US3660876A - Method of making an upholstered body - Google Patents

Method of making an upholstered body Download PDF

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Publication number
US3660876A
US3660876A US753391A US75339168A US3660876A US 3660876 A US3660876 A US 3660876A US 753391 A US753391 A US 753391A US 75339168 A US75339168 A US 75339168A US 3660876 A US3660876 A US 3660876A
Authority
US
United States
Prior art keywords
core body
mold
core
walls
cover
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US753391A
Other languages
English (en)
Inventor
Philipp Krier
Lothar Fendler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MIRABED AG ZUG
Original Assignee
MIRABED AG ZUG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by MIRABED AG ZUG filed Critical MIRABED AG ZUG
Priority to US00250328A priority Critical patent/US3821823A/en
Application granted granted Critical
Publication of US3660876A publication Critical patent/US3660876A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
    • A47C27/06—Spring inlays
    • A47C27/065—Spring inlays of special shape
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/20—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with springs moulded in, or situated in cavities or openings in foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1266—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being completely encapsulated, e.g. for packaging purposes or as reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G11/00—Finished upholstery not provided for in other classes
    • B68G11/04—Finished upholstery not provided for in other classes mainly composed of resilient materials, e.g. of foam rubber
    • B68G11/06—Finished upholstery not provided for in other classes mainly composed of resilient materials, e.g. of foam rubber with embedded springs, e.g. bonded
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S297/00—Chairs and seats
    • Y10S297/02—Molded
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/48—Upholstered article making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/48—Upholstered article making
    • Y10T29/481—Method
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/48—Upholstered article making
    • Y10T29/482—Tufting

