WO2001019559A1

WO2001019559A1 - Apparatus and methods of forming resilient materials

Info

Publication number: WO2001019559A1
Application number: PCT/NZ2000/000182
Authority: WO
Inventors: Lynn Craig Turner
Original assignee: Sleepyhead Manufacturing Company Limited
Priority date: 1999-09-15
Filing date: 2000-09-15
Publication date: 2001-03-22
Also published as: AU774484B2; AU7462700A

Abstract

The invention is directed to an apparatus (1) for predeterminedly configuring a resilient blank of material (5) including a support (2) means for said material, at least one configuring means (30) positionable according to at least two intersecting axes relative to said blank, said configuring means actuable to configure said blank by forming at least one bore (A) therein in a predetermined position, movement provided between said support and said configuring means on said axes to control the relative position of said configuring means and said blank during forming of said bore and to methods for configuring a mattress in particular.

Description

APPARATUS AND METHODS OF FORMING RESILIENT MATERIALS

TECHNICAL FIELD

This invention relates to apparatus and methods of manufacture of resilient elements such as a primary or ancillary resilient elements, for example mattress cores, overlays and the like.

The apparatus and method is particularly relevant to the manufacture of a resilient mattress element of the foam spring type having metal compression springs housed in bores in a resilient foam "blank" or "core", however is not limited to such resilient members. The apparatus and method is essentially relevant to all configurations of resilient members.

BACKGROUND ART

In the past, when forming a resilient member to have a plurality of apertured bores therein for housing the metal compression spring members, substantially as described in relation to New Zealand patent specification No. 330983 (equivalent to Australian application No. 391 933/99) and others, generally the resilient foam member has either been pre-formed with appropriate bores therein, or alternatively, a foam "blank" has been created and is subsequently provided with the apertures or bores therein, for example by the use of appropriate cutting, boring or grinding machinery. Such arrangements have been both time consuming and have often resulted in damage or product loss as a result of imperfect operation, for example tearing of portions of the blank adjacent the apertures. There is also a difficulty in providing repeatably, and/or with sufficient accuracy a controlled positioning of the apertures to enable mattresses to be desirably "posturised" in their resilience to suit the intended users physical characteristics of weight, shape and size. Forming of the mattress blank with the bores was a time consuming procedure being a primary rate limiting step in the mass production of mattresses and is a limitation on automated manufacture in respect of aspects of production of mattresses, preventing reduction in the labour component in the final product.

OBJECT OF THE INVENTION

It is accordingly an object of the invention to come some way in overcoming the above-mentioned problems or at least provide the public with a useful choice.

It is a further object of the invention to provide an apparatus and method which covers some way in facilitating the convenient and efficient configuration of a resilient element in a substantially controlled, efficient and repeatable manner.

SUMMARY OF INVENTION

According to one aspect of this invention there is provided an apparatus for predeterminedly configuring a resilient blank of material including a support means for said material, at least one configuring means positionable according to at least two intersecting axes relative to said blank, said configuring means actuable to configure said blank by forming at least one bore therein in a predetermined position, movement provided between said support and said configuring means on said axes to control the relative position of said configuring means and said blank during forming of said bore.

Preferably the movement provides between said support and said configuring means on said axes is made relative to predetermined data.

According to a further aspect of this invention, the configuring means is movably positioned relative to the support, said configuring means moveable according to one of said axes arranged substantially longitudinally of the blank, and another axes arranges substantially transversely of the blank.

According to a further aspect of the invention, the configuring means is moveably positioned relative to the support, said configuring means movable according to one of said axes arranged parallel with at least one side portion of the blank, preferably when supported on said support.

According to a further aspect of this invention, a plurality of configuring means are provided each to be operable independently movable one relative to the other.

According to a still further aspect of this invention, the configuring means is secondarily movable relative to the support.

According to a further aspect of this invention, the support means for the blank is movable relative to said configuring means, or vice versa.

According to a still further aspect of the invention, the configuring means includes hollow rotational boring means adapted for boring said blank means and for removing a bore slug of resilient material from said blank.

According to a further aspect of this invention there is provided a method of configuring a mattress including the steps of positioning at least one configuring means in a predetermined position relative to a resilient material blank supported in a predetermined position, bringing the mattress blank and an actuated configuring means together to configure said blank with a bore therein in a predetermined position, the predetermined positional relationship of the configuring means and blank controlled by data controlled positioning means for said configuring means in relation to said blank, or vice versa.

