plies of material, and retains the coil spring in its location when the insertion member is moved to its retracted position.
  • the capture member may comprise a rod, arranged for reciprocating movement, which may pass through at least one of the plies of material. The capture member may therefore have a shape and/or a sufficiently small cross-section that the capture member may be removed, without damaging the material.
  • a single first coil spring and a single second coil spring may be inserted between the plies of material between each increment of relative movement between the plies of material and the insertion members.
  • a single coil spring for each of any additional insertion members may be inserted between the plies of material between each increment of relative movement between the plies of material and the insertion members.
  • the first coil spring and the second coil spring, and any further coil springs may be inserted substantially simultaneously.
  • the first and second insertion members, and any further insertion members may be moving at the same time, and may be synchronised.
  • the first insertion member inserts the first coil spring between the plies of material to a first location on a first side of the operative axis of the apparatus
  • the second insertion member inserts the second coil spring between the plies of material to a second location on a second, opposite side of the operative axis of the apparatus.
  • Further coil springs may be inserted between the plies of material to a location on an opposite side of a further operative axis of the apparatus relative to the first and/or second coil spring
  • the first location may be a centre point, eg the geometrical centre, of the first coil spring
  • the second location may be a centre point, eg the geometrical centre, of the second coil spring.
  • Further locations may be a centre point, eg the geometrical centre, of further coil springs.
  • the first and second locations may have a transverse separation relative to the operative axis.
  • the transverse separation may be a separation between longitudinal axes extending through the centre points, eg the geometrical centres, of the first and second coil springs, which longitudinal axes are parallel to the operative axis.
  • the transverse separation of the first and second coil springs may be greater than the sum of the radii of the first and second coil springs, and may be at least 1.2 times, at least 1.5 times or at least twice this distance.
  • first or second and further locations may have a transverse separation relative to the further operative axis.
  • the transverse separation may be a separation between longitudinal axes extending through the centre points, eg the geometrical centres, of the first or second and further coil springs, which longitudinal axes are parallel to the further operative axis.
  • the transverse separation of the first or second and further coil springs may be greater than the sum of the radii of the first or second and further coil springs, and may be at least 1.2 times, at least 1.5 times or at least twice this distance.
  • the first coil spring may have a boundary axis that is the tangential line that is parallel to the operative axis and closest to the second coil spring
  • the second coil spring may have a boundary axis that is the tangential line that is parallel to the operative axis and closest to the first coil spring, wherein the boundary axes of the first and second coil springs are separated.
  • the separation between the boundary axes of the first and second coil springs may be at least 20% of, at least 50% of, or at least equal to, the sum of the radii of the first and second coil springs.
  • Further coil springs may have a boundary axis that is the tangential line that is parallel to the further operative axis and closest to the first or second coil spring. Boundary axes of the further and first or second coil springs may be separated, and may, for example, be separated by at least 20% of, at least 50% of, or at least equal to, the sum of the radii of the first and further coil springs, or the sum of the radii of the second and further coil springs.
  • the transverse separation of the first and second coil springs, and the separation between the boundary axes of the first and second coil springs, may be sufficient to form a dividing wall between adjacent first and second coil springs of successive actuations of the insertion mechanism, eg by joining the first and second plies of material between the adjacent coil springs.
  • the transverse separation of the first or second and further coil springs, and the separation between the boundary axes of the first or second and further coil springs, may be sufficient to form a dividing wall between adjacent first or second and further coil springs of successive actuations of the insertion mechanism, eg by joining the first and second plies of material between the adjacent coil springs.
  • the first, second and further coil springs are inserted between the plies of material to the first, second, and further locations, which are at different positions on the operative axis and/or further operative axis of the apparatus.
  • the position of the first location on the operative axis may be the point at which a transverse axis of the first coil spring intersects with the operative axis, the transverse axis extending between a centre point, eg the geometrical centre, of the first coil spring and the operative axis, and being orthogonal relative to the operative axis.
