WO1998053933A1 - Procede et appareil permettant de fabriquer des ressorts a boudin - Google Patents

Procede et appareil permettant de fabriquer des ressorts a boudin Download PDF

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Publication number
WO1998053933A1
WO1998053933A1 PCT/US1998/011355 US9811355W WO9853933A1 WO 1998053933 A1 WO1998053933 A1 WO 1998053933A1 US 9811355 W US9811355 W US 9811355W WO 9853933 A1 WO9853933 A1 WO 9853933A1
Authority
WO
WIPO (PCT)
Prior art keywords
wire
springs
coil
spring
forming
Prior art date
Application number
PCT/US1998/011355
Other languages
English (en)
Inventor
Michael W. Mauldin
Bernard W. Kuchel
Original Assignee
Simmons Company
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 Simmons Company filed Critical Simmons Company
Priority to EP98926211A priority Critical patent/EP1015151A1/fr
Priority to JP11501035A priority patent/JP2000512914A/ja
Priority to SK1613-99A priority patent/SK161399A3/sk
Priority to AU78104/98A priority patent/AU7810498A/en
Priority to BR9809886-1A priority patent/BR9809886A/pt
Priority to IL13318698A priority patent/IL133186A0/xx
Priority to PL98337209A priority patent/PL337209A1/xx
Priority to CA002291822A priority patent/CA2291822A1/fr
Publication of WO1998053933A1 publication Critical patent/WO1998053933A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F33/00—Tools or devices specially designed for handling or processing wire fabrics or the like
    • B21F33/04—Connecting ends of helical springs for mattresses
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/02—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for springs

