WO2003095312A1

WO2003095312A1 - Method of packaging spring units

Info

Publication number: WO2003095312A1
Application number: PCT/US2003/014602
Authority: WO
Inventors: Niels Mossbeck; Thomas J. Wells
Original assignee: L & P Property Management Company
Priority date: 2002-05-10
Filing date: 2003-05-08
Publication date: 2003-11-20
Also published as: US20020124531A1; AU2003241404A1

Abstract

A method of packaging spring units (10) in which at least one web of insulator material (26, 28) is fixedly located against one of the top (12) and bottom (14) surfaces of the spring units (10). Each web of insulator material (26, 28) is secured to the outermost coil springs (20) along longitudinal edges of the spring units (10) with securing elements (57). The resultant bedding products are then roll-packed.

Description

METHOD OF PACKAGING SPRING UNITS

Cross-Reference to Related Applications

This patent application is a continuation-in-part application of

U.S. Patent Application Serial No. 10/034,823 filed December 27, 2001 ,

entitled METHOD OF PACKAGING SPRING UNITS, which is a continuation-

in-part application of U.S. Patent Application Serial No. 09/712,503 filed

November 14, 2000, entitled METHOD OF PACKAGING SPRING UNITS,

now abandoned. U.S. Patent Application Serial No. 09/712,503 is a

continuation-in-part application of U.S. Patent Application Serial No.

09/397,337, filed September 15, 1999, entitled "METHOD OF

PACKAGING SPRINGS AND RESULTING PACKAGED PRODUCT", now

abandoned. All of the above-identified applications are fully incorporated by

reference herein. Field of the Invention

This invention relates to the packaging of springs. More

specifically, this invention relates to a method of roll-packing plural spring

units.

Background of the Invention

At the present time, most mattress spring core assemblies are

manufactured by a spring company and then compressed and shipped in a

crate to a mattress manufacturer, who then uncrates the spring cores,

applies a primary insulator to the top and bottom surfaces of the mattress,

and then applies conventional padding and upholstery to complete the

mattress. In order to keep the mattress springs straight and avoid the

mattresses top and bottom surfaces being permanently canted and distorted

as the springs are compressed for shipment in a crate, there are rods

inserted through the springs during the compression process. These rods

function to prevent misalignment of the top and bottom surfaces of the

springs during compression, which rods are then removed after compression

and during shipment within the crate.

As an alternative to compression of the springs for shipment in

crates, some spring assemblies are compressed and roll-packed while

sandwiched only between separator plies of paper or plastic, which paper or

plastic may be either discarded or reused, depending on the nature of the

separating materials. For instance, it is known in the art to pack spring units for use

in making mattresses by winding disposable paper or re-usable hessian

around a mandrel and feeding the spring units successively into the nip

between the growing roll and the traveling web material. The spring units

are compressed as they are drawn into the roll, and the result is that the

roll-packed springs have a much reduced volume as compared to

conventionally stacked spring units.

One type of machine known for this purpose has a winding

mandrel to which a holding bar is bolted by its ends for holding the leading

end of a packing web material. An upwardly moveable pressure roller is

mounted above the mandrel so as to define therewith an entry nip for the

web material. The web material is fed from a reel supported at the rear of

the machine over the pressure roller and on to the mandrel. An operator

standing at the front of the machine feeds springs into the entry nip.

Another machine for packing bedding springs is seen in U.S.

Patent No. 4,669,247. The '247 patent describes packing spring units into

a roll with a web of disposable paper or reusable material. A similar spring

packing machine is seen in U.S. Patent No. 2,1 14,008, in which a roll of

disposable wrapping paper is fed along a table and into a wrapping

mechanism whereat spring assemblies are placed upon the paper and fed

into the machine by the paper movement. All of these prior art machines compress and wrap springs in a

single web of disposable paper or reusable material which separates the

multiple layers of spring units in a roll and maintains the springs in a

compressed state for shipment from a spring manufacturer to a mattress

manufacturer. The mattress manufacturer then must apply and attach an

insulated pad to at least the top and usually the top and bottom of the

spring unit before adding conventional padding and upholstery to the unit to

complete the mattress.