  • the position of the second location on the operative axis may be the point at which a transverse axis of the second coil spring intersects with the operative axis, the transverse axis extending between a centre point, eg the geometrical centre, of the second coil spring and the operative axis, and being orthogonal relative to the operative axis.
  • the position of the further location on the further operative axis may be the point at which a transverse axis of the further coil spring intersects with the further operative axis, the transverse axis extending between a centre point, eg the geometrical centre, of the further coil spring and the further operative axis, and being orthogonal relative to the further operative axis.
  • the first and second coil springs may have a longitudinal separation that is the distance between the positions of the first and second coil springs on the operative axis.
  • the longitudinal separation of the first and second coil springs may be greater than the sum of the radii of the first and second coil springs, and may be at least 1.2 times, at least 1.5 times or at least twice this distance.
  • the first or second and further coil springs may have a longitudinal separation that is the distance between the positions of the first or second and further coil springs on the further operative axis.
  • the longitudinal separation of the first or second and further coil springs may be greater than the sum of the radii of the first or second and further coil springs, and may be at least 1.2 times, at least 1.5 times or at least twice this distance.
  • the first coil spring may have a boundary axis that is the tangential line that is orthogonal to the operative axis and closest to the second coil spring
  • the second coil spring may have a boundary axis that is the tangential line that is orthogonal to the operative axis and closest to the first coil spring, wherein the boundary axes of the first and second coil springs are separated.
  • the separation between the boundary axes of the first and second coil springs may be at least 20% of, at least 50% of, or at least equal to, the sum of the radii of the first and second coil springs.
  • Further coil springs may have a boundary axis that is the tangential line that is orthogonal to the further operative axis and closest to the first or second coil spring. Boundary axes of the first or second coil springs and the further coil spring may be separated. The separation between the boundary axes of the first or second and further coil springs may be at least 20% of, at least 50% of, or at least equal to, the sum of the radii of the first or second and further coil springs.
  • the longitudinal separation of the coil springs, and the separation between the boundary axes of the coil springs, may be sufficient to form a dividing wall between adjacent first coil springs and between adjacent second coil springs, and between adjacent further coil springs of successive actuations of the insertion mechanism, eg by joining the first and second plies of material between the adjacent coil springs.
  • the longitudinal separation between the first and/or second and/or locations, and hence the longitudinal separation between the inserted coil springs, in the direction of the operative axis and/or further operative axis may be substantially equal to each increment of the relative movement between the plies of material and the insertion mechanism, between each actuation of the insertion mechanism.
  • the retention mechanism and the insertion mechanism may both form part of an encapsulation section of the apparatus, in which the coil springs are inserted between the first and second plies of material, which are then joined together to form pockets about the coil springs, eg with each pocket enclosing a coil spring.
  • the apparatus, and specifically the encapsulation section may be configured to join the first and second plies of material in a manner that encapsulates each coil spring in a pocket of material.
  • the mechanism for joining the two plies of material may comprise any conventional mechanisms for that purpose.
  • two plies of material are formed by a sheet of weldable material, eg fabric
  • the welding of the two sheets of material may be carried out in any suitable fashion, eg using ultrasonic welding.
  • the welds may be interrupted, rather than continuous.
  • each pocket in the row of coil springs adjacent to the fold may be formed by applying two transverse welds that are orientated substantially transversely to the operative axis, at either side of the coil spring, and an axial weld that is substantially aligned with the operative axis, on the other side of the spring from the fold.
  • Each pocket in the other row of coil springs may therefore be formed in a similar manner, by applying two transverse welds that are orientated substantially transversely to the operative axis, at either side of the coil spring, and an axial weld that is substantially aligned with the operative axis, on the other side of the spring from the fold.
  • the apparatus may therefore comprise both axial and transverse joining members, which may take the form of welding members.
  • the welding members may be slidably mounted on suitable guide rails and may be driven by a suitable rack and pinion mechanism or the like.
  • the required position of the welding members may be calculated automatically by a controller, and the position of the welding members may be altered automatically, or the required position may be displayed and the welding members positioned manually.