Definitions

  • the present invention relates to a method and apparatus for manufacturing a strip or length of connected, pocketed coil springs and, more particularly, to a method and apparatus for manufacturing connected, pocketed coil springs which provide for fast, effective, efficient, and inexpensive product.
  • the method and apparatus for making a strip of pocketed coil springs include machinery that coils wire supplied from a large spool, the coil spring is compressed into a space created by folded fabric and the combination is then enclosed using ultrasonic welding. Thereafter, the attitude of the compressed spring is altered and it is expanded within the fabric pocket whereby a line of joined or connected, individually encased, coil springs is created. Multiple strips may then be bonded together by adhesives to form, for example, the central portion of a mattress where upon the strips are encased with upholstery.
  • Manipulating wire induces stress, particularly when the wire is first formed to the desired diameter and again when the wire is formed into coils.
  • small diameter wire is formed from larger diameter wire by forcing the wire, while heated, through progressively smaller dies.
  • a coil typically is formed by forcing "cold" wire against a die that bends the wire in a desired fashion.
  • stress relief of the finished coil could be accomplished by batch heating the formed springs in an oven, or connecting each spring to an electrical source and passing a current through the wire. Neither of these processes are particularly effective or efficient. Batch heating results in springs with inconsistent characteristics in that those in one part of an oven may be heated differently from those in another part of the oven. With electric current heating, consistent and proper heating depends upon an operator's ability to consistently connect each spring in exactly the same way. In addition, use of electric current sometimes creates an undesirable electric arc which may mechanically degrade a spring.
  • the present invention provides for a substantial improvement on the previous methods and apparatus for producing a strip of connected, pocketed coil springs.
  • What is first described here is a method for making a length of connected, pocketed coil springs comprising the steps of providing a wire adapted to be formed into a plurality of coil spring, providing material for forming a plurality of spaces, each space to receive a coil spring, heating the wire to a temperature for relieving stress in the wire, forming the wire into a coil spring while the wire is at an elevated temperature, cooling the resulting coil wire spring to a temperature where intended deformation of the spring will be below the elastic limit of the wire, compressing the coil spring, manipulating the material to form the spaces, inserting the compressed coil springs into the spaces, and enclosing the material around each of the spaces to form a plurality of connected, spring filled pockets.
  • An apparatus for forming a length of pocketed coil springs comprising in combination a wire supply apparatus for providing a wire to be coiled, a heating apparatus operatively connected to the wire supply apparatus for induction heating the wire as it passes from the supply apparatus to a coil forming apparatus, a coil forming apparatus operatively connected to the heating apparatus for bending the wire while the wire is at an elevated temperature, a severing apparatus operatively connected to the coil forming apparatus for separating coil wire springs from the wire supply apparatus, a cooling apparatus operatively connected to the coil forming apparatus for reducing the temperature of the coil wire springs, a material supply apparatus operatively connected to the coil forming apparatus for providing a length of material, a pocketing apparatus operatively connected to the material supply apparatus for receiving the length of material from the material supply apparatus and for receiving the coil wire springs from the cooling apparatus wherein each of the springs is inserted into a corresponding space formed by the length of material, an enclosing apparatus operatively connected to the
  • An object of the present invention is to provide a method and apparatus which allow for stress relief of the metal wire that forms the coil springs of a length of connected, pocketed springs.
  • Another aspect of the present invention is to provide a method and apparatus for making a strip of connected, pocketed coil springs that integrates heating of the wire from which coil springs are formed so as to relieve stress in the wire.
  • a further aim of the present invention is to provide a method and apparatus for manufacturing a strip of connected, pocketed coil springs which are efficient thereby achieving a cost savings.
  • Yet another advantage of the present invention is to provide a method and apparatus for cooling formed coil springs prior to their insertion in spaces formed in a length of material.
  • Figure 1 is a flow diagram illustrating a method for making a strip of connected, pocketed coil springs.
  • Figure 2 is a diagrammatic view of an apparatus for manufacturing a strip of connected, pocketed coil springs.
  • the present invention relates to a method and an apparatus for making a line of connected, individually pocketed coil springs typically used in mattresses.
  • the structure is commonly known as the Marshall construction.
  • each spring is encased within its own fabric container or pocket.
  • Pockets are generally formed between two plies of a strip of fabric, formed by one piece of fabric being folded upon itself and then fastened together longitudinally and transversely after compressed coil springs are inserted in the spaces between the plies.
  • FIG. 1 there is shown a flow diagram illustrating the method of manufacturing a strip of connected, pocketed coil springs.
  • the process begins with the provision of a spool of wire (10) and a spool of fabric material (12).
  • the spool of material provides a fabric strip to a folding station (14) where the fabric is folded over on itself to form spaces for receiving compressed coil springs.
  • the wire from the spool is heated (16) with the intention of relieving stress induced during the wire making process.
  • the wire is then pushed against a tool (18) while at an elevated temperature which causes the wire to bend into a coiled shape. Because of the heating, the resulting wire is more ductile and there is a reduction in the coil forming stress.
  • the wire is severed (20) freeing the coil spring from the wire strand emanating from the spool.
  • the spring is then cooled (22) in a rotating carousel before the compressing step (24) which compresses the spring to a height of about 0.5 inches.
  • a conveyor may be used.
  • the wire spring is inserted (26) into a space provided in the folded fabric. Thereafter, the combined spring and fabric are passed to an enclosing station (28) where the fabric is formed into pockets by selectively attaching the two plies of the fabric using ultrasonic welding. The attachments occur both between each spring and along the longitudinal ends where the fabric strip folds come together or overlap. This forms an enclosure around each spring.