Other aspects of this invention will become apparent from the following description which is given by way of example of one form of the invention. The invention is not limited to the one form described and modifications and developments may be incorporated without departing from the scope or spirit of the invention.

Alternative embodiments to the apparatus described in this form are also outlined hereinafter and may be incorporated into the invention as described, or alternative forms as outlined.

DRAWINGS

In describing the invention in more detail, reference will be made to the accompanying drawings in which -

Figure 1 Is a substantially diagrammatic perspective view of an embodiment of the apparatus incorporating a substantially static support table and a longitudinal movable gantry table having a transversely movable operable configuring means thereon.

Figure 2 is a similar view to that of Figure 1 , however showing the apparatus having ganged configuring means and furthermore, showing in broken lines a typical arrangement of resilient blanks mounted on the table.

Figure 3 Is a substantially diagrammatic cross sectional side elevation of a typical boring tip of the configuring means, showing the apparatus partially boring a portion of resilient material forming the blank with apparatus 4 slug removal after boring of the slug from the blank.

Figure 4 Shows a substantially similar view to that of Figure 3, showing alternative slug removal apparatus utilising air pressure as an alternative to the mechanical means of Figure 3.

Figure 5 Shows a still further alternative arrangement of slug removal in a view similar to that of Figures 3 and 4.

DETAILED DESCRIPTION

In general terms, the invention is directed to an apparatus for the formulation of a resilient member, such as would be used in a mattress for example. The invention is also generally directed to a method of forming such a product. However, whilst the invention is described with reference to the formation of a resilient member for a mattress incorporating a plurality of compression springs mounted within bores, substantially as described in the before-mentioned patent specification, and as shown substantially diagrammatically in relation to the drawings hereinafter, the invention is not limited to the configuration of a mattress resilient member and could be alternatively incorporated into other assemblies and arrangements, for example furniture, cushioning, seating, squabs, buffers, resilient overlays, packing and cushioning materials for domestic, transportational and other purposes.

The preferred form of the invention is described with reference to the formation of a typical "double" mattress which is preferably formed utilising a polyurethane foam blank bored from a surface which is intended to lie adjacent a first use surface, to adjacent the opposite surface and in a variety of bore "patterns" so as to enable metal compression springs of predetermined sizes to be inserted therein. The mattress is thus posturised by varying the compression spring positioning (by the varying positioning of the bores) to enable, for example the mattress to be "tuned", to use by a light person (where the mattress requires preferably different resilience characteristics to that required for a heavy person) substantially, but not exclusively, as outlined in our co-pending New Zealand patent application No. 330983 (equivalent to Australian application No. 391 933/99 - the disclosure of which is herein incorporated in its entirety by way of reference).

In the preferred form of the invention, the apparatus is preferably connected to a computer based numerically controlled positioning arrangement to enable positioning of configuring means for creating the bores in the foam blank according to predetermined patterns, for example patterns selected from a variety of standard configurations which can be selected by the apparatus operator to most closely approximate the pattern required to suit the weight and body characteristics of the person for whom the mattress may be intended.

In other forms of the invention the apparatus can be provided to configure the mattress blank in a substantially standard or other custom or one off form in a substantially automated manner, to efficiently form the bores within the mattress blank in a manner which minimises "rate limiting" aspects of this part of production in a production line, for greater sufficiency.

In the preferred form of the invention the configuring means is preferably formed as either a single or a plurality of "ganged" boring apparatus each arranged to be brought into configuring contact with the foam blank at predetermined positions. Preferably the boring means is arranged to remove a substantially externally cylindrically shaped "slug" of resilient material from the resilient blank to enable insertion, either simultaneously, or subsequently of a spring or other resilient means therein, to provide the appropriate resilience characteristics for the mattress. Whilst this preferred form of the invention proposes the configuring means to be movable relative to the support for the resilient blank, it is to be appreciated that in alternative forms of the invention, the apparatus and method can be alternatively adapted to provide a substantially fixed single or ganged configuring means, and where the resilient blank is brought into and out of configuring relationship with the configuring means on appropriate positioning of the blank.

Referring to the drawings and in particular, Figures 1 and 2 thereof, the forming apparatus as generally indicated by arrow 1 incorporates a support 2 which is preferably provided as a legged support table having a supporting surface 4 preferably arranged of a size to suit the typically largest size of mattress resilient member 5 (see broken lines on Figure 2 thereon).

Preferably the apparatus is manufactured from a selection of appropriately robust and durable metal and other materials, for example mild steel, aluminium alloy and the like.