  • the apparatus may comprise a mechanism for moving the coil springs encapsulated within pockets of material.
  • the apparatus may comprise a mechanism for rotating the coil springs, eg about a rotation axis that is substantially parallel to the operative axis of the apparatus.
  • the first and second coil springs may be inserted between the first and second plies of material with their operative axes being juxtaposed and substantially parallel.
  • the apparatus may rotate the first and second coil springs by about 90°, such that the operative axes of transversely adjacent coil springs are substantially aligned, eg substantially transversely across the two plies of material.
  • the apparatus may include one or more worm gears which rotate transversely to the direction of travel of the completed pockets, and which serves to orient the springs as they expand within the pockets.
  • the continuous string of pocketed coil springs may then be severed to form separate strings of pocketed coil springs suitable for forming an innerspring assembly for a mattress, a cushion, or the like.
  • Figure 1 shows a first coiling unit, generally designated 10, and a first insertion mechanism 1a of the apparatus according to the invention.
  • the first insertion mechanism 1a comprises a counter-clockwise rotating wheel 11a with eight radially extending arms 12a.
  • Springs 20a produced in the first coiling unit 10 are fed to a conveyor (not shown), which subsequently feeds the springs 20a automatically onto the arms 12a.
  • the path travelled by the springs 20a along the conveyor may allow the springs 20a time to cool from any heat treatment they may have received during the coiling process.
  • the arms 12a carrying the springs 20a move through longitudinal slots in a pair of compression plates 13a,14a, the space between which is progressively reduced, causing the springs 20a to be compressed.
  • the terminal portions of the compression plates 13a,14a are disposed parallel and horizontally so as to constitute a delivery chute from which the compressed springs 20a are delivered to a reciprocating cassette 15a which moves as indicated by the double-headed arrow.
  • the cassette 15a transfers the springs 20a to an encapsulation unit and in particular to the space between the two leaves of a folded sheet of non-woven fabric 25 (shown in broken lines).
  • a pneumatically driven rod When the cassette 15a is located between the leaves of fabric 25, a pneumatically driven rod is raised and engages the spring 20a through the lower leaf and a slot in the base of the cassette 15a. This rod retains the spring 20a in position when the cassette 15a is withdrawn from the fabric 25.
  • the insertion mechanism of the apparatus further comprises a second insertion mechanism 1b, which is substantially identical in form to the first insertion mechanism 1a shown in Figure 1 , with like features denoted by common reference numerals with the suffix "b", and receives springs 20b from a second coiling unit in a similar manner at the same time as the first insertion mechanism 1a receives springs 20a from the first coiling unit 10.
  • the difference between the first 1a and second 1b insertion mechanisms is that the reciprocating cassette 15b of the second insertion mechanism 1b is configured to extend to a different location within the leaves of fabric 25, relative to the first insertion mechanism 1a, such that the springs 20a,20b delivered by the first 1a and second 1b insertion mechanisms are delivered to different transverse locations between the leaves of fabric 25, as discussed in more detail below.
  • the reciprocating cassette 15b of the second insertion mechanism 1b is shorter and configured to extend to a proximal transverse location within the leaves of fabric 25, whereas the reciprocating cassette 15a of the first insertion mechanism 1a is longer and configured to extend to a distal transverse location within the leaves of fabric 25, such that the springs 20a,20b delivered by the first 1a and second 1b insertion mechanisms are delivered to locations on either side of a central operative axis between the leaves of fabric 25, and the springs 20a,20b are therefore arranged diagonally relative to the central operative axis.
  • the second insertion mechanism 1b is disposed in a more advanced position, relative to the direction of travel of the fabric 25 (along an operative axis of the apparatus), relative to the first insertion mechanism 1a, such that the springs 20b from the second coiling unit are located in a more advanced position, between the leaves of fabric 25, than the springs 20a from the first coiling unit, on each actuation of the insertion mechanisms 1a, 1b.
  • This arrangement is shown schematically in Figure 3 , with the direction of travel of the fabric 25 denoted by arrow A.