  • the final step is orienting or turning (30) the spring in the pocket thereby allowing the spring to fully expand so as to create (32) the final length of connected, pocketed coil springs.
  • the wire used for the springs is upholstery spring wire, SAE1065- SAE1075, and is one of three diameters: 0.071 inches, 0.083 inches or 0.094 inches.
  • Tensile strength of the wire is approximately ASTM 230,000 to 305,000 p.s.i. It is, of course, understood that the tensile strength is a function of wire size and material.
  • the wire is usually provided in feed rolls or supply reels (50) where the wire is wound around a tubular steel carrier in lengths of about 79,000 feet or 1800 pounds.
  • the wire is pulled off the carrier by a set of powered rollers (51) operating at a speed to move the wire at approximately 320 feet per minute.
  • Suitable wire may be purchased from Insteel Wire Products of Andrews, South Carolina.
  • the wire then passes through a magnetic induction heating apparatus or station (52).
  • the heating apparatus is a 25KW induction device which may be purchased from Inductoheat of Romeo, Michigan.
  • the heating apparatus is formed in an insulative box, measuring about 43 inches long, 6 inches high and 6 inches wide. The heating apparatus will increase the temperature of the wire to between 450 °F and 500°F in approximate 0.63 seconds.
  • the purpose of the heating apparatus is to heat- treat or stress-relieve the wire of those stresses induced during the wire manufacturing process and to provide a ductile material for coil forming, thereby reducing forming stresses.
  • the heating process like the entire process, is conducted in a stop/go or on/off manner.
  • the heater is activated only when the wire is moving. When there is a pause in the movement of the wire the heating apparatus is turned off. This insures consistent heating of each wire segment.
  • the wire is heated in lengths of about 41 inches, and each spring is about 9 inches in length.
  • the wire After the wire is heated it moves to a forming apparatus or station (54) where the wire is formed into a coiled shape while at an elevated temperature. This is done by forcing or pushing the wire against a tool.
  • the tool is hardened steel and is shaped to bend the wire pushed against it in a continuous and predetermined manner. The result is a coil of about 2 5/8 inches in diameter.
  • the wire is severed by a moveable cutting blade which shears the wire as it is forced against a stationary blade. It is to be noted that heating the wire before it is coiled allows for the "hot" forming of each spring.
  • each coil spring is moved to a cooling apparatus or station (58) where each coil spring is positioned on a circular cooling carousel (59) which is mounted to rotate in a timed, indexed fashion.
  • the carousel has a number of slots or openings, such as opening (61), for receiving springs. Each spring rests on the carousel as the carousel is rotated for a predetermined time.
  • the amount of time each spring spends on the carousel is a function of the required temperature drop.
  • the carousel is designed to support each spring for the predetermined time.
  • the design of the carousel is a function of the manufacturing rate, the number of slots to be used and the position of the carousel slots when the springs are received and expelled by the carousel.
  • the spring may be subjected to cooling air from a blower (57).
  • the power of the blower whether the air should be refrigerated, the amount of air being moved, the temperature of the air and other such factors are a function of the predetermined cooled temperature to be reached, the velocity of the carousel, the starting temperature of the spring, the size of the opening or slot in the carousel and the diameter of the carousel, for example.
  • the desired "cooled" temperature is approximately 150°F.
  • the cooled spring is moved to a compressing apparatus or station (60) where an air operated piston descends and compresses each coil spring to about a half inch in preparation for its insertion into a pocket.
  • the cooled spring temperature approximately 150°F, is a function of the metal used and should be below that temperature where a permanent deformation set will occur when the spring is compressed. Thereafter, the compressed spring is inserted into a fabric pocket; hence, the temperature must also be sufficiently low so as to not burn the fabric.
  • a fabric material supply apparatus or station (62).
  • a large spool of fabric material provides a length of fabric which is stretchable in a direction parallel to the direction of movement of the fabric.
  • the fabric then proceeds to a folding apparatus or station (64) where the fabric is guided automatically to fold over onto itself to create a space which will later be occupied by the compressed springs.
  • a pair of rollers (65) provide the drive for pulling the fabric from the supply station.
  • the fabric then moves to a pocketing or inserting apparatus or station
  • the loaded fabric moves next to an orienting or turning apparatus or station (70) where the pocketed springs, which will have partially expanded, are rotated by approximately 90° and allowed to expand fully to about 6 3/4 inches.
  • the rotation and full expansion are accomplished by a series of rotating paddles which beat the pockets as the strip is pulled along by a chain drive (71).
  • the final result is a completed length of connected, pocketed coil springs having the usual configuration of a connected row of fabric cylinders.
  • Controlling the process and the manufacturing apparatus is a control apparatus (74) which functions to signal the appropriate stations when each is to perform an operation on the wire or on the fabric. In this fashion, the invention described above allows for a production rate of approximately 72 coil springs per minute.
  • the control apparatus also provides for the stop/go, on/off or indexed movement of the entire process.
  • the inventive method and apparatus provides for a number of advantages. First, stress imparted to a wire during the wire forming stage is reduced and the stress induced during coil forming is minimized. Second, minimizing such stress greatly improves the performance characteristics of the springs. Unwanted and undesirable deformation of the wire is dramatically reduced, and durability of the springs is enhanced.
  • the present invention provides for a heat treating operation which conforms to an in-line manufacturing operation.
  • the heating is rapid, non- contacting, and independent of the condition of the wire.
  • the result is consistent springs from one to the next. Furthermore, no delay is introduced into the existing manufacturing operation.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Wire Processing (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Springs (AREA)

