GB2416690A

GB2416690A - Apparatus for producing a pocketed innerspring contsruction mattress

Info

Publication number: GB2416690A
Application number: GB0419259A
Authority: GB
Inventors: Thomas Patrick Kellett
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-07-30
Filing date: 2004-08-31
Publication date: 2006-02-08
Anticipated expiration: 2024-08-31
Also published as: IE20040577A1; GB0419259D0; IES20040519A2; GB2416690B

Abstract

An apparatus (1) for assembling innerspring construction mattresses from rows of pocketed coil springs (3). Rows of pocketed coil springs (3) are retained by a pressure plate (4) on a planar support surface with the longitudinal axes of the coil springs all disposed normal to the surface. A cradle (6) receives a first row of pocketed coil springs (12) to which bonding material is applied with the cradle in a first position. The cradle (6) is movable between the first position and a second position in which the first row of coil springs (12) is pushed into contact with and secured to a second row of coil springs (3a) retained on the support surface.

Description

241 6690

APPARATUS FOR PRODUCING A POCKETED INNERSPRING

CONSTRUCTION MATTRESS

The present invention relates generally to innerspring constructions for mattresses.

More particularly, the invention relates to an apparatus for producing pocketed innerspring constructions mattresses.

Mattress innerspring construction is well known in the bedding industry. One well known type of innerspring construction is known as a Marshall construction in which coil springs are pocketed within fabric to create finite lengths or springs of pocketed coils. The coil spring pockets are defined by sewing transverse and longitudinal seams, or have more recently been formed by the use of ultrasonic thermal welding as disclosed in U.S. 4,234,983 Stumpf.

Once the strings of pocketed coils are constructed, they may be assembled to form an innerspring construction for a mattress by a variety of methods and apparatus. The most common approach involves securing a row or string of pocketed coils to an adjacent row by applying hot melt adhesive techniques as disclosed in U.S. 4,566,926, Stumpf. In this method, lengths of strings of pocketed coils are assembled on a table to form mattress innersprings by applying hot melt adhesive to the sides of the pocket fabric and then using - e.

A: a pusher bar to force an adjacent row or string of pocketed coils into contact with the A.- applied adhesive. One disadvantage of the apparatus disclosed for use in this method is that it is limited to one size of the pocketed coil.

U.S. 5,746,877 discloses an apparatus for assembling innerspring constructions from strings of pocketed coils. The apparatus comprises a bonding material applicator for . applying bonding material to a first row of pocketed coils retained by a pressure plate. A ale pusher bar assembly pushes a second row of pocketed coils into contact with the first row and they become bonded together. The pusher bar assembly includes a fixture having two opposed sides with differently spaced dividers for receiving different sizes of pocketed coils. The fixture is manually rotatable and the bonding material applicator includes means for synchronizing application of bonding material depending on the pocketed coil size being assembled.

Although satisfactory innerspring constructions are provided using the methods and apparatus of the above-referenced prior art, an improved apparatus for creating innerspring constructions of different sizes and which also exhibit improved physical properties such as firmness and dimensional stability is desirable.

It is an object of the present invention to provide such an improved apparatus for producing innerspring constructions.

Accordingly, the present invention provides an apparatus for assembling a mattress innerspring construction from rows of pocketed coil springs, comprising: a generally planar support surface; means for retaining rows of pocketed coil springs on the support surface with the longitudinal axes of the coil springs all disposed normal to the surface; a cradle, which includes means for receiving a first row of pocketed coil springs; means for applying bonding material to the first row of coil springs; means for pushing the first row of coil springs into contact with a second row of pocketed coil springs retained by the retaining means; wherein the cradle is movable between a first position in which bonding material is applied to the first row of coil springs and a second position in which the first row of coil springs is pushed into contact with the second row of coil springs. :' ë

Ideally, the cradle is horizontally disposed in the first position. *

A

' Preferably, the cradle is at generally 90 to the horizontal and disposed normal to the support surface in the second position. a

Optionally, the cradle is movable between the first and second positions by pivoting "e means.

Conveniently, the pivoting means is operable by hydraulic, pneumatic or mechanical means.

Ideally, the cradle comprises a plurality of V-shaped holders disposed within a frame and defining a plurality of receivers for a row of pocketed coil springs.

Preferably, the pushing means is operable to push the V-shaped holders containing a row of pocketed coil springs laterally away from the frame when the cradle is in the second position.

Optionally, the pushing means is further operable to push the frame laterally towards the planar support surface when the cradle is in the second position.

Advantageously, the V-shaped holders are slideable to and lockable in different positions along the frame of the cradle.

Preferably, the apparatus further comprises an indexing control means for automatically moving the V-shaped holders between positions along the frame of the cradle.

Conveniently, the V-shaped holders are removable and replaceable with holders of different size.

Ideally, the retaining means comprises a pressure plate mounted above and parallel to the support surface.

Advantageously, the pressure plate is adjustable to different spacings above the support surface allowing assembly of pocketed coil springs of different sizes. . . .

Preferably, the apparatus further comprises means for controlling the application of bonding material to a row of coil springs.