  • first 1a and second 1b insertion mechanisms are disposed upon a common axis of rotation 21 such that the second insertion mechanism 1b is disposed in a more advanced position, relative to the direction of travel of the fabric 25, to the first insertion mechanism 1a.
  • the insertion mechanisms 1a, 1b rotate synchronously about the common axis of rotation 21.
  • electromagnets 27a,27b (see Figure 2 ) mounted on the topmost parts of the upper compression plates 13a,13b, either side of the longitudinal slots 28a,28b running down the centre of that compression plates 13a,13b.
  • a further electromagnet 27c is located on a common compression plate 13 c, which is disposed between the compression plates 13a, 13b so as to define the slots 28a,28b.
  • the electromagnets 27a,27b,27c hold each spring 20a,20b as it exits the coiling units until the corresponding arm 12a,12b of the wheels 11a, 11b transport the springs 20a,20b away.
  • Figure 4 shows the encapsulation unit 40 of the apparatus according to the invention, the operative axis of which is disposed perpendicularly to that of the coiling unit 10.
  • the sheet 25 of fabric is folded by conventional means (not shown) and fed through the encapsulation unit 40 from right to left, as viewed in Figure 4 , in incremental steps.
  • the sheet 25 passes firstly between a pair of guide rollers 41.
  • a fixed separating guide (not shown) then parts the two leaves of the sheet 25 sufficiently for springs 20a,20b to be inserted between them by the reciprocating cassettes 15a,15b of the first and second insertion mechanisms.
  • the first insertion mechanism 1a may be configured to insert a single spring 20a between the two leaves of the sheet 25, as shown in Figure 5(a) .
  • the spring 20a is inserted such that it is located in a distal transverse region of the sheet 25.
  • the sheet 25 is then advanced by one increment along the operative axis of the apparatus, this increment being equal to the width of fabric required for each pocket.
  • This initial insertion step may be included in order to ensure that the leading element of the string of pocketed coil springs being manufactured contains two co-axial pocketed coil springs. Alternatively, this initial insertion step could be omitted, and the leading element of the string of pocketed coil springs, which would only contain one pocketed coil spring (as will be evident from the description below), could be severed from the string.
  • the first 1a and second insertion 1b mechanisms simultaneously insert springs 20a,20b into the sheet 25, as shown in Figure 5(b) .
  • spring 20a is located in a distal transverse region of the sheet 25, whilst spring 20b is located in a proximal transverse region of the sheet 25.
  • the reciprocating cassette 15b of the second insertion mechanism 1b extends to a proximal transverse location within the leaves of fabric 25, whereas the reciprocating cassette 15a of the first insertion mechanism 1a extends to a distal transverse location within the leaves of fabric 25, such that the springs 20a,20b delivered by the first 1a and second 1b insertion mechanisms are delivered to locations on either side of a central operative axis between the leaves of fabric 25, and the springs 20a,20b are therefore arranged diagonally relative to the central operative axis.
  • the sheet 25 is then advanced by another increment, and the insertion step described above with reference to Figure 5(b) is repeated, as shown in Figure 5(c) .
  • the sheet 25 is then advanced by another increment, and the insertion step described above with reference to Figure 5(b) is repeated again, as shown in Figure 5(d) .
  • Successive movements of the sheet 25 and insertion steps, in this manner insert springs 20a,20b into the sheet 25 such that each spring 20a in a first row (the upper row as shown in Figure 5 ) shares a common axis with a spring 20b in a second row (the lower row shown in Figure 5 ).
  • the second insertion mechanism 1b may be configured to insert a single spring 20b between the two leaves of the sheet 25.
  • the spring 20b would be inserted such that it is located in a proximal transverse region of the sheet 25.
  • This final insertion step may be included in order to ensure that the trailing element of the string of pocketed coil springs being manufactured contains two co-axial pocketed coil springs.
  • this final insertion step could be omitted, and the trailing element of the string of pocketed coil springs, which would only contain one pocketed coil spring, could be severed from the string.