Abstract

La présente invention concerne un procédé et un appareil permettant de former une longueur de ressorts à boudin enfermés dans des poches et reliés entre eux, destinés à des matelas et analogues. Selon ledit procédé, on chauffe (16), avant de l'enrouler, le fil (10) provenant d'une source de distribution à une température comprise entre 450 et 500 degrés Fahrenheit à l'aide d'un appareil chauffant à induction. Ensuite, le fil est enroulé à chaud (18), coupé (20), et refroidi (22) à une température inférieure à la température à laquelle une déformation permanente pourrait survenir lors du traitement ultérieur du ressort. On comprime (24) ensuite le ressort pour le préparer à être inséré (26) dans un espace aménagé dans de la toile extensible provenant d'une bobine débitrice. On replie (14) la toile (12) sur elle-même pour ménager cet espace. La température du ressort doit être assez basse pour que le ressort puisse entrer en contact avec la toile sans la brûler ou l'endommager. Après avoir inséré le ressort comprimé dans l'espace, on soude la toile par ultrasons (28) afin de créer des poches individuelles mais reliées entre elles pour chaque ressort. Enfin, on oriente (30) les ressorts afin que chacun d'eux puisse s'étendre et, ce faisant, on crée la longueur de ressorts à boudin enfermés dans des poches et reliés entre eux.
PCT/US1998/011355 1997-05-30 1998-05-29 Procede et appareil permettant de fabriquer des ressorts a boudin WO1998053933A1 (fr)

Priority Applications (8)

Application Number Priority Date Filing Date Title
EP98926211A EP1015151A1 (fr) 1997-05-30 1998-05-29 Procede et appareil permettant de fabriquer des ressorts a boudin
JP11501035A JP2000512914A (ja) 1997-05-30 1998-05-29 コイルバネを製造するための方法及び装置
SK1613-99A SK161399A3 (en) 1997-05-30 1998-05-29 A method and apparatus for forming a length of connected, pocketed coil springs
AU78104/98A AU7810498A (en) 1997-05-30 1998-05-29 Method and apparatus for manufacturing coil springs
BR9809886-1A BR9809886A (pt) 1997-05-30 1998-05-29 Processo e aparelho para fabricação de molas espirais
IL13318698A IL133186A0 (en) 1997-05-30 1998-05-29 Method and apparatus for manufacturing coil springs
PL98337209A PL337209A1 (en) 1997-05-30 1998-05-29 Method of and apparatus for making helical springs
CA002291822A CA2291822A1 (fr) 1997-05-30 1998-05-29 Procede et appareil permettant de fabriquer des ressorts a boudin

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US86812097A 1997-05-30 1997-05-30
US08/868,120 1997-05-30

Publications (1)

Publication Number Publication Date
WO1998053933A1 true WO1998053933A1 (fr) 1998-12-03

Family

ID=25351115

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1998/011355 WO1998053933A1 (fr) 1997-05-30 1998-05-29 Procede et appareil permettant de fabriquer des ressorts a boudin

Country Status (16)

Country Link
EP (1) EP1015151A1 (fr)
JP (1) JP2000512914A (fr)
CN (1) CN1264327A (fr)
AR (1) AR012893A1 (fr)
AU (1) AU7810498A (fr)
BR (1) BR9809886A (fr)
CA (1) CA2291822A1 (fr)
CO (1) CO4870768A1 (fr)
HU (1) HUP0003166A3 (fr)
IL (1) IL133186A0 (fr)
PE (1) PE43399A1 (fr)
PL (1) PL337209A1 (fr)
SK (1) SK161399A3 (fr)
TW (1) TW407074B (fr)
WO (1) WO1998053933A1 (fr)
ZA (1) ZA984692B (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2347638A (en) * 1999-03-11 2000-09-13 Thomas Patrick Kellett Method and apparatus for manufacturing mattress spring units
WO2009054886A3 (fr) * 2007-10-19 2009-09-11 Nhk International Corporation Procédé de conception d'un ressort hélicoïdal basé sur l'ingénierie inverse
CN103057109A (zh) * 2012-12-20 2013-04-24 昆山三多乐电子有限公司 弹簧自动卷曲装置
US8912472B1 (en) 2010-07-19 2014-12-16 Barnes Group Inc. Induction heating of springs
WO2018118035A1 (fr) * 2016-12-21 2018-06-28 Sealy Technology, Llc Système et procédé de production d'un ressort pour un matelas
WO2020233872A1 (fr) 2019-05-20 2020-11-26 Nv Bekaert Sa Procédé de fabrication d'un noyau de ressorts pour un matelas ou pour des produits d'assise