Definitions

  • ABSTRACT I An u bolstered bod es eciall mattress and seat for automo- A .l9,l967 G ..P1685176.6 P P Y ug ermany biles, and mthod 'of making the same, according to which a 52 U.S.C1 ..29 91,29/91.1,29 91.2 core d of Coil Springs has a Seamless Cover of foamed [51] Int. Cl ..B68g' 7/00 material, for instance, of p y 0r p y r n i core body.
  • the present invention relates to a mattress and method of making the same, according to which a spring core is provided with a cover of foam material.
  • FIG. 2 shows a section through a further embodiment of a mattress according to the invention.
  • FIG. 3 is a top view of a cutout portion of a spring core of a mattress according to the invention.
  • FIG. 4 is a perspective view of the springs shown in FIG. 1.
  • FIG. 5 illustrates, similar to FIG. 3, a further embodiment of a spring core according to the invention.
  • the method according to the present invention according to which a spring coreis covered with a cover of foam material, is characterized in that the prefabricated spring core in a foaming process is provided with a cover closed in itself of polyester, polyether, or a similar soft foam material. Due to the fact that the foam layer foams directly in the spring core and thus is shaped accordingly, the covering or coating of the spring core can be effected in a minimum of time.
  • the spring core itself forms the inner form of the cover so that the latter will precisely fit.
  • the cover prepared according to the invention is completely seamless so that even when being relatively thin it will have a considerable strength.
  • the method according to the invention can easily be practiced when the spring core, prior to the foaming of the layer of foam material is covered with textile material, synthetic material, or the like so that, at any rate, the layer of foam material will be prevented from passing between the springs or with a cover, for instance, of textile fabric, since such textile fabric cover enters'into an intimate connection with the foam material in such a way that the air entrapped in the spring core can escape during the foaming process.
  • This air core will then, during the further foaming operation, produce a counter pressure against the foaming pressure.
  • the thus formed air core is therefore during the manufacture of the mattress very advantageous during the foaming operation.
  • edges of the mattress may, in conformity with a further feature of the invention, be applied in the form of a reinforcing fabric or the like which intimately combines with the soft foam.
  • a reinforcement may, in conformity with a further feature of the invention, be applied in the form of a reinforcing fabric or the like which intimately combines with the soft foam.
  • certain edges of the mattress may be designed in a simple manner as form retaining edges. Textile fabric, wire fabric, fabric of synthetic material, wood or metal parts, are particularly suitable for this reinforcement.
  • a coating layer for the spring core for instance, a textile fabric
  • the spring core is, in said mold, covered with the soft foam layer so that the coating layer firmly combines-with the soft foam layer.
  • the cover layer is, due to its fixed connection with the soft foam cover, prevented from slipping. Due to this cover, also the reinforcing areas are covered by the inserted fabric.
  • said covering layer is pressed against the inner wall of the mold by gas under pressure. This gas filling is, advantageously, during the introduction of soft foam, withdrawn 'to the extent to which the soft foamisintroduced into the mold.
  • the soft foam layer is thicker or thinner at the side of the spring core than it is at the two large surfaces of the spring core.
  • the spring core may have a height of 7.5 centimeters, and the soft foam layer at the top and bottom side may have a height of approximately 3 centimeters, while the soft foam layer at the sides may have a thickness of approximately 2 centimeters.
  • the thinner side parts of the soft foam layer have a higher weight per volume during the foaming operation and thereby become stiffer so that a laterial stiffening, and consequently an increase in the form stability will be assured.
  • a spring core 24 (FIG. 1) is provided with a cover 25 which may be formed, for instance, by an envelope of nettle cloth, jute, or the like.
  • the thus formed spring core 24 is placed in a foaming mold 26 which comprises two mold sections 27 and 28. Between the inner surface of the foaming mold 26 and the-outer surface of the cover 25, there is provided a gap 29 extending all the way around said spring core 24, The height of this gap corresponds to the desired height of the layer of foam material.
  • the spring core24 is floatingly arranged, and this floating mounting may be realized by pins or similar spacer means (not shown in the drawings).
  • the material to be foamed is then introduced into the closed mold composed of the sections 27 and 28 through one or more feeding passages 30 and is foamed directly around the spring core 24 so that a layer of foam material closed in itself forms the surface of the spring core.
  • FIG. 2 shows a further embodiment of a mattress with a preferred size ratio between the spring core 24a and the cover 32 of foam material.
  • the layer 32 of foam material has a thickness which is only slightly less than half the height of the spring core 24a.
  • the lateral parts 33 of the foam material layer 32 are only slightly thicker than a fourth of the height of the spring core 240. These lateral parts 33, however, have a greater density and thus have an increased stiffness or rigidity.
  • reinforcements 34 in the form of textile fabric or the like are embedded in the layer 32 of foam material so that the mattress will have form retaining edges.
  • the entire layer 32 of indicated by the arrow 4, and which when looking down on the spring core 24a have an angular or corner shape.
  • the springs are, in the transverse direction (arrow 4) of the spring core, arranged adjacent to each other in rows 5 whereas in longitudinal direction of the spring core (arrow 3) are arranged one after the other in rows 6, 7.
  • the individual springs are interconnected by fine wires 8 10 extending in transverse direction (arrow 4) and furthermore interconnected by fine wires 11 13 extending in longitudinal direction (arrow 3).
  • the outermost spring coils 14 of the springs 1 are located in planes which are parallel to the plane of the spring core. These outermost coils are formed by three legs 15 16 arranged at a right angle with regard to each other. The next two legs 18, 19 adjacent to the outermost spring coil 14 extend at an inclination with regard to the plane of the spring core. The then adjacent legs 20, 21 of the spring 1 are again located in a plane parallel to the plane of the spring core. The inclination of the legs 18, 19 is so selected that the distance of the legs 20, 21; 15, 16 which are plane parallel to the spring core will in the longitudinal direction of the spring 1 equal approximately the length of the legs 15, 16, 18, 19, 20 and 21. With the embodiment illustrated in the drawing, the legs 15, 16; 20, 21 are located in four superimposed planes parallel to each other.
  • the springs 1 when seen from the top have a substantially trapezoidal shape while each two legs 15, 16; 20, 21 are forming a right angle with regard to each other and the other two oppositely located legs 18, 19 define with each other an angle of slightly less than 20
  • the springs l of the spring rows 6, 7 extending in the longitudinal direction (arrow 3) of the spring core are arranged in the respective rows 6, 7 in a position corresponding to each other.
  • the springs 1 of the rows 6, 7 which extend in the longitudinal direction (arrow 3) and are adjacent to each other in the transverse direction (arrow 4) are offset with regard to each other by 90 in such a way that, for instance, the spring end legs 17 of said adjacent rows 6, 7 are ofiset to each other by 90.
  • each spring row extending in the longitudinal direction (arrow 3) of the spring core are arranged in the same position, but are offset with regard to the springs of the adjacent spring row by 90.
  • the legs parallel to the plane of the spring core and respectively pertaining to two adjacent spring rows are located directly adjacent to each other while the legs 15, 16 which are arranged along a straight line one behind the other are interconnected by fine wires 13 in such a way that according to FIGS. 3 and 4, always two fine wires 13 are arranged directly adjacent to each other. This brings about that the legs 15, 16 of the adjacent spring rows can in response to a load acting upon the spring move toward each other and thereby can support each other.
  • the longitudinal central area of the spring core is reinforced by the fine wire 13 arranged in pairs adjacent to each other so that also in the central area a sufiicient force of the spring core will be assured.
  • the asymmetry of the springs is balanced with regard to each other by the offset arrangement of the individual springs.
  • the springs l are so arranged that in the longitudinal direction of the spring core (arrow 3) and in the transverse direction thereof (arrow 4) always two legs 16, 20; 15, 16; 21, 20, are located along a straight line and plane parallel to the plane of the spring core one behind the other.
  • the helical fine wires 8 13 are wound around these just-mentioned legs of the spring 1.
  • the outermost windings 14 are interconnected by means of two fine wires 8, 9; 11, 12 pointing in the same direction whereby an additional reinforcement of the marginal area 2 of the spring core will be assured.
  • the marginal area 2 of the spring core may also be reinforced by one or more flat steel frames 22, as shown in FIG. 5.
  • Such frame 22 is connected to the marginal springs located in the marginal area and is preferably embedded in the cover of foam material.
  • the ends 23 of the fine wires 8 13 are bent at a right angle and are wound around the legs of the corresponding springs 1, said legs forming the marginal area 2 of the spring core.
  • the soft foam may be so foamed upon the cover 25 of the spring core that it combines with the cover in such a way that this layer will have great strength, especially against wear. Between the spring core and the soft foam layer proper there is thus formed an intermediate layer which will assure a safe support on the spring core.
  • the method according to the invention is not limited to the making of mattresses, but also covers the making of upholstered bodies, such as seats for automobiles, and the like.
  • a method of making an upholstered body having a core body comprising metallic springs which includes the steps of enclosing said core body within the walls of a closed mold with space between the core body and mold walls on all sides, and introducing foaming material into said space between the core body and mold walls, completely filling said space with foamed material to surround said core body on all sides, so that the core body and air are enclosed within said foamed material and act to cushion said upholstered body.
  • a method of making an upholstered body having a core body comprising metallic springs which includes the steps of covering the core body with sheet material, enclosing the covered core body within the walls of a closed mold with space between the core body and mold walls on all sides, and introducing a foaming material into said space between the core body and mold walls, completely filling said space with foamed material to surround said core body on all sides, so that the core body and air are enclosed within said foamed material and act to cushion said upholstered body.
  • a method of making an upholstered body as claimed in claim 2 which includes the step of lining the walls of the mold with a sheet material to form a cover for the foamed material of the upholstered body.
  • a method of making an upholstered body having a core body comprising metallic springs which includes the steps of covering the core body with textile material, enclosing the covered core body within the walls of a closed mold with space between the core body and mold walls on all sides, in-