  • the springs 20a,20b While the springs 20a,20b are being inserted into the sheet 25, the springs 20a,20b are maintained in a compressed condition by a cover plate 42 which, together with the bed of the encapsulation unit 40, defines a channel through which the encapsulated springs 20a,20b are transported.
  • the two leaves of the sheet 25 are joined by transverse welds formed by a first reciprocating welding horn 43. Further welding horns 44a,44b form longitudinal welds, which complete the encapsulation of the springs 20a,20b.
  • the first reciprocating welding horn arrangement 43 is used to form a transverse weld across the sheet 25 prior to insertion of springs 20a,20b (this step is not shown). Then, after the sheet 25 has been advanced by one increment, the first reciprocating welding horn arrangement 43 is used to apply another transverse weld to the sheet 25, such that transverse welds are formed either side of a first pair of springs 20a,20b, as shown in Figure 6(a) .
  • the sheet 25 is moved along by one increment, and the first 44a of the further welding horns applies a weld longitudinally along the sheet 25 between the first pair of springs 20a,20b, as shown in Figure 6(b) .
  • the sheet 25 is moved along by one further increment, and the second 44b of the further welding horns applies a weld longitudinally along an open edge of the sheet 25 in the region of the first pair of springs 20a,20b, as shown in Figure 6(c) .
  • the first pair of springs 20a,20b are sealed within sub-pockets of the sheet 25 via welds applied by the welding horns 43,44a,44b.
  • a second cover plate 45 extends from the region of the first welding horn arrangement 43, past the further welding horns 44a,44b, and also past a drive roller arrangement 46,47 which acts on the folded fabric sheet 25 so as incrementally to draw the sheet 25 through the encapsulation unit 40.
  • the drive roller arrangement 46,47 comprises a driven roller 46 which acts on the underside of the sheet 25 and a second roller 47 which is pneumatically pressurised into engagement with the upper surface of the sheet 25. Both rollers 46,47 have rubberised surfaces, the rubberised surface of the upper roller 47 being partly cut away to accommodate the second cover plate 45.
  • the finished product has the form of a string of co-axially aligned springs enclosed within pockets formed in the non-woven fabric, the pockets being connected at the weld lines which define the sides of the pockets.
  • Such a finished product is shown schematically in Figure 7 .
  • the finished strings can be assembled, for example via adhesive, to form an innerspring assembly as shown in Figure 8 .
  • the reciprocating motion of the first welding arrangement 43 and of the further welding horns 44a,44b is synchronised with the incremental actuation of the drive roller arrangement 46,47 under the control of a programmable logic controller (PLC).
  • PLC programmable logic controller
  • a second embodiment of apparatus according to the present invention is shown schematically in Figure 9 .
  • the second embodiment is substantially the same as the first embodiment, and differs in that it comprises three insertion mechanisms 100a, 100b, 100c. It will be recognised that embodiments comprising more than three insertion mechanisms may also be realised.
  • the insertion mechanisms 100a, 100b, 100c have substantially the same form as the first 1a and second 1b insertion mechanisms of the first embodiment of apparatus of the present invention. Each insertion mechanism receives springs from an associated coiling unit (not shown).
  • the second insertion mechanism 100b is disposed in a more advanced position, relative to the direction of travel of the fabric (along an operative axis of the apparatus), relative to the first insertion mechanism 100a, such that springs 102b from a second coiling unit are located in a more advanced position, between the leaves of fabric, than springs 102a from a first coiling unit, on each actuation of the insertion mechanisms 100a, 100b.
  • the third insertion mechanism 100c is similarly disposed in a more advanced position, relative to the direction of travel of the fabric (along an operative axis of the apparatus), relative to the second insertion mechanism 100b, such that springs 102c from a third coiling unit are located in a more advanced position, between the leaves of fabric, than springs 102b from a second coiling unit, and than springs 102a from a first coiling unit, on each actuation of the insertion mechanisms 100a, 100b.
  • FIG. 9 This arrangement is shown schematically in Figure 9 , with the direction of travel of the fabric denoted by arrow B.