The invention will hereinafter be more particularly described with reference to the accompanying drawings which show, by way of example only, one embodiment of an ''' apparatus for pocketed innerspring construction. In the drawings: Figure 1 is a perspective view of the apparatus for pocketed innerspring construction according to the invention; Figure 2 is a perspective view of the cradle of the apparatus in a first position; Figure 3 is a perspective view of cradle of the apparatus in a second position; Figure 4 is a perspective view of a row of pocketed coil springs; Figure 5 is a perspective view of a first innerspring construction; and Figure 6 is a perspective view of a second innerspring construction.

Referring to the drawings and initially to Figure 1, the apparatus for assembling innerspring constructions from rows of pocketed coil springs, indicated generally by reference numeral 1, is shown and for brevity will be referred to as the apparatus 1.

The apparatus 1 comprises a generally planar table surface 2 and an adjustable pressure plate 4 for retaining rows of pocketed coil springs 3 in an upright position. An adhesive applicator 5 is supported for transverse movement along the apparatus and above a cradle 6. Adhesive is supplied to the applicator 5 through a tube 7 connected to a suitable reservoir (not shown).

The cradle is pivotably mounted on cams 8 which may be mechanically, hydraulically or pneumatically operated. The cradle is disposed adjacent the table surface 2 parallel to the retained rows of coil springs 3. The cradle 6 comprises a plurality of V-shaped holders 9 disposed within a frame 10. Openings 11 defined by the V-shaped holders 9 are . dimensioned to receive an individual pocketed coil spring. The cradle arrangement . . *, receives a row of pocketed coil springs for assembly into an innerspring construction. The apparatus will now be described in use.

Initially, the cradle 6 is in a horizontal position as shown in Figure 1. Referring to Figure 2, a string or row of pocketed coil springs 12 is placed in the cradle and is received by the openings 11. Adhesive is delivered by the applicator 5 in discrete deposits at predetermined locations along the length of the string 12. This is usually at the circumferentially abutting surfaces of the coil pockets but may also be at the transverse seams of the pocketing fabric.

Once adhesive (not shown) has been applied to the string 12, the cams 8 activate pivoting the cradle 6 containing the string 12 into a position 90 to the horizontal and normal to the table surface 2 as shown in Figure 3. A pusher bar assembly 13 is provided to push the cradle 6 and protruding string of coil springs 12 into intimate contact with the retained s rows 3. The adhesive bonds the string 12 to the outermost row 3a of the retained rows of pocketed coil springs 3 and the pusher bar assembly 13 retracts. The cradle 6 returns to its initial horizontal position, another string 12 of pocketed coil springs is loaded, and the process is repeated resulting in the assembly of an innerspring construction.

Figures 5 and 6 illustrate different innerspring constructions possible using the apparatus of the invention. Figure 4 illustrates a string of pocketed coil springs of five pockets in length. Figure 6 shows the conventional belly-to-belly type innerspring construction suitable for use when a soft mattress is required. Figure 5 illustrates another construction whereby the circumferentially abutting surfaces 14 of coil pockets on one string are bonded to transverse seams 15 in the pocket fabric of another string. This type of construction requires a greater number of strings of pocketed coil springs for a given mattress size compared with a belly-to-belly type construction. As a result greater innerspring and mattress firmness can be achieved as well as a reduced tendency for "leaning coils".

The construction depicted in Figure 5 can be achieved by alternating the orientation of a string 12 on the cradle 6 for every other string which is added to the retained rows 3. This is done simply by moving the V- shaped track 9 to obtain the necessary alignment. The track 9 can be moved manually or automatically. Referring to Figure 3, an indexing ëce control means 16 is programmable and operable to automatically move the track 9. Abbe e, C..

It will of course be understood that the present invention is not limited to the specific details herein described which are given by way of example only, and that various alterations and modifications may be made without departing from the scope of the invention as defined by the appended claims. e a as.

Claims

CLAIMS: 1. An apparatus for assembling a mattress innerspring construction

from rows of pocketed coil springs, comprising: a generally planar support surface; means for retaining rows of pocketed coil springs on the support surface with the longitudinal axes of the coil springs all disposed normal to the surface; a cradle, which includes means for receiving a first row of pocketed coil springs; means for applying bonding material to the first row of coil springs; means for pushing the first row of coil springs into contact with a second row of pocketed coil springs retained by the retaining means; wherein the cradle is movable between a first position in which bonding material is applied to the first row of coil springs and a second position in which the first row of coil springs is pushed into contact with the second row of coil springs.
2. An apparatus for assembling a mattress innerspring construction as claimed in Claim 1, in which the cradle is horizontally disposed in the first position.
3. An apparatus for assembling a mattress innerspring construction as claimed in 20 Claim 1 or Claim 2, in which the cradle is at generally 90 to the horizontal and disposed normal to the support surface in the second position. e.e