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
US753391A 1967-08-19 1968-08-19 Method of making an upholstered body Expired - Lifetime US3660876A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US00250328A US3821823A (en) 1967-08-19 1972-05-04 Upholstered body and method of making same

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE1685176 1967-08-19

Publications (1)

Publication Number Publication Date
US3660876A true US3660876A (en) 1972-05-09

Family

ID=5687288

Family Applications (1)

Application Number Title Priority Date Filing Date
US753391A Expired - Lifetime US3660876A (en) 1967-08-19 1968-08-19 Method of making an upholstered body

Country Status (8)

Country Link
US (1) US3660876A (en, 2012)
AT (1) AT278508B (en, 2012)
BE (1) BE719635A (en, 2012)
CH (1) CH481614A (en, 2012)
DE (1) DE1685176A1 (en, 2012)
FR (1) FR1576350A (en, 2012)
GB (1) GB1243514A (en, 2012)
NL (1) NL6811592A (en, 2012)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3790972A (en) * 1970-03-18 1974-02-12 Mirabed Ag Spring core mattress and method of making same
US20070083996A1 (en) * 2005-10-13 2007-04-19 Wells Thomas W Continuous wire spring mattress or seating product and method of manufacture
US20080083069A1 (en) * 2006-10-06 2008-04-10 Dell Accio Giacomo Foam mattress

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH658778A5 (de) * 1982-06-28 1986-12-15 Spuehl Ag Federkern fuer eine matratze.
AU603209B2 (en) * 1987-04-29 1990-11-08 Plaskona Industries Pty Ltd Vandal resistant seat
GB2204235B (en) * 1987-04-29 1990-10-03 Henderson S Federal Spring Wor Vandal resistant seat
GB2205491B (en) * 1987-06-08 1991-03-13 Tachi S Co Method of making a seat cushion

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3090154A (en) * 1959-06-26 1963-05-21 Gen Motors Corp Cushion and method of manufacture
US3142515A (en) * 1959-12-03 1964-07-28 Gen Motors Corp Unitary seat construction
US3258511A (en) * 1961-12-22 1966-06-28 Mobay Chemical Corp Process for the manufacture of upholstery

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3090154A (en) * 1959-06-26 1963-05-21 Gen Motors Corp Cushion and method of manufacture
US3142515A (en) * 1959-12-03 1964-07-28 Gen Motors Corp Unitary seat construction
US3258511A (en) * 1961-12-22 1966-06-28 Mobay Chemical Corp Process for the manufacture of upholstery

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3790972A (en) * 1970-03-18 1974-02-12 Mirabed Ag Spring core mattress and method of making same
US20070083996A1 (en) * 2005-10-13 2007-04-19 Wells Thomas W Continuous wire spring mattress or seating product and method of manufacture
US7251847B2 (en) * 2005-10-13 2007-08-07 L&P Property Management Company Continuous wire spring mattress or seating product and method of manufacture
WO2007047391A3 (en) * 2005-10-13 2007-12-13 L & P Property Management Co Continuous wire spring mattress or seating product and method of manufacture
US20080083069A1 (en) * 2006-10-06 2008-04-10 Dell Accio Giacomo Foam mattress

Also Published As

Publication number Publication date
DE1685176A1 (de) 1975-02-06
NL6811592A (en, 2012) 1969-02-21
AT278508B (de) 1970-02-10
BE719635A (en, 2012) 1969-02-03
FR1576350A (en, 2012) 1969-07-25
GB1243514A (en) 1971-08-18
CH481614A (de) 1969-11-30

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