  • the first 100a, second 100b, and third 100c, insertion mechanisms are disposed upon a common axis of rotation 104 such that the second insertion mechanism 100b is disposed in a more advanced position, relative to the direction of travel of the fabric , to the first insertion mechanism 100a, and such that the third insertion mechanism 100c is disposed in a more advanced position, relative to the direction of travel of the fabric, to the second insertion mechanism 100b.
  • the insertion mechanisms 100a, 100b, 100c rotate synchronously about the common axis of rotation 104.
  • the electromagnets 106a,106b, 106c,106d hold each spring 102a,102b,102c as it exits the coiling units until the corresponding arm of the wheels of the insertion mechanisms 100a, 100b, 100c transport the springs 102a, 102b, 102c away.
  • FIG 11 shows an insertion section of apparatus according to the second embodiment of the present invention.
  • the insertion section is substantially the same as the insertion section of the first embodiment of the present invention (as shown in Figure 4 ), and differs only in that three springs 102a,102b,102c are inserted and maintained in a compressed condition by a cover plate 112.
  • the springs 102a,102b,102c are inserted in a similar manner to the insertion steps shown in Figures 5(a)-(d) and Figures 6(a)-(e) .
  • the insertion mechanisms 100a, 100b, 100c simultaneously insert springs 102a,102b,102c into the sheet.
  • a first spring 102a is located in a distal transverse region of the sheet
  • a second spring 102b is located in a medial transverse region of the sheet
  • a third spring 102c is located in a proximal transverse region of the sheet.
  • Reciprocating cassettes of the insertion mechanisms 100a, 100b, 100c extend to different transverse locations within the leaves of fabric, such that the first 102a and second 102b springs are delivered to locations either side of a first operative axis of the apparatus, whilst the second 102b and third 102c springs are delivered to locations either side of a second operative axis of the apparatus.
  • the first 102a, second 102b, and third 102c springs are arranged diagonally relative to the first and second operative axes of the apparatus.
  • each spring 102a in a first row shares a common axis with a spring 102b in a second row, and a common axis with a spring 102c in a third row.
  • the welding procedure is substantially the same as the procedure described with reference to Figures 6(a)-(e) , and differs in the addition of a further longitudinal welding horn which applies a weld longitudinally along the sheet between the second 102b and third 102c springs.
  • the addition of this further longitudinal welding horn thereby allows the sheet to be formed into three distinct sub-pockets, each of which comprises a coil spring.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Wire Processing (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Claims (15)

  1. Appareil pour fabriquer des ressorts hélicoïdaux ensachés, l'appareil comprenant un mécanisme de retenue pour retenir des première et seconde couches de matériau (25) par rapport à un axe opérationnel (A) de l'appareil, et assurant un mouvement relatif entre les couches de matériau (25) et un mécanisme d'insertion (1a, 1b), le long de l'axe opérationnel (A) de l'appareil, entre chaque actionnement du mécanisme d'insertion (1a, 1b), et le mécanisme d'insertion (1a, 1b) ayant au moins un premier élément d'insertion (15a) et un second élément d'insertion (15b), lors de chaque actionnement du mécanisme d'insertion (1a, 1b), le premier élément d'insertion (15a) insérant un premier ressort hélicoïdal (20a) entre les couches de matériau (25) à un premier emplacement sur un premier côté de l'axe opérationnel (A) de l'appareil, et le second élément d'insertion (1b) insérant un second ressort hélicoïdal (20b) entre les couches de matériau (25) à un second emplacement sur un second côté opposé de l'axe opérationnel (A) de l'appareil, et à une position différente sur l'axe opérationnel (A) de l'appareil par rapport au premier emplacement, de sorte que les premier et second ressorts hélicoïdaux (20a, 20b) insérés par les premier et second éléments d'insertion (1a, 1b) soient disposés en diagonale entre les couches de matériau (25) par rapport à l'axe opérationnel (A) de l'appareil.