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN100460105C (zh) * 2007-06-20 2009-02-11 重庆大学 钢丝盒张力抽丝的防变形装置
CN101435476B (zh) * 2007-11-15 2010-09-08 上海中国弹簧制造有限公司 增加负荷检测次数的弹簧生产工艺流程
CN101458533B (zh) * 2007-12-14 2010-05-26 重庆望江工业有限公司 绕制多股螺旋弹簧的钢丝张力控制方法及装置
CN102172746B (zh) * 2011-03-09 2012-12-12 徐建坤 多功能蛇形弹簧生产装置
JP5361098B1 (ja) * 2012-09-14 2013-12-04 日本発條株式会社 圧縮コイルばねおよびその製造方法
CN104438982B (zh) * 2013-09-25 2017-03-01 澳门泰华机械有限公司 袋装弹簧自动生产设备
CN109186156A (zh) * 2018-08-30 2019-01-11 无为县天天乐床垫厂 一种用于床垫弹簧加工用的冷却设备
CN111167979A (zh) * 2019-12-31 2020-05-19 江苏新华合金有限公司 一种利用钢丝生产的弹簧的试制工艺

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2219376A (en) * 1939-11-13 1940-10-29 Young Method of manufacturing coil springs
US3541832A (en) * 1968-10-21 1970-11-24 Torrington Mfg Co Metal forming machine and wire preheating apparatus
US4439977A (en) * 1977-05-05 1984-04-03 Simmons U.S.A. Corporation Method and apparatus for making a series of pocketed coil springs
US5572853A (en) * 1994-08-15 1996-11-12 Simmons Company Method and apparatus for conditioning pocketed coil springs

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2219376A (en) * 1939-11-13 1940-10-29 Young Method of manufacturing coil springs
US3541832A (en) * 1968-10-21 1970-11-24 Torrington Mfg Co Metal forming machine and wire preheating apparatus
US4439977A (en) * 1977-05-05 1984-04-03 Simmons U.S.A. Corporation Method and apparatus for making a series of pocketed coil springs
US5572853A (en) * 1994-08-15 1996-11-12 Simmons Company Method and apparatus for conditioning pocketed coil springs

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2347638A (en) * 1999-03-11 2000-09-13 Thomas Patrick Kellett Method and apparatus for manufacturing mattress spring units
GB2347638B (en) * 1999-03-11 2002-08-07 Thomas Patrick Kellett Method of and apparatus for manufacturing mattress spring units
WO2009054886A3 (fr) * 2007-10-19 2009-09-11 Nhk International Corporation Procédé de conception d'un ressort hélicoïdal basé sur l'ingénierie inverse
US8214184B2 (en) 2007-10-19 2012-07-03 Nhk International Corp. Reverse engineering based coil spring design method
US8912472B1 (en) 2010-07-19 2014-12-16 Barnes Group Inc. Induction heating of springs
US10472695B1 (en) 2010-07-19 2019-11-12 Barnes Group Inc. Induction heating of spring
CN103057109A (zh) * 2012-12-20 2013-04-24 昆山三多乐电子有限公司 弹簧自动卷曲装置
WO2018118035A1 (fr) * 2016-12-21 2018-06-28 Sealy Technology, Llc Système et procédé de production d'un ressort pour un matelas
WO2020233872A1 (fr) 2019-05-20 2020-11-26 Nv Bekaert Sa Procédé de fabrication d'un noyau de ressorts pour un matelas ou pour des produits d'assise

Also Published As

Publication number Publication date
CA2291822A1 (fr) 1998-12-03
CO4870768A1 (es) 1999-12-27
BR9809886A (pt) 2000-06-27
PL337209A1 (en) 2000-08-14
AR012893A1 (es) 2000-11-22
JP2000512914A (ja) 2000-10-03
AU7810498A (en) 1998-12-30
IL133186A0 (en) 2001-03-19
CN1264327A (zh) 2000-08-23
EP1015151A1 (fr) 2000-07-05
ZA984692B (en) 1999-01-04
TW407074B (en) 2000-10-01
HUP0003166A3 (en) 2001-03-28
HUP0003166A2 (hu) 2001-02-28
SK161399A3 (en) 2000-08-14
PE43399A1 (es) 1999-05-06

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