Applicant's U.S. Patent No. 6,357,209 discloses a method of

packaging spring units in which at least one layer of insulator material is

permanently secured to multiple spring units before the spring units and

insulator material are roll packed. One method of securing the insulator

material to the spring units disclosed in this patent is to fold side portions of

the web of insulator material around end turns of the outermost coil springs

of the spring units and then secure the side portions of the web of insulator

material to a central portion of the web of insulator material. If a thick or

heavy layer of insulator material is used, folding the layer of insulator

material around the end turns of the outermost coil springs of the spring

units may be difficult or impractical.

Therefore, it has been one objective of the present invention to

provide a method of roll packaging spring units in which the spring units are

packaged in part with a relatively heavy layer of insulator material of a width identical to the width of the spring units that becomes part of the

mattress and is used by the mattress manufacturer in mattress production.

It has been a further objective of the present invention to

facilitate and ease the manufacture of spring mattresses by the mattress

manufacturer.

It has been yet another objective of the present invention to

provide a series of roll packed spring units in which a relatively heavy

or thick layer of insulator material is permanently applied to the spring units

either as a part of or before the roll packing of the spring units.

Summary of The Invention

The preferred embodiments of the present invention

accomplish these objectives with a method of packaging a plurality of

resilient spring units each comprising a plurality of interconnected coil

springs. In one embodiment of the present invention, first and second webs

of spring insulator material are attached to the spring units so as to be

located against top and bottom surfaces of the spring units. The spring

units with the webs of insulator material permanently attached thereto are

thereafter roll-packed for shipment from a spring manufacturer to a

mattress manufacturer who simply unrolls the spring units and, if the

insulator material had not been previously cut between spring units prior to

roll packing, cuts the insulator material between the spring units and proceeds to complete the mattress by adding conventional padding and

upholstery.

Each spring unit has a uniform depth defined by a generally

planar top or first surface and a parallel generally planar bottom or second

surface. The spring unit has a longitudinal dimension or length defined by a

pair of opposed parallel end surfaces and a transverse dimension or width

defined by a pair of opposed parallel side surfaces. The longitudinal

dimension or length is generally greater than the transverse dimension or

width of the spring unit as in most bedding products. However, a square

spring unit in which the longitudinal and transverse dimensions are equal

may also be packaged using this inventive method.

The method of the present invention includes providing a first

and usually first and second web rolls of insulator material spaced from one

another. The first web roll includes a first web of spring insulator material,

e.g., woven or non-woven material, wound about a core. Similarly, the

second web roll includes a second web of spring insulator material wound

about a core. Each of the first and second webs of insulator material have

a pair of opposed side edges defining a width of the web which is

approximately equal to the transverse dimension or width of each spring

unit.

The first web of insulator material is passed over and located

against the first surface of the spring unit, and the second web is passed under and located against the second surface of the spring unit. The

longitudinal dimension of the spring unit is generally parallel to the opposed

side edges of the first and second webs which are generally parallel to one

another.

In one preferred embodiment, the first and second webs are

secured to the top and bottom turns of the edgemost coil springs of the

spring unit by the application of securing elements. These securing

elements may be pieces of adhesive tape, hog rings or equivalent fasteners

or any other elements separate from the insulator pads. In another

embodiment, only one web of insulator material is secured to the end turns

of select edgemost coil springs of the spring unit by the application of

securing elements.

In yet another embodiment of this invention, the fastener or

securing element may be a flexible, extruded plastic fastener which is

extruded onto the edge of the spring unit and the edge of the covering

insulator material after that insulator material is applied to the top and/or

bottom surface of the spring unit and before the combined spring unit and

insulator pad is roll packed. The extruded plastic fastener may be shaped

and sized so as to secure the edge of the insulator pad to the edge of the

spring unit or the plastic of the extruded plastic fastener may have

sufficient adhesive properties to adhere the insulator pad to the spring unit.

In any event, the extruded flexible fastener element acts as a border rod on the sides of the spring unit to which it is applied as well as an insulator pad

fastener element.

The bedding product having the insulator material permanently

attached thereto is inserted into a roll packing machine in which the bedding

product is compressed and rolled onto a dowel or mandrel whereafter the

bedding product is removed from the dowel or mandrel and maintained in

this rolled and compressed state for shipment to a mattress manufacturer.