Preferably longitudinal sides 6 of the support 2 each are provided with rails 7 arranged to extend substantially along the longitudinal sides 6 thereof, to position a movable gantry 8 longitudinally movable thereon according to arrow 9. In the preferred form of the invention, movement of the gantry 8 is controlled by servo actuated and numerically controlled prime mover driven belt means 10 preferably toothed belt means 10 coupled with the gantry 8 at 1 1 and operating around drive and driven toothed gears 1 2 provided at or adjacent the ends 1 3 of the table. In the preferred form of the invention servo motors (not shown) driving at least one pair of toothed gears 12 are numerically controlled via suitable computer means to control the extent of rotation thereof, and thus the positioning of the gantry 8 longitudinally relative to the table 2 according to the longitudinal axis 9.

Preferably barrier fence means 1 6 are provided on at least 2 peripheral edges of the table 2, and in the preferred form adjacent a longitudinal side, and a conjoining end 1 3 of the table 2 so as to assist in positioning the foam blanks 5 thereon, and maintaining that positioning. Preferably the fence 1 6 is formed in suitable sheet material, for example sheet stainless steel, plywood and the like.

In the preferred form of the invention and as shown in Figure 2, preferably the supporting surface 4 of the table top incorporates a foamed sheet 1 7 thereover, which provides a substantially "gripping" surface for co-acting with the opposing surface of the foam blank 5 thereon and provide retainment in use.

The gantry 8 is mounted by rollers (not shown) positioned adjacent a base 20 of the gantry 8 on the rails 7 to each longitudinal side of the table 2. In the preferred form of the invention, the gantry 8 is formed in substantially light materials, for example aluminium alloy and the like and is arranged to overlie and substantially span the table top 2 at a height to clear an upper surface 5A (see Figure 2) of the foam blank 5 uppermost, and in the preferred form of the invention, preferably double stacked foam blanks 5 as is shown in Figure 2.

The gantry 8 incorporates a pair of transverse rail members 21 being spaced apart and extending transversely of the gantry to movably mount at least one, or (as will be seen with reference to Figure 2), a plurality of configuring means 30. In the preferred form of the invention, the configuring means 30 are each provided to be substantially transversely movable relative to the table top 2, on the gantry 8 and positionable in a substantially numerically controlled and belt driven manner (not shown) similar to that described with reference to the longitudinal side 6 of the table 2. The configuring means 30 mounting 31 is preferably arranged as a substantially inverted U-shape 31 positioned about the spanning portion of the gantry 8 and movable transversely according to the numerically controlled mechanism. A first leg 31 a (see Figure 1 ), of the mounting 31 incorporates a rail mount 32 which mounts a car member 33 which is movable, being raisable and lowerable relative to said table top 2 to bring (in this embodiment) a substantially parallely orientated boring tube 34 into and out of boring contact with the resilient members 5 mounted on the table 2, at predetermined intervals, and when the position of the boring tube 34 is set up in the correct position to bore a predetermined bore or bores A (see Figure 2), in the foam blank 5 mounted there beneath.

In the preferred form of the invention, the car 33 preferably incorporates a prime mover 35 mounted thereon to controllably drive the rotation of the boring tube 34. In addition, preferably the prime mover 35 also empowers a moving means (not shown), connected between the car 33 and the mounting 31 , so that upon actuation of the boring tube 34, the prime mover 35 brings the boring tube 34 into contact with the foam blank 5, bores the foam blank 5 and then returns the boring tube 34 to a retracted rest position substantially as is shown in Figure 1 , ready for a further actuation.

While it will be appreciated that the position of the boring tube 34 is controlled by the transverse movement of the configuring means 30 on the gantry 8 and longitudinal positioning of the gantry 8 relative to the resilient blank 5, limited secondary movement of the boring tube 34 within predetermined parameters is also achievable by sliding mountings (not shown), which are provided for the boring tube 34 assembly at least in one and preferably in two or more intersecting axes under the influence of suitable secondary moving means, for example, fluid driven rams, or electrically operated lever mechanisms and the like. This arrangement will, on actuation, provide a high degree of positional control of the boring tube 34, and thus the positioning of bores A in the resilient blank 5.

It is envisaged that the positional control of the configuring means 30 and in particular, the boring centres of the boring tube 34, will ultimately be substantially automatically controlled by computer, with reference to inputted predetermined data, however the invention is not limited to this configuration.

It is also envisaged that alternative arrangements, such as manually selected parameters may be appropriate in certain circumstances.

