US2133408A - Spring unit - Google Patents

Description

S. A. WALKER SPRING UNIT Filed Dec. 5', 1934 Oct. 18, 1938.

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' INVENTOR, ,S/verman 4. War/ker- ATTORNEY.

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S. A. WALKER Oct. 18, 1938.

S PRING UNIT F,iled Dec. 5, 1934' 2 Sheets-Sheet 2 f 0 MW 4 a m m n Jig. 4

ATTORNEY.

Patented Oct. 18, 1938 I UNITED STATES SPRING UNIT Sheridan A. Walker, Newburgh, N. Y., in... to Walker Spring 00., Inc., Newbnrgh, N. Y., a corporation of New York Application December 5, 1934, Serial No. 758,013

8 Claims.

This invention is a spring unit adapted for various uses in the arts, but intended primarily for employment in so-called inner'spring mattresses.

Spring units for use in mattresses are generally constructed from a large number of coil springs secured in spaced relation to one another by canvas, tapes or the like with the bottom and top of the unit covered with a fabric over which the upholstery in the form of padding or the like is laid within an appropriate fabric cover. The whole is tufted for the sake of appearance and to further hold the padding against shifting.

Numerous variations in this conventional way of making mattresses have been suggested from time to time, but the same principle, as above outlined, remains the standard practice today. It is open, however, to certain pronounced disadvantages, chief among which is the tendency of the padding to work down into the springs. This is due to the fact that, as a general rule, there is only a fabric interposed between the padding and the springs, and while the springs bear against the padding over very restricted areas which constitute substantially line contact, the greater portion of the padding must be supported by the fabric which in due course sags about the springs and becomes torn or disrupted.

I am aware that attempts have been made to increase the foundation for the padding by covering the springs with strips of material which would increase the support for the padding, but these proposed devices have never proved commercial for the reasons well understood by those skilled in the art. For example, they have, in many cases, proven wholly impractical for use in spring construction. In other cases, the cost was prohibitive, while, in other cases, the structure was noisy and thus unacceptable for the use stated.

With these considerations in mind, the primary object of the present invention is to provide a spring unit embodying coil springs set on end and spaced apart in all cross axial directions by means of metallic bands of resilient material, preferably spring steel. The bands are so placed as to extend preferably lengthwise of the unit below and above the springs and are so placed that adjacent springs overlap the bands and are secured thereto by an eflicient and highly novel form of attaching means which anchors each two lateral adjacent springs firmly to one another and to the strip which mutually overlies them and serves the further function of spacing the springs apart by a tight gripping action which eliminates noise.

An important feature of this attaching means resides in the economy of its manufacture and the ease with which it may be attached manually and without requiring the use of tools or complicatedmachinery. The steel bands employed in the use of this invention are sufllciently wide to bridge over appreciable portions of adjacent springs and they are preferably spaced 8. distance apart about equal to the width of the bands, so that when a fabric is laid over these -bands the superimposed padding will be effectually supported against sagging and the springs will be precluded from cutting into the padding.

The spring unit of the present invention also contains a novel form of edging in order to properly reinforce the edge and preclude sagging thereof. the employment of a resilient metal band, preferably spring steel, threaded through the terminal convolutions of the springs at the edge of the unit and-covered with an envelope held in place by metal clamps which also serve to anchor the edging to the springs.

A highly important practical feature of the invention consists in the simplicity of the construction, the economy of its manufacture and ease of assembly.

Features of the invention, other than those adverted to, will be apparent from the hereinafter detailed description and claims, when read in conjunction with the accompanying drawings.

The accompanying drawings illustrate ,one practical embodiment of the invention, but the construction therein shown is to be understood as illustrative, only, and not as defining the limits of the invention.

This novel form of edging consists in.

Figure l is a. fragmental plan view of a portion of a spring unit embodying the present invention.

Figure 2 is an edge view of the structure shown in Figure 1 as viewed from the right hand side of the latter figure.

Figure 3 is an edge view of the structure of Figure l, as viewed from the bottom of said figure.

Figure 4 is a fragmental perspective view showing the manner of assembly of the springs and metal bands, as well as the manner of attaching the edging to the springs.

Figure 5 is an enlarged fragmental perspective showing the manner of attaching two adjacent springs to a mutually overlapping band. This figure shows a novel clip forming part of the present invention partly assembled.

Figure 6 is a section on the line 68 of Figure 5.

Figure 'I is a view similar to Figure 5, but showing the attachment completed.

Figure 8 is a section on the line 8-8 of Figure '7.

Figure 9 shows the parts of the clip dismantled and separate from one another.

In making the spring unit of the present invention, I employ a relatively large number of coiled springs I. These springs are spaced apart between upper and lower metal bands 2. The bands are preferably of spring steel. They may extend transversely of the unit or longitudinally thereof, but the latter arrangement is preferred. They are arranged in parallel relation and in a manner so that they transversely bridge the upper and lower ends of laterally adjacent springs I, as shown best in Figures 1 and 3 and they are secured to these laterally adjacent springs by means of a novel form of clip shown best in Figures 5-9 inclusive.