In one embodiment of the present invention, each of the spring

units is compressed in a transverse direction (from side to side) so as to

decrease temporarily the width of the spring unit before the web or cut

sections of web of insulator material are applied to the spring unit. The

distance the spring unit may be compressed is preferably from 0.5 inches to

one inch but may be any distance. After the web or webs of insulator

material are permanently secured to the spring unit with the securing

elements, the spring unit is permitted to de-compress or expand in a

transverse direction (from side to side), thereby causing the web or webs of

insulator material to tighten and become taut in the transverse direction.

This process eliminates any excess insulator material and folds along the

top or bottom surfaces of the spring unit.

In one embodiment of the present invention, after the insulator

material is applied to the first and second surfaces of the spring unit,

additional separator packing material such as paper or sheet plastic is used to separate layers of rolled bedding product. In particular, first and second

webs of separating material are located against respective first and second

webs of insulator material. As the bedding products are roll-packed, the

first and second webs of separating material further package the series of

bedding products.^, Then, the series of packaged bedding products formed

by the spring manufacturer is thereafter shipped to the mattress

manufacturer. The series of roll-packed bedding products is then unrolled

by the mattress manufacturer and, if the webs of insulator material had not

been severed prior to roll packing, are severed into separate bedding

products with the insulator material still applied to each spring unit so that

the mattress manufacturer may use the permanently attached insulator

material in the manufacture of a mattress.

As an alternative to the use of two webs of separating material

located against first and second webs of insulator material during the roll

packing of the bedding product having the insulator material permanently

applied to at least one surface thereof, only one web of separating material

may be utilized. In this event or embodiment, the web of separating

material is first attached to the dowel or mandrel by having at least one

wrap of the separating material applied to the dowel or mandrel after which

the bedding products are sequentially fed into the nip between the dowel or

mandrel and the web of separating material. The separating material then

functions to maintain the roll packed bedding products in a compressed state and separated one from the other as they are rolled up through

multiple plies or layers onto the dowel or mandrel. After an appropriate

number of bedding products have been roll packed onto the dowel or

mandrel, the single web of separating material is then wound about the

exterior of the roll of roll packed bedding products and taped or glued or

otherwise secured to the exterior of the pack to complete the roll pack.

This roll pack is then shipped to the mattress manufacturer where the roll

pack is unrolled by the manufacturer and the web or webs of insulator

material are severed between separate bedding products if the web or webs

of insulator material had not been severed prior to insertion of the bedding

products into the roll packing machine. That mattress manufacturer then

uses the bedding products having the insulator material already permanently

attached to the spring units to manufacture a mattress by simply applying

conventional padding and upholstery to the bedding product.

These and other objectives and advantages of this invention

will be readily apparent from the following description of the drawings.

Brief Description of the Drawings

Fig. 1 is a perspective view of a first preferred embodiment of

the present inventive method of packaging resilient spring units; Fig. 1 A is a cross-sectional view of a spring unit being

compressed in a transverse direction prior to application of the securing

elements;

Fig. 1 B is a cross-sectional view similar to Fig. 1 A, illustrating

securing elements being applied to join the insulator pad or pads and

edgemost coil springs of the spring units;

Fig. 1 C is a cross-sectional view taken along line 1 C-1 C of Fig.

1 ;

Fig. 2 is a side view of bedding products being roll packed;

Fig. 3 is a perspective view of an alternative embodiment of

the present inventive method of packaging resilient spring units;

Fig. 4 is a cross-sectional view of a bedding product produced

by the method illustrated in Fig. 3;

Fig. 5 is a flow chart of the method illustrated in Fig. 6;

Fig. 6 is a perspective view similar to Fig. 3 but illustrating an

alternative embodiment of the present invention; and

Fig. 7 is a flow chart of a portion of the method of the present

invention;

Fig. 8 is a cross-sectional view similar to Fig. 1 C, illustrating

hog rings to secure the insulator pad or pads to select coil springs of the

spring units; Fig. 9 is a cross-sectional view similar to Fig. 1 C, illustrating

extruded plastic to secure the insulator pad or pads to selected edgemost

coil springs of the spring units;

Fig. 10 is a cross-sectional view similar to a portion of Fig.9

illustrating another embodiment of an extruded plastic fastener used to

secure the insulator pad or pads to selected edgemost coil springs of the

spring units.