The gantry 8 additionally provides a movable conveying means 40 thereon. Preferably the conveyor 40 is arranged as a substantially channelled member having a movable conveyor belt 41 therein, adapted to run transversely of the table 2 to facilitate removal of "slug " (not shown), of resilient material removed from the blank 5 by the boring tube 34 on actuation.

The conveyor 40 is movable according to arrows 43 according to a longitudinal axis of the table 2, and on rails 44 on which the conveyor 40 slides under the influence of moving mechanisms, for example a pneumatic rams 45. In this form of the invention, preferably the conveyor 40 positions at a rest position where it is substantially positioned away from the boring tube 34 axis of operation (the opposite of that shown in Figures 1 and 2), so that the boring tube 34 can operate between the conveyor 40 and the remaining gantry portions 8. On retraction of the boring tube 34 after actuation, a sequencing mechanism will actuate the rams 45, to draw the conveyor 40 to a position as is shown in Figure 1 , substantially beneath the boring tube 34, whereupon a longitudinally actuated pusher member 50 (see Figure 3) can remove the slug of resilient material removed from the resilient blank 5 and held inside the boring rube 34 on to the conveyor 40, whereupon the conveyor 40 can take the slug away for disposal, recycling, or alternative use. With reference additionally to Figures 3 and 4, the preferred form of the invention, the boring tube 34 is preferably provided as a substantially hollow mechanism, driven from its periphery via suitable belt mechanisms connected with the prime mover 35 of the configuring means 30 to, upon actuation, rotate the boring tube 34 and bring a sharpened tip 51 into contact with the blank 5 drill or bore the blank 5, leaving slug inside the tube 34. It will be appreciated that the slug will pass through an annular bore 52 defined within the sharpened edge of the tip 51 and which remains lodged in the tube 34 until removed by the pusher ram 50 on to the conveyor 40.

In the preferred form of the invention, the boring tube 34 is provided to be substantially hollow formed, that is, where the sharpened tip 51 of the boring tube 34 is provided to have a bore of a somewhat lesser diameter (see Figures 3 and 4), than remaining internal portions of the tube. During boring action, the slug once separated from the resilient member 5 (which rotates at a speed of up to approximately 3000 rpm) passes through a substantially restricted opening of the tip 51 and then lodges as is shown by broken lines of Figure 3, substantially upwardly of the tip 51 , until forcibly removed. This assembly controls the slug once separated from the remaining portions of the resilient blank 5 and enable convenient and secure removal at the intended time.

In the preferred form of the invention, the drill tip 51 is removable and is preferably attached via screw threading at 53 and preferably the periphery 54 of the tip 51 is slightly greater than the periphery of remaining portions of the tube forming the boring tube 34, such that in use a small clearance is provided between remaining portions of the tube 34 and any formed bore. At least the exterior, and preferably also the exterior of the boring tube 34 are formed with a slip coating, for example a PTFE (Teflon™) to reduce frictional interaction between the boring tube 34 and remaining portions of the resilient blank 5 in use.

The removable tip 51 of the boring tube 34 facilitates the convenient exchange of blunt tips with resharpended tips, so as to conveniently provide maintenance ability.

Whilst the invention has been described with reference to slug removal by the ram means 50 on to the conveyor 40, in an alternative form of the invention, substantially as is shown diagrammatically in relation to Figure 4, an alternative form of the invention incorporates the boring tube 34 extending upwardly to position an upper portion 60 thereof, to be coupled with a coupling 61 °, which in the preferred form of the invention is provided as a substantially slidable coupling, to facilitate connection of the boring tube 34 in communication with a vacuum connection 62 coupled to a vacuum pumping arrangement (not shown). In this form of the invention a pivotable transfer tube 63 is mounted to pivot between a first position X and a secondary position (as is shown by broken lines) where in the first position X, the transfer tube 63 positions substantially between the vacuum connection 62 and the upper open end of the boring tube 34, and substantially seals therewith, and moving to the second position Y, the transfer tube 63 pivots out of register with the vacuum connection 62 and upper end 60 of the boring tube 34, to align the transfer tube 34 in communication with an air pressure means 64 adjacent an upper end 63a thereof, to orientate an open bottom 63b thereof, directed toward the conveyor 40 alongside.

Preferably the upper end 63a of the transfer tube 63 is provided with a small restriction or perforated baffle therein to enable a vacuum from the vacuum connection 62 to be applied through the transfer tube 36 to the boring tube 34 at least whilst said boring tube 34 is rotational use. Furthermore, it is anticipated that sliding seals provided to each end of the transfer tube 63, and the relevant portions of the vacuum connection 62 and boring tube 34 upper end 60 are sufficient to provide a sufficiently workable seal for vacuum to be applied to the tube 34 in use.