This clip embodies two parts, one of which consists in a retaining member 3, while the other constitutes a clamping and spacing member 4. The retaining member or retainer 3 is of double hooked cross section; that is to say, it is made with a sheet metal body with the opposite ends returned upon themselves to form opposing hooks 5 with an intermediate gap 5 through which the wire of the spring may be passed. The resulting split tubular structure is punched cross axially to provide alined slots 1 and 8, the length of which is equal to the desired spacing apart of adjacent springs, while the internal distance between the hooked portions 5 is substantially equal to the length of the slots I and 8 plus twice the thickness of the wire from which the resilient coil springs I .are formed. The clamping or spacing member hereinafter referred to as the clamp and spacer or key 4, is made from a strip of sheet metal which may be readily bent. This strip is bent upon itself to form a head 9 and a tongue III embodying two leaves which may be separated and bent after the manner of a cotter pin. The width of the strip from which the clamp 4 is formed is substantially equal to the length of the slots 1 and 8. The retainer 3 is made relatively rigid and is not intended to be bent at any time, although it may be clamped in place if desired.

Prior to assembling the parts, each of the bands .2 is punched at spaced intervals to provide slots II corresponding in size and shape to the cross section of the tongues ID of the clamp and spacer, so as to permit the introduction of such a tongue through each of the slots II. As each two adjacent springs is assembled upon one of the bands 2, the terminal convolutions of each spring is passed through the gap 6 of a retainer and internally engaged with one of the hooked portions 5 thereof. In other words, each pair of laterally adjacent springs is brought into hooked relation with an interposed retainer. Thereafter the retainer is brought into cooperative relation with the band 2, and a clamp and spacer 4 is thereupon forced through the appropriate slot II of the band so that the tongue I0 passes through the slot in the band and consecutively through the slots I and 8 in the retainer, as shown in Figures 5 and 6. The two leaves of the retainer tongue III are then bent apart after the manner of splitting a cotter pin and thereupon bent down to clamp the retainer 3 to the band 2, and lock the clamp and spacer 4 against removal to complete the assembly. The split locking member 4 thus constitutes a key to lock two springs of each retainer and to also secure the retainer to one of the bands 2.

To facilitate the introduction of the clamp and spacer 4, the ends of the tongues I0 are preferably tapered as shown and as the tongue is forced through the slots I and 8 of the retainer, the tapering end of the tongue I0 serves to spread the springs apart and wedge them tightly into the hooked portions 5, so that when the key 4 is finally in position, it spaces the terminal convolutions of the springs I apart and locks them tightly within the hooked portions 5. To facilitate the bending of the leaves of the tongue III for finally locking the parts in position, one leaf is preferably somewhat longer than the other as shown in Figure 9.

In practice, I find it entirely feasible to effect the bending of these leaves by hand so that no tools are required. The key. 4 is sufficiently strong to carry the lateral strain, while load applied to the spring unit is applied in a direction normal to the bands 2 and in the direction of the springs I, so that there is little if any strain in this direction and consequently the key 4 may be made relatively light and yet is well able to carry out its spacing and locking function. This structure is thus a pronounced departure from prior suggestions wherein bending tools and swedging apparatus have been employed to anchor a spring to a band. The practical view of the employment of machinery in this connection is that it is not feasible to so manufacture a spring unit. The springs are set closely together and there is no room to work with machinery or apparatus for the purpose stated.

After the main portion of the structure is assembled in the manner described by attaching the springs I and bands 2, as stated, the unit is provided with an edging. This edging is also in the form of spring steel bands I2. These bands are threaded alternately through the terminal convolutions of the springs I and over and under the ends of alternate bands 2 to interfit with said parts. This arrangement brings about an interfitting of the terminal convolutions with respect to the bands 2 and I2, as clearly appears in Figure 1, and results in a very strong construction. After threading the bands I2, as described, a fabric binding strip I3 bent medially of its width is folded about the edging strips I2 and clamped to these strips by metal clamps I4, best shown in Figures 1 and 4.

One of these clamps is preferably associated with each spring along the edge of the unit and at the top and bottom surface of the unit and serves not only to clamp the binding strip I3 in place, but also maintains the edging bands I2 substantially tangential to the springs I, whereby they cannot work loose and project beyond the edging bands I2. The free edges of the binding strip I3 may be left raw or they may be hemmed or felled as desired, although they do not need to be sewed together as the clamps I4 will effectually hold them in place.

This arrangement is thus not only simple, but economical and produces nevertheless a fine edge well able to withstand hard usage and one which will not sag.

The finished unit embodies upper and lower surfaces formed of spring steel bands preferably spaced apart a distance approximating the width of the individual bands and interposed between these facial bands are the springs I firmly anchored to the bands and properly spaced apart in such a way that they cannot become inadvertently disconnected or released therefrom.