  2. Appareil selon la revendication 1, les premier et second ressorts hélicoïdaux ayant une séparation longitudinale qui est la distance entre les positions des premier et second ressorts hélicoïdaux sur l'axe opérationnel, et la séparation longitudinale des premier et second ressorts hélicoïdaux étant supérieure à la somme des rayons des premier et second ressorts hélicoïdaux, ou au moins 1,2 fois, au moins 1,5 fois ou au moins deux fois cette distance.
  3. Appareil selon la revendication 1 ou 2, le premier ressort hélicoïdal ayant un axe limite qui est la ligne tangentielle qui est orthogonale à l'axe opérationnel et la plus proche du second ressort hélicoïdal, et le second ressort hélicoïdal ayant un axe limite qui est la ligne tangentielle qui est orthogonale à l'axe opérationnel et la plus proche du premier ressort hélicoïdal, les axes limites des premier et second ressorts hélicoïdaux étant séparés.
  4. Appareil selon l'une quelconque des revendications précédentes, les premier et second ressorts hélicoïdaux ayant une séparation longitudinale qui est la distance entre les positions des premier et second ressorts hélicoïdaux sur l'axe opérationnel, et la séparation longitudinale étant suffisante pour former une paroi de séparation entre des premiers ressorts hélicoïdaux adjacents et entre des seconds ressorts hélicoïdaux adjacents d'actionnements successifs du mécanisme d'insertion, en joignant les première et seconde couches de matériau entre les ressorts hélicoïdaux adjacents.
  5. Appareil selon l'une quelconque des revendications précédentes, les premier et second ressorts hélicoïdaux ayant une séparation longitudinale qui est la distance entre les positions des premier et second ressorts hélicoïdaux sur l'axe opérationnel, et la séparation longitudinale étant sensiblement égale à chaque incrément du mouvement relatif entre les couches de matériau et le mécanisme d'insertion, entre chaque actionnement du mécanisme d'insertion.
  6. Appareil selon l'une quelconque des revendications précédentes, les premier et second emplacements ayant une séparation transversale qui est la séparation entre les axes longitudinaux s'étendant à travers les points centraux des premier et second ressorts hélicoïdaux, lesdits axes longitudinaux étant parallèles à l'axe opérationnel, et la séparation transversale des premier et second ressorts hélicoïdaux étant supérieure à la somme des rayons des premier et second ressorts hélicoïdaux, ou au moins 1,2 fois, au moins 1,5 fois ou au moins deux fois cette distance.
  7. Appareil selon l'une quelconque des revendications précédentes, le premier ressort hélicoïdal ayant un axe limite qui est la ligne tangentielle qui est parallèle à l'axe opérationnel et la plus proche du second ressort hélicoïdal, et le second ressort hélicoïdal ayant un axe limite qui est la ligne tangentielle qui est parallèle à l'axe opérationnel et la plus proche du premier ressort hélicoïdal, les axes limites des premier et second ressorts hélicoïdaux étant séparés.
  8. Appareil selon l'une quelconque des revendications précédentes, les premier et second emplacements ayant une séparation transversale qui est la séparation entre les axes longitudinaux s'étendant à travers les points centraux des premier et second ressorts hélicoïdaux, lesdits axes longitudinaux étant parallèles à l'axe opérationnel, et la séparation transversale étant suffisante pour former une paroi de séparation entre des premier et second ressorts hélicoïdaux adjacents d'actionnements successifs du mécanisme d'insertion, par exemple en joignant les première et seconde couches de matériau entre les ressorts hélicoïdaux adjacents.
  9. Appareil selon l'une quelconque des revendications précédentes, le mécanisme de retenue et le mécanisme d'insertion faisant tous deux partie d'une section d'encapsulation de l'appareil, les ressorts hélicoïdaux étant insérés entre les première et seconde couches de matériau, qui sont ensuite jointes pour former des poches autour des ressorts hélicoïdaux.
  10. Appareil selon l'une quelconque des revendications précédentes, le premier ressort hélicoïdal inséré par le premier élément d'insertion ayant des caractéristiques différentes de celles du second ressort hélicoïdal inséré par le second élément d'insertion.