With particular reference to Figure 4 the operation of the pivoting of the transfer tube 63 is sequenced to operate in conjunction with other aspects of the apparatus, such that during boring operations, that is, when the boring tube 34 is in contact with, and is boring the blank 5, the transfer tube 63 is the first position X and applies vacuum to the interior of the boring tube 34. As the boring operation reaches a conclusion, it will be appreciated that the vacuum applied to the boring tube 34 has the effect of sucking the detached "slug" of blank separated by the boring action into the transfer tube 63 such that it lodges adjacent the baffle as is shown by broken lines of Figure 4. Thereafter, the transfer tube 63 is moved to the second position Y; pressure P applied by the air pressure means 64 overcomes any frictional and static attachment of the slug to the transfer tube 63 and removes it into the adjacent conveyor 40, for disposal.

In this form of the invention, it is envisaged that the vacuum at the vacuum connection 62, and the air pressure of the air pressure means 64 is provided continuously, however this is in no way essential to the invention and in alternative arrangements it is envisaged that one or both of the air vacuum and air pressure may be provided sequentially pulsed at the appropriate time to control the movement of the detached slug in the manner substantially as is described.

In a still further alternative embodiment of the invention as shown diagrammatically in relation to Figure 5, an alternative form of the invention incorporates the boring tube 34 extending upwardly to position the upper portion 60 thereof to be coupled with a rotatable coupling 61 which enables the vacuum connection 62 to facilitate connection to the appropriate vacuum system for removal of the slug upwardly through the boring tube 34 once formed, to an appropriate low pressure receiving means suitable slug "reticulation" pipework (not shown).

In this form of the invention, not only does the arrangement provide for convenient controlled removal of the slug it has also been found that the low pressure area created in the vicinity of the tip 51 of the boring tube 34 as the boring tube 34 is brought into contact with the foam blank 5 and during boring operations, the suction created on the partially formed slug and the surrounding area of the blank 5 (substantially as is showing in Figures 4 and 5), and the resultant the pressure differential created between the interior of the boring tube and the ambient external tip pressure assists in the boring action reducing any tendency for portions of the blank 5 adjacent the bore puckering, thus enabling delicate boring of blank 5 of low density. Additionally, boring of bores very close together which would ordinarily, in the absence of application of vacuum lead to possible tearing of the inter bore wall areas, can be achieved. The stabilisation effect created by the application of vacuum during boring operations materially assists the effectiveness of the boring action.

Where a plurality of blanks 5 are mounted one above the other, it is also envisaged that vacuum applied to the interior of the boring tube 34 and adjacent blank area during boring operations will reduce any tendency for movement of the foam blanks 5 one relative to the other as the tip 51 breaks through from one blank 5 to the next.

Turning to Figure 2 in particular, in this form of the invention, a substantially similar arrangement to that described with reference to the necessary figures can be provided, however, in this form of the invention, preferably a plurality of ganged configuring means 30 are provided on the gantry 8, each being substantially independently movable one relative to the other. In this arrangement it is envisaged that the speed of production can be significantly increased and furthermore, a wider variety of predetermined positions of apertures can be provided, particularly utilising the ability to independently move the boring tubes 34 centres one relative to the other utilising the secondary movement facility described hereinbefore.

In a still further embodiment of the invention, it is envisaged that the configuring means 30 may be provided as a plurality of independently operable "heads", each substantially permanently mounted to the gantry 8 arrangement, with sufficient configuring means 30 to provide a row of predetermined bores across the resilient blank 5 where required, the secondary movement facility provided for the configuring means 30 being utilised to bring the boring tubes 34 into the required positions, and to enable variation of the positional density of the bores created in the resilient blanks 5 for posturisation.

Whilst the invention has been described with reference to a substantially static table 2 and a movable gantry 8, together with a single or multiply ganged configuring means 30 mounted on the gantry 8, it is alternatively envisaged that the configuring mechanism can be provided as a single or multiply headed arrangement in a static assembly with the table 2 being movable according to at least one axis or more axes intersecting whereby upon actuation, the configuring means 30 may be brought into and out of engagement with the resilient blank 5, or alternatively, where the table is raisable and lowerable relative to the configuring means to achieve the perforation or boring of the resilient blank 5 as predetermined.