In incorporating the spring unit in a mattress or other structure, the same is covered with an appropriate fabric covering and the padding is laid over this covering and in turn enclosed within an appropriate envelope. The arrangement is such that the padding will be properly supported by the bands 2 and I2, and will not work down lnbetween the springs, but will, on the contrary, remain in proper serviceable condition for years under the most adverse conditions of usage.

It should be further borne in mind that the spring steel bands which enter into the construction of my invention, while relatively thin, are

sufliciently resilient to properly distribute weight imposed thereon, so that not only the padding is properly supported, but the whole construction is maintained in proper shape indefinitely.

The foregoing detailed description sets forth this invention in its preferred practical form, but the invention is to be understood as fully commensurate with the appended claims.

Having thus fully described the invention, what I claim as new and desire to secure by Letters Patent is:

1. A spring unit comprising two sets of spring metal bands arranged in parallel planes and resiliently spaced apart by interposed coiled springs having parallel axes and so positioned that each end of each spring laterally overlaps two bands of one of said sets, means securing the juxtaposed ends of each two laterally adjacent springs to one another and to an overlapping band, a spring metal edging strip interwoven with respect to the corresponding ends of consecutive springs along the edge of the unit and over and under alternate bands at the ends of the unit, a flexible binding over said strip, and means securing the said binding to thestrip and the strip to said springs.

2. A spring unit comprising two sets of spring metal bands arranged in parallel planes and resiliently spaced apart by interposed coiled springs having parallel axes and so positioned that each end of each spring laterally overlaps two bands of one of said sets, means securing the juxtaposed ends of each two laterally adjacent springs to one another and to an overlapping band, a spring metal edging strip interwoven with respect to the corresponding ends of consecutive springs along the edge of the unit and over and under alternate bands at the ends of the unit, a flexible binding over said strip, and metal clips securing the said binding to the strip and the strip to said springs.

3. A spring clip comprising a metal body, the opposite ends of which are returned upon themselves to form spaced apart opposed reentrant portions, the base of the body having therein a slot and the returned ends of which also have slots alined with the slot of the body, and a split key having a head from which projects parallel bendable leaves proportioned to extend through the slots of said body and ends, the free ends of the leaves being bendable to preclude withdrawal of the key.

4. A spring unit comprising cross axially spaced apart rows of coil springs in each of which said springs are also spaced from one another, slotted sheet metal bands arranged in parallel relation and facially overlying corresponding ends of said springs in parallel relation to said rows with each of said bands laterally overlapping the springs of two adjacent rows, a.'slotted.retainer having opposed hooks engaged with juxtaposed ends of each two laterally adjacent springs to preclude lateral spreading thereof, and a split locking key having bendable leaves extending through each slot in each band and through the slot in the associated retainer and bent over to simultaneously secure the retainer to the band and associated springs and laterally space the said ends of the springs apart.

5. A spring unit comprising cross axially spaced apart rows of coiled springs in each of which said springs are also spaced from one another, sheet metal bands arranged in parallel relation and facially overlying corresponding ends of said springs in parallel relation to said rows with each of said bands laterally overlapping the springs of two adjacent rows, a retainer having opposed hooks engaged with juxtaposed ends of each two laterally adjacent springs to preclude lateral spreading thereof, and a locking key extending through the band and through each retainer to simultaneously secure each retainer to the band and associated springs.

6. A spring unit comprising cross axially spaced apart rows of coiled springs in each of which said springs are also spaced from one another, sheet metal bands arranged in parallel relation and facially overlying corresponding ends of said springs in parallel relation to said rows with each of said bands laterally overlapping the springs of two adjacent rows, and a clip securing juxtaposed ends of each two laterally adjacent springs to one another and to the overlapping band, each clip including a plate positioned between the springs and band to space the springs from the band and provided with hook shaped ends hooked over the terminal convolutions of laterally adjacent springs to preclude their separation from one another, said sheet metal bands being individually at least substantially as wide as the spaces between laterally adjacent bands.

7 A spring unit comprising cross axially spaced apart rows of coiled springs in each of which said springs are also spaced from one another, sheet metal bands arranged in parallel relation and facially overlying corresponding ends of said springs in parallel relation to said rows with each of said bands laterally overlapping the springs of two adjacent rows, and each band having a width approximately equal to the radius of the terminal convolutions of said springs and a clip securing juxtaposed ends of each two laterally adjacent springs to one another and to the overlapping band, each clip including a plate positioned between the springs and band. to space the springs from the band and provided with hook shaped ends hooked over the terminal convolutions of laterally adjacent springs to preclude their separation from one another, said sheet metal bands being individually at least substantially as wide as the spaces between laterally adjacent bands.

8. A spring unit comprising two sets of spring metal bands arranged in parallel planes and resiliently spaced apart by interposed coiled springs having parallel axes and so positioned that each end of each spring laterally overlaps two bands of one of said sets, and means secured centrally to each band simultaneously securing laterally adjacent overlapping springs thereto, said sheet metal bands being individually at least substantially as wide as the spaces between laterally adjacent bands.

SHERIDAN A. WALKER.

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