Dreamwell, Ltd.

Michael DiMarco

Michael Stephen DeFranks

Bernhard W Kuchel

Larry Banks

Michael W Mauldin

The systems and methods include a feed mechanism supplying multi-strand wire to a coil-spring winder. The coil spring typically has a plurality of turns and is resilient. The multi-strand wire is typically steel, but may be of other suitable material, or a combination of materials. The coil-spring winder receives wire from a spool of wire and forms that wire into a coil spring. Typically, but not always, the coil-spring winder cuts the coil spring to a desired length, and thereby forms a plurality of coil springs of the type that can be employed in mattresses, furniture, car seats, for industrial machines, or for any other application. To feed the coil-spring winder, the systems include a wire holder that supplies the wire to the coil-spring winder along a feed direction. The wire holder is supported for rotation about an axis that may be aligned with the feed direction. The rotation of the wire holder may be substantially synchronous with the formation of the turns of the coil spring. In one embodiment, the spool of wire is mounted onto a wire holder rotatable about a holding axis for reducing torque about a cross section of the wire. Thus, as the spool of wire revolves around the central spool axis, the spool also revolves around a second axis, which typically is orthogonal to the spool axis. In this way, it is understood that the coil-spring winder can pull wire off the spool without it causing twisting that may unravel or snap the multi-strand wire.

Methods for manufacturing coil springs

An apparatus and method for winding strings of pocketed coils onto a spool. The coil spooling apparatus includes a feed mechanism and a spooler. The feed mechanism includes buffer rollers and an adjustable hollow feed arm. The feed arm terminates adjacent to the spooler. The spooler includes a spool with a horizontally or vertically oriented spool core, a drive mechanism, and a turntable base with a pallet. The drive mechanism powers the rotation of the spool core. The rotation of the spooler winds the string of pocketed coils received from the feed mechanism. The feed mechanism buffers the tension and directs the string of pocketed coils along the horizontal and vertical axis. After the desired size of wound package is reached, the rotation of the spooler ceases. The completed wound package can then be lifted while attached to the spool through the use of a fork lift. The vertical spools can be stored and transported in a vertical position since the core base is flat. The spools can be unwound and the springs uncompressed when needed to manufacture mattress constructions.

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Atlanta, GA, United States of America

Michael DiMarco