:
4. An apparatus for assembling a mattress innerspring construction as claimed in any . one of the preceding claims, in which the cradle is movable between the first and second positions by pivoting means. .. e.
5. An apparatus for assembling a mattress innerspring construction as claimed in Claim 4, in which the pivoting means is operable by hydraulic, pneumatic or mechanical means.
6. An apparatus for assembling a mattress innerspring construction as claimed in any one of the preceding claims, in which the cradle comprises a plurality of V-shaped holders disposed within a frame and defining a plurality of receivers for a row of pocketed coil springs.
7. An apparatus for assembling a mattress innerspring construction as claimed in Claim 6, in which the pushing means is operable to push the Vshaped holders containing a row of pocketed coil springs laterally away from the frame when the cradle is in the second position.
8. An apparatus for assembling a mattress innerspring construction as claimed in Claim 6 or Claim 7, in which the pushing means is further operable to push the frame laterally when the cradle is in the second position.
9. An apparatus for assembling a mattress innerspring construction as claimed in Claims 6 to 8, in which the V-shaped holders are slideable to and lockable in different positions along the frame of the cradle.
10. An apparatus for assembling a mattress innerspring construction as claimed in any one of the preceding claims, in which the apparatus further comprises an indexing control means for automatically moving the V-shaped holders between positions along the frame of the cradle.
11. An apparatus for assembling a mattress innerspring construction as claimed in Claims 6 to 10, in which the V-shaped holders are removable and replaceable with ala. holders of different size. ë e.e

. :
12. An apparatus for assembling a mattress innerspring construction as claimed in any one of the preceding claims, in which the retaining means comprises a pressure plate mounted above and parallel to the support surface. .

.
13. An apparatus for assembling a mattress innerspring construction as claimed in Claim 12, in which the pressure plate is adjustable to different spacings above the support surface allowing assembly of pocketed coil springs of different sizes.
14. An apparatus for assembling a mattress innerspring construction as claimed in any one of the preceding claims, in which the apparatus further comprises means for controlling the application of bonding material to a row of coil springs.
15. A mattress including a mattress Innerspring construction as claimed in Claim 14.

15. An apparatus for assembling a mattress innerspring construction from rows of pocketed coil springs substantially as herein described with reference to and as shown in the accompanying drawings.

16. A mattress innerspring construction when manufactured on an apparatus as claimed in any one of the preceding claims.

17. A mattress including a mattress innerspring construction as claimed in Claim
16. ! ... ..e ëe. e.e

. . ; . t He I. ë e.

Amendments to the claims have been filed as follows ) q CLAIMS: 1 An apparatus for assembling a mattress Innerspring construction from rows of pocketed coil springs, composing: a generally planar support surface; means for retaining rows of pocketed coil springs on the support surface with the longitudinal axes of the coil springs all disposed normal to the surface, a cradle comprising a plurality of V-shaped holders disposed within a frame and defining a plurality of receivers for a first row of pocketed coil springs; means for applying bonding material to the first row of coil springs; means for pushing the first row of coil springs into contact with a second row of pocketed coil springs retained by the retaining means; the cradle being movable between a first position in which bonding material Is applied to the first row of coil springs and a second position in which the first row of coil springs is pushed into contact with the second row of coil springs; and an indexing control means for automatically moving the holders between positions along the frame of the cradle.

2 An apparatus for assembling a mattress innerspring construction as claimed in Claim 1, In which the cradle is horizontally disposed In the first position.

3 An apparatus for assembling a mattress innerspring construction as claimed in Claim 1 or Claim 2, in which the cradle is at generally 90 to the horizontal and disposed normal to the support surface In the second position.

4 An apparatus for assembling a mattress innerspring construction as claimed in any one of the preceding claims, in which the cradle is movable between the first and second positions by pivoting means.

5 An apparatus for assembling a mattress innerspring construction as claimed in Claim 4, in which the pivoting means is operable by hydraulic, pneumatic or mechanical means 1 6 An apparatus for assembling a mattress nnerspnng construction as claimed in any preceding claim, in which the pushing means is operable to push the V-shaped holders containing a row of pocketed coil springs laterally away from the frame when the cradle is in the second position.

7. An apparatus for assembling a mattress innerspring construction as claimed in any preceding claim, In which the pushing means Is further operable to push the frame laterally when the cradle Is In the second position.

8 An apparatus for assembling a mattress innerspring construction as claimed in any preceding claim, in which the V-shaped holders are slideable to and lockable in different positions along the frame of the cradle.

9. An apparatus for assembling a mattress innerspring construction as claimed in any preceding claim, in which the V-shaped holders are removable and replaceable with holders of different size.

10. An apparatus for assembling a mattress innerspring construction as claimed in any one of the preceding claims, in which the retaining means comprises a pressure plate mounted above and parallel to the support surface.

11 An apparatus for assembling a mattress innerspring construction as claimed in Claim 10, in which the pressure plate is adjustable to different spacings above the support surface allowing assembly of pocketed coil springs of different sizes.

12 An apparatus for assembling a mattress innerspring construction as claimed in any one of the preceding claims, in which the apparatus further comprises means for controlling the application of bonding material to a row of coil springs.

13. An apparatus for assembling a mattress innerspring construction from rows of pocketed coil springs substantially as herein described with reference to and as shown in the accompanying drawings.

14 A mattress innerspring construction when manufactured on an apparatus as claimed In any one of the preceding claims.