Detailed Description of the Preferred Embodiment

As can be seen in Figs. 1 and 1 A, a spring unit 10 generally

has a generally planar top or first surface 12 and a generally planar bottom

or second surface 14. The spring unit 10 has a length or a longitudinal

dimension L and a width or a transverse dimension D, the longitudinal

dimension L being generally larger than the transverse dimension D.

However, it will be appreciated by those in the art that L may be

substantially similar to D in dimension. As seen in Fig. 1 C, the spring unit

10 has a thickness T defined between the first surface 1 2 and the second

surface 14. As illustrated in Fig. 1 , the spring unit 10 also has opposing

end surfaces 1 6a, 1 6b and opposing side surfaces 18a, 18b.

The spring unit 10 is generally comprised of a plurality of

aligned coil springs 20 arranged in longitudinally extending columns and

transversely extending rows. The coil springs 20 are secured one to another by means generally known in the art such as helical lacing wires

(not shown). Each coil spring 20 has a top turn 22 comprising a portion of

the first surface 1 2 and a bottom turn 24 comprising a portion of the

second surface 14.

The first and second surfaces 1 2, 1 4 of the spring unit 1 0 are

covered with first and second webs 26, 28, respectively, of insulator

material. The insulator material used to cover the first and second surfaces

1 2, 1 4 of the spring unit 1 0 is generally a woven or non-woven material but

may be any other suitable material. Each of the first and second webs of

insulator material 26, 28 has an outer surface 30 and inner surface 32.

The inner surface 32 of each of the first and second webs of insulator

material 26, 28 is located against the first and second surfaces 1 2, 14 of

the spring unit 10, respectively.

As seen in Figs. 1 A, 1 B and 1 C, each of the first and second

webs 26, 28 has a center portion 34 and opposed side portions 36. Each

of the first and second webs 10 has a substantially similar width W

approximately equal to the transverse dimension D of the spring unit 1 0 so

that the opposed side portions 36 are located generally above or below the

end turns 22,24 of the outermost or edgemost coil springs 20 of the spring

unit 1 0. The lengths of the first and second webs 26, 28 are considerably

longer than the longitudinal dimension L of a single spring unit 1 0 so that plural spring units 1 0 may be packaged by the inventive method described

in further detail below.

In the present inventive method of packaging a spring unit 1 0,

the first and second webs 26, 28 are carried upon respective first and

second cores 40, 42 which allow the first and second webs of insulator

material 26, 28 to be drawn therefrom in reverse directions as indicated by

directional arrows 40a, 42a (see Fig. 1 ) . The first and second webs of

insulator material 26, 28 are drawn between respective first and second

guide rollers 44, 46, the rollers 44, 46 being spaced apart from each other

so that spring unit 1 0 may be received therebetween. A conveyor 48

transports the spring unit 1 0 in the direction of arrow 48a into a space 50

defined between the first and second rollers 44, 46. The first and second

webs 26, 28 are then passed over and under and located against the first

and second surfaces 1 2, 14, respectively, of the spring unit 1 0.

In a first embodiment, after the first and second webs of

insulator material 26, 28 are located against the respective first and second

surfaces 1 2, 14 of the spring unit 1 0, a securing unit 54 applies a securing

element to the spring unit 10 in order to secure the first and second webs

of insulator material 26, 28 to the spring unit 10. See Figs. 1 B and 1 C.

In one embodiment of the present invention illustrated in FIGS.

1 A- 1 C, the spring unit 1 0 is compressed in a transverse direction in the

direction of arrows 55 so that the width W1 of the spring unit 10 is temporarily decreased. The springs 20 of the spring unit 1 0 are moved

temporarily from their at rest position illustrated in dashed lines to a

compressed position illustrated in solid lines in FIG. 1 A. As illustrated in

FIG. 1 B, after webs of insulator material 26,28 are located against surfaces

1 2, 1 4 of the spring unit 1 0, the securing unit 54 wraps a securing element

in the form of adhesive tape 57 around the end turns 22, 24 of the

edgemost or outermost coil springs 20 of the spring unit 1 0, thereby

securing the side portions 36 of each of the first and second webs 26, 28

to the spring unit 1 0. As illustrated in FIG. 1 C, the adhesive tape 57 has a

substantially C-shaped form including an inner leg portion 58 wrapped

around and secured to the end turn of the coil spring 20 and an outer leg

portion 59 which is secured to the outer surface 30 of one of the webs of

insulator material 26, 28. This method of compressing the width of the

spring unit 1 0 prior to the location of the web or webs of insulator material

being applied may be used regardless of which type of securing element is

used.