  11. Procédé de fabrication de ressorts hélicoïdaux ensachés à l'aide d'un appareil selon l'une quelconque des revendications précédentes, le procédé comprenant les étapes consistant à :
    (a) retenir des première et seconde couches de matériau par rapport à l'axe opérationnel de l'appareil ;
    (b) actionner le mécanisme d'insertion, qui insère un premier ressort hélicoïdal à un premier emplacement entre les couches de matériau sur un premier côté de l'axe opérationnel de l'appareil, et insère un second ressort hélicoïdal à un second emplacement entre les couches de matériau sur un second côté opposé à l'axe opérationnel de l'appareil, et à une position différente sur l'axe opérationnel de l'appareil par rapport au premier emplacement, de sorte que les premier et second ressorts hélicoïdaux soient disposés en diagonale entre les couches de matériau par rapport à l'axe opérationnel de l'appareil ; et
    (c) assurer un mouvement relatif entre les couches de matériau et le mécanisme d'insertion, le long de l'axe opérationnel, entre chaque actionnement du mécanisme d'insertion.
  12. Procédé selon la revendication 11, les première et seconde couches de matériau étant jointes pour former des poches autour des ressorts hélicoïdaux.
  13. Procédé selon la revendication 11 ou 12, un premier ressort hélicoïdal unique et un second ressort hélicoïdal unique étant insérés entre les couches de matériau entre chaque incrément de mouvement relatif entre les couches de matériau et les éléments d'insertion.
  14. Procédé selon l'une quelconque des revendications 11 à 13, le premier ressort hélicoïdal et le second ressort hélicoïdal étant insérés sensiblement simultanément.
  15. Procédé selon l'une quelconque des revendications 11 à 14, les première et seconde couches de matériau étant formées par une feuille de matériau soudable qui est pliée autour d'un axe longitudinal, et chaque poche dans la rangée de ressorts hélicoïdaux adjacente à la couche étant formée en appliquant deux soudures transversales qui sont orientées sensiblement transversalement à l'axe opérationnel, de chaque côté du ressort hélicoïdal, et une soudure axiale qui est sensiblement alignée avec l'axe opérationnel, de l'autre côté du ressort à partir du pli, et chaque poche dans l'autre rangée de ressorts hélicoïdaux étant formée d'une manière similaire, en appliquant deux soudures transversales qui sont orientées sensiblement transversalement à l'axe opérationnel, de chaque côté du ressort hélicoïdal, et une soudure axiale qui est sensiblement alignée avec l'axe opérationnel, de l'autre côté du ressort à partir du pli.
EP16185360.1A 2015-08-24 2016-08-23 Perfectionnements apportés à des ensembles à ressorts internes Active EP3135630B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1515008.9A GB2541663A (en) 2015-08-24 2015-08-24 Improvements related to innerspring assemblies

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EP3135630A1 EP3135630A1 (fr) 2017-03-01
EP3135630B1 true EP3135630B1 (fr) 2018-05-16

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GB (1) GB2541663A (fr)
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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023161642A1 (fr) * 2022-02-23 2023-08-31 Hs Products Ltd Procédé et appareil de manipulation de ressorts

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB9806778D0 (en) * 1998-03-31 1998-05-27 Elson & Robbins Limited Apparatus for the production of pocketed coil springs
GB0220125D0 (en) * 2002-08-30 2002-10-09 Harrison Bedding Ltd Method of forming pocketted sponges
CN105129716B (zh) * 2015-09-02 2017-12-26 广州市联柔机械设备有限公司 一种多层袋装弹簧串及其制造装置、方法

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023161642A1 (fr) * 2022-02-23 2023-08-31 Hs Products Ltd Procédé et appareil de manipulation de ressorts

Also Published As

Publication number Publication date
EP3135630A1 (fr) 2017-03-01
GB201515008D0 (en) 2015-10-07
GB2541663A (en) 2017-03-01
TR201809180T4 (tr) 2018-07-23

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