Simmons U.s.a. Corporation

Simmons Company

Sidhil Technology, LLC

International Bedding Corporation, Inc.

Walter Stumpf

Paul J Dillon

W Kenneth McLaren

The subject matter is a cushion core construction in which individual elements of cushion material in plug-like form are connected together in a string by capturing them between two strips of flexible sheet material which are joined together between adjacent elements to hold the elements in place. The preferred structural unit is a two-row module formed by joining two such strings at intervals of at least two elements to enable them to stand alone, and to facilitate their handling in their assembly with like modules to form a more extensive core.

Jacketed cushioning elements and assemblies thereof in mattresses and upholstery

This method and apparatus contemplate the making of pocketed springs for mattresses and cushions by inserting compressed springs at intervals along and between the plies of a folder two-ply strip of sheeting, maintaining the springs compressed therein while seaming the edges of the plies to form a sleeve about the compressed springs as the strip is drawn lengthwise toward a release point at which each spring is free to expand to spread the plies. This transposes the edge seaming to mid-height of the spring. A previously made cross seam incorporating the transposed edge seaming limits the forward movement of the spring and a further such cross seam made behind the spring encloses the spring within an individual pocket of the sleeve. The repetition of spring release and cross seaming behind each spring released produces a string or chain of pocketed springs with the closing seam of the sleeve at mid-height of the springs.

Method and apparatus for the manufacture of pocketed springs

Disclosed are pocketed upholstery springs in strip form characterized by placement of the closing seam midway between the ends of the springs of the strip, with the marginal flaps of the pocket strip fabric outwardly of the closing seam folded over as a two-ply belt and incorporated into the cross seams which define the pockets about the springs. Adjacent rows of such strips are joined together by tacking through their respective belts at the cross seams to form two-row modules for ease of mattress/cushion assembly, or to form full-size mattress/cushion constructions by joining row upon row.

Belted pocketed springs and assemblies thereof

The apparatus takes coil springs and sequentially forms fabric pockets around the coil springs to form a string of pocket coil springs. It includes a system for forming a length of folded fabric for movement on a frame, a split cylinder which moves to an inclined position to receive a coil spring and then to a generally vertical position to locate the coil spring on a support member and to allow a compressing member to extend through the gap of the split cylinder to compress the coil spring. An inserting device is employed to insert the compressed coil spring between the folded layers of the length of folded fabric which then is moved on the frame to bonding units to allow an edge bond and transverse bonds to be made to form a pocket around each coil spring. The bonding units includes of two stationary ultrasonic bonding devices fixedly located below the length of folded fabric with movable anvils located above the