It will be appreciated that whilst the manufacture of mattress blanks adopting a generally rectangular configuration is the primary focus of the invention, the apparatus and the method of use is also highly applicable to the formation of resilient componentary of irregular shapes, for example, odd sized shaped bed mattresses, boat or caravan squabs configured to fit within unusual shape confines and the like. The advantage of this apparatus and method for forming resilient blanks for these types of structures is that the apparatus can be specifically programmed or manually operated to configure the resilient blank in a manner which best meets use requirements, specifically enabling the resilient blanks 5 to be tailored and otherwise configured to their use.

Whilst the invention has been described with reference to the preferred boring arrangement as described particularly in relation to the drawings, the invention is not so limited and could incorporate alternative configuring arrangements, for example water jet and laser cutting heads and alternative configurations to drilling.

Furthermore, whilst the invention in the preferred form of the invention contemplates a resilient blank 5A having a substantially planar or "block like" configuration where the upper surface is substantially flat, in other forms of the invention it is envisaged that the surface of the blank 5 may be alternatively configured and furthermore, that the gantry assembly may incorporate additional cutting means so as to configure resilient blank 5 into a predetermined, for example, non uniform configuration and for a bore density to be adjusted to inter- relate with the configurational shapes if required. It is anticipated that profiling or configuration of the surface of the resilient blank 5 could also be achieved by the addition of "fly cutting" devices (not shown), positioned outwardly of a periphery of the boring tube 34, so that when the boring tube 34 is approaching a position of maximum operational depth (such that as the boring device 34 reaches its maximum travel) the fly cutter comes into operation and configures portions of the blank 5 surface adjacent to the bore A to a predetermined shape. Thus by this invention there is provided a method and apparatus for predeterminedly configuring a resilient blank in relation to a predetermined arrangement.

The invention has been described with reference to preferred forms and examples thereof. Alterations or modifications to the invention, or to component parts or steps thereof, as would be obvious to a skilled person are intended to be included within the scope and spirit of the invention as defined in the appended claims.

Claims

1 . Apparatus for predeterminedly configuring a resilient blank of material including a support means for said material, at least

one configuring means positionable according to at least two intersecting axes relative to said blank, said configuring means actuable to configure said blank by forming at least one bore

therein in a pre-determined position, movement provided between said support and said configuring means on said axes

to control the relative position of said configuring means and

said blank during forming of said bore.

2. An apparatus as claimed in claim 1 wherein the movement provided between said support and said configuring means on said axes is made relative to predetermined data.

3. An apparatus as claimed in claim 2 wherein the configuring

means is moveably positioned relative to the support, said configuring means moveable according to one of said axes

arranged substantially parallel with at least one side portion of the blank.

4. An apparatus as claimed in claim 1 wherein the apparatus provides the support means to be moveably positioned relative to the configuring means on the said support being moveable according to one of said axes arranged substantially parallel with a side portion of a blank when supported on said support.

5. An apparatus as claimed as claimed in claim 1 wherein a plurality of configuring means are provided each to be operable

independently moveable one relative to the other.

6. An apparatus as claimed in claim 5 wherein said plurality of

configuring means are controllably moveable in both a primary and secondary movement phase independently one relative to the other.

7. An apparatus as claimed in any one of preceding claims wherein the configuring means include a hollow rotational boring means

adapted for boring said blank means and for removing a bore

slug of material from the said blank.

8. An apparatus as claimed in claim 7 wherein removal of the slug

from the blank is by way of a passage internally of said boring means.

9. A method of configuring a mattress including the steps of positioning at least one configuring means in a pre-determined position relative to a resilient material brank supported in a pre- determined position, bringing the mattress blank and an actuated configuring means together to configure said blank with a bore therein in a pre-determined position, the pre¬

determined positional relationship of the configuring means and blank controlled by pre-determined data.

10. A method as claimed in claim 9 wherein the pre-determined

positional relationship of the configuring means on blank is controlled by data controlled positioning means for said

configuring means relative said blank.

1 1 . A method of configuring a mattress as claimed in claim 9

wherein the pre-determined positional relationship of the configuring means and blank is controlled by data controlled

positioning means for a support for said blank in relation to said configuring means.

1 2. A method of configuring a mattress as claimed in claim 9

including the stamp of forming pre-determined sets of data selected relative to potential user body data and utilising such

data to control the pre-determined positional relationship between said configuring means and said blank during configuration.

1 3. An apparatus substantially as herein described with particular reference to any one of the attached Figures.

4. A method of configuring a mattress substantially as herein

described with particular reference to any one of the attached

Figures.