After the first and second webs 26, 28 have been located

against the first and second surfaces 1 2, 14 of the spring unit 1 0 and

permanently secured thereto by application of the securing elements 57 as

described above, the spring unit 1 0 with the first and second webs 26, 28

permanently secured thereto is then passed to a roll packing machine 60 as

best seen in Fig. 2. The roll packing machine 60 has a plurality of rollers 62 which carry thereon an endless belt 64 traveling in a direction indicated by

directional arrow 64a. The spring unit 10 with the first and second webs

26, 28 attached permanently thereto comprises a bedding or seating

product 68 ready for shipment, for example, from a spring manufacturer to

a mattress or seat manufacturer. As the product 68 is wound about a core

70 upon which it is to be transported, the roll packing machine 60 at least

partially compresses the bedding or seating product 68 so that plural

bedding or seating products 68 may be so packaged.

When the packaged roll of bedding or seating units 68 arrive at

the mattress or seat manufacturer's facility, all that the manufacturer

needs to do is unroll the packaged products from the roll and transverse cut

the webs 26, 28 at a location between the spaced spring units 10. The

resulting bedding or seating product 68 having the insulator material

permanently secured to its top and bottom sides is than ready for

application of the appropriate padding and upholstery materials to complete

the mattress or seat.

Another embodiment of this invention is seen in Figs. 3 and 4

in which like numerals refer to like elements. After the webs of insulator

material 26, 28 are applied to the first and second surfaces 1 2, 14 of the

spring unit 10, additional roll-packing material such as paper or sheet plastic

is used as separating material between layers of rolled bedding products. In

particular, first and second sheets or webs of separating material 72, 74 are located against respective first and second webs of insulator material 26,

28. Each first and second web of separator material 72, 74 has outer and

inner surfaces 76, 78, respectively, and opposed side edges 80, 82 defining

a width. The width of the webs of separator material 72, 74 is similar to

the transverse dimension D of the spring unit 1 0. The first and second

webs of separator material 72, 74 are carried upon respective first and

second cores 84, 86 which allow the first and second webs 72, 74 to be

drawn therefrom. The first and second webs 72, 74 are drawn between

respective first and second guide rollers 88, 90, the rollers 88, 90 being

spaced apart from each other so that the spring unit 10 with the first and

second webs of insulator material 26, 28 applied thereto may be received

therebetween.

Thereafter, as the bedding products 68 are roll-packed, the

first and second sheets of separating material 72, 74 further package the

series of plural bedding products 68. When the roll-packed bedding

products 68 are sent from the spring manufacturer to the mattress

manufacturer, the mattress manufacturer would then unroll the series of

bedding products 68, each being connected by the continuous webs of

insulator material 26, 28, discard the additional webs of separator material

72, 74, and then simply sever the webs of insulator material 26, 28

connecting the series of bedding products 68 to form plural separate

bedding products. Alternatively, the webs of insulator material 26, 28 may be severed between bedding products 68 before roll packing in this

embodiment because of the inclusion of the webs of separating materials

26, 28 between the roll packed bedding products 68.

Thus, in each of the embodiments of the present inventive

method, a series of plural packaged bedding products 68 is formed by the

spring manufacturer which is thereafter shipped to the mattress

manufacturer. The series of roll-pack bedding products 68 is unrolled by

the mattress manufacturer and, if necessary, severed into separate bedding

products with the webs of insulator material 26, 28 still securely applied to

each spring unit.

With reference now to Fig. 6, there is illustrated another

method of roll packing bedding products 68. This method is very similar to

the method illustrated and described hereinabove with reference to Figs. 3

and 4. Accordingly, in this embodiment, those components of the

illustrated system which are identical to the components of Figs. 3 and 4

have been given identical numerical designations.

The method and system illustrated in Fig. 6 is substantially

identical to the method illustrated in Figs. 3 and 4, but differs in that it

omits the use of the second web 72 of separator material. In many

applications, there is no need for a second web of separator material.

In the event that only a single web 74 of separator material is

employed, as illustrated in Fig. 6, the end of the web 74 of separator material is first attached to the dowel or mandrel 70 by having at least one

wrap of the separating material applied to the dowel or mandrel after which

the bedding products 68, - having the web of insulator material already

previously permanently attached thereto - are sequentially fed into the nip

73 between the dowel or mandrel 70 and the web 74 of separating

materials. The web of separating material then functions to maintain the

roll packed bedding products 68 in a compressed state and separated one

from the other as they are rolled up through multiple plies or layers onto the

dowel or mandrel 70.

After an appropriate number of bedding products 68 have been

roll packed onto the dowel or mandrel 70, the single web 74 of separating

material is then cut and wound about the exterior of the roll of roll packed

bedding products 68 and taped or glued or otherwise secured to the

exterior of the pack to complete the roll pack. This roll pack is then shipped

to the mattress manufacturer where the roll pack is unrolled by the

manufacturer and the web or webs 26, 28 of insulator material are

transversely severed between separator bedding products if the web or

webs of insulator material had not been severed prior to insertion of the

bedding products into the roll packing machine. That mattress

manufacturer then uses the bedding product 68 having the insulator

material already permanently attached to the spring units to manufacture a

mattress by simply applying conventional padding and upholstery to the bedding product. This saves the mattress manufacturer from having to

inventory, cut to size and apply the insulator material to the spring unit with

a resulting substantial reduction in manual labor.

With reference to Fig. 5, there is illustrated the method

practiced by the apparatus disclosed in Figs. 3 and 6. As is there evident,

after the application of the insulator webs to the multiple spring units as

depicted in Figs. 1 -4 and 6, the bedding products having the insulator

material permanently applied thereto, are supplied to the roll packing

machine where they are roll packed. The web or webs of insulator material

applied to the spring units may be cut between the spring units before the

bedding products are roll packed or the web or webs may be cut between

the bedding products after unrolling of the roll packed products.

In another alternative embodiment of the present invention

illustrated in FIG. 8, the securing unit 54 applies hog rings 100 or other

mechanical fasteners such as staples around the end turns of select

edgemost or outermost coil springs 20 of the spring unit 10, thereby

securing the side portions 36 of each of the first and second webs 26, 28

to the spring unit 10. Although the end turns 22, 24 of each coil spring 20

along the edge of the spring unit may be mechanically secured with

securing elements 100 to the first and second webs 26, 28; it is within the

contemplation of the present invention that only a few select coil springs

20 are secured with securing elements 100 to the first and second webs 26, 28 of insulator material, regardless which type of securing element is

used.

In another alternative embodiment of the present invention

illustrated in FIG. 9, the securing unit 54 extrudes a flexible hot melt plastic

which wraps around the end turns 22, 24 of the edgemost or outermost

coil springs 20 of the spring unit 10, thereby securing the side portions 36

of each of the first and second webs 26, 28 to the spring unit 10. The hot

melt plastic cools into a substantially C-shaped securement 102 having an

inner leg portion 104 and outer leg portion 106 which is sandwiched

between the inner surface 107 of one of the webs of insulator material and

the end turns of the edgemost coil springs. If the adhesive properties of the

extruded plastic do not adhere to the insulator web, then adhesive may be

extruded or sprayed onto the inner surface 107 of the web 26, 28 before

application of the extruded plastic.

As an alternative to extruding the flexible plastic as a flexible

bead 102 around the outer edge of the edgemost springs of the spring unit

and then applying the web 26, 28 of insulator material against the outer

surface of the outer leg portion 106 of the bead 102, the extruded plastic

may be extruded as a C-shaped bead 102' having an inner leg portion 104'

and an outer leg portion 106' (see Fig. 10). The C-shaped bead 102'

extends around the outer surface 30 of the web and the outer edge of the

edgemost springs to form a longitudinally extending fastener element 102' on the side edges of the combined insulator web and spring unit.

Irrespective of whether the extruded plastic bead 102 or 102' has an outer

leg portion 106 inside (Fig. 9) or outside 106' (Fig. 10) of the edgemost

portion 36 of the web of insulator material 26, 28, the bead of plastic

fastener element acts as a flexible border rod on the edge of the combined

insulator pad and spring unit.

In each of the embodiments discussed above, although the

securing unit 54 is illustrated as being a single unit, it may comprise

multiple elements or applicators. In addition, in each of the embodiments

discussed above, only one web of insulator material may be permanently

secured to the spring units.

From the above disclosure of the detailed description of the

present invention and the preceding summary of the preferred embodiment,

those skilled in the art will comprehend the various modifications to which

the present invention is susceptible. Therefore, we desire to be limited only

by the scope of the following claims and equivalents thereof.

WE CLAIM:

Claims

1. A method of packaging a plurality of spring units, each spring

unit comprising a plurality of coil springs, each of said coil springs having a

top turn and a bottom turn, said top turns of said coil springs defining a

generally planar first surface and said bottom turns of said coil springs

defining a generally planar second surface, said method comprising the

steps of:

providing first and second webs of insulator material, each of

said webs of insulator material being adapted to separate said spring units

from padding to be applied to said spring units,

locating said first and second webs of insulator material

against said first and second surfaces, respectively, of said spring units;

permanently securing said first and second webs of insulator

material to said spring units with securing elements; and

roll-packing said spring units and said webs of insulator

material such that said spring units are at least partially compressed and

upon unrolling, said webs of insulator material remain permanently

connected to said spring units.

2. The method of claim 1 wherein said step of permanently

securing said first and second webs of insulator material to said spring units

comprises taping said top and bottom turns of outermost coil springs of

said spring units to said first and second webs of insulator material.

3. The method of claim 1 wherein said step of permanently

securing said first and second webs of insulator material to said spring units

comprises hog ringing said top and bottom turns of select coil springs of

said spring units to said first and second webs of insulator material.

4. The method of claim 1 further comprising the steps of:

providing first and second web rolls carrying said first and

second webs of insulator material, respectively; and

passing said first and second webs of insulator material

between respective first and second rollers before locating said first and

second webs of insulator material against said first and second surfaces,

respectively, of said spring units.

5. The method of claim 1 further comprising the step of unrolling

said spring units, said spring units remaining connected to said webs of

insulator material.

6. The method of claim 5 further comprising the step of cutting

said webs of insulator material between adjacent spring units.

7. The method of claim 1 wherein said step of permanently

securing said first and second webs of insulator material to said spring units comprises extruding plastic to secure said top and bottom turns of select

coil springs of said spring units to said first and second webs of insulator

material.

8. A method of packaging a plurality of spring units, each of said

spring units comprising a plurality of coil springs, each of said coil springs

having a top turn and a bottom turn, each of said spring units having a

generally planar first surface defined by said top turns and a generally planar

second surface defined by said bottom turns, a longitudinal dimension and a

transverse dimension, said method comprising the steps of:

providing first and second web rolls of insulator material, each

of said web rolls comprising a web of insulator material carried upon a core

and each of said webs of insulator material having inner and outer surfaces,

each of said webs of insulator material being adapted to separate said

spring units from padding to be applied to said spring units;

passing said first and second webs of insulator material over

said first and second surfaces of said spring units, respectively;

applying securing elements around said first and second webs

of insulator material and edgemost springs of said spring units; and

roll-packing said spring units with said first and second webs

of insulator material secured to said spring units such that said spring units

are at least partially compressed and upon unrolling said spring units, said

webs of insulator material remain permanently secured to said spring units.

9. The method of claim 8 further comprising the step of unrolling

said spring units.

10. The method of claim 8 further comprising the step of cutting

said webs of insulator material between adjacent spring units before roll-

packing said spring units.

1 1 . The method of claim 8 further comprising the step of cutting

said webs of insulator material between adjacent spring units after said

spring units are roll-packed.

1 2. A method of packaging a plurality of spring units, each spring

unit comprising a plurality of coil springs, each of said coil springs having a

top turn and a bottom turn, said top turns of said coil springs defining a

generally planar first surface and said bottom turns of said coil springs

defining a generally planar second surface, said method comprising the

steps of:

providing a web of insulator material, said web of insulator

material being adapted to separate said spring units from padding to be

applied to said spring units,

locating said web of insulator material against one of said first

and second surfaces, respectively, of said spring units;

applying securing elements to permanently secure said web of

insulator material to said spring units; and

roll-packing said spring units and said web of insulator material

such that said spring units are at least partially compressed and upon

unrolling, said web of insulator material remains permanently connected to

said spring units.

1 3. The method of claim 1 2 wherein said step of applying securing

elements comprises taping one of said top and bottom turns of outermost

coil springs of said spring units to said web of insulator material.

14. The method of claim 12 wherein said step of applying securing

elements comprises applying a bead of extruded plastic to select coil

springs of said spring units to said web of insulator material.

15. The method of claim 12 wherein said step of applying securing

elements comprises hog ringing select coil springs of said spring units to

said web of insulator material.

16. A method of packaging a plurality of spring units, each spring

unit comprising a plurality of coil springs, each of said coil springs having a

top turn and a bottom turn, said top turns of said coil springs defining a

generally planar first surface and said bottom turns of said coil springs

defining a generally planar second surface, said method comprising the

steps of:

providing first and second webs of insulator material, each of

said webs of insulator material being adapted to separate said spring units

from padding to be applied to said spring units,

locating said first and second webs of insulator material

against said first and second surfaces, respectively, of said spring units;

permanently securing said first and second webs of insulator

material to said spring units with securing elements,

locating at least one web of separator material against one of

said webs of insulator material; and

roll-packing said spring units and said webs of insulator

material such that said spring units are at least partially compressed and

upon unrolling, said webs of insulator material remain permanently

connected to said spring units.

17. The method of claim 16 wherein said step of permanently

securing said first and second webs of insulator material to said spring units

comprises taping said top and bottom turns of outermost coil springs of

said spring units to said first and second webs of insulator material.

18. The method of claim 16 further comprising cutting said webs

of insulator material between adjacent spring units prior to locating said at

least one web of separator material against one of said webs of insulator

material.

19. The method of claim 16 wherein said step of permanently

securing said first and second webs of insulator material to said spring units

comprises hog ringing said top and bottom turns of outermost coil springs

of said spring units to said first and second webs of insulator material.

20. A method of packaging a plurality of spring units, each spring

unit comprising a plurality of coil springs, each of said coil springs having a

top turn and a bottom turn, said top turns of said coil springs defining a

generally planar first surface and said bottom turns of said coil springs

defining a generally planar second surface, said method comprising the

steps of:

providing a web of insulator material, said web of insulator

material being adapted to separate said spring units from padding to be

applied to said spring units,

locating said web of insulator material against one of said first

and second surfaces, respectively, of said spring units;

applying securing elements to said web of insulator material

and said spring units to permanently secure said web of insulator material

to said spring units,

locating at least one web of separator material against said

web of insulator material; and

roll-packing said spring units and said web of insulator material

such that said spring units are at least partially compressed and upon

unrolling, said web of insulator material remains permanently connected to

said spring units.

21 . The method of claim 20 further comprising cutting said web of

insulator material between adjacent spring units prior to locating said at

least one web of separator material against said web of insulator material.

22. A method of packaging a plurality of spring units, each spring

unit comprising a plurality of coil springs, each of said coil springs having a

top turn and a bottom turn, said top turns of said coil springs defining a

generally planar first surface and said bottom turns of said coil springs

defining a generally planar second surface, said method comprising the

steps of:

compressing each of said spring units in a transverse direction;

providing a web of insulator material, said web of insulator

material being adapted to separate said spring units from padding to be

applied to said spring units,

locating said web of insulator material against one of said first

and second surfaces of said transversely compressed spring units,

respectively, of said spring units;

applying securing elements to said web of insulator material

and said spring units to permanently secure said web of insulator material

to said spring units;

allowing each of said spring units to expand in a transverse

direction to tighten said web of insulator material; and

roll-packing said spring units and said web of insulator material

such that said spring units are at least partially compressed and upon

unrolling, said web of insulator material remains permanently connected to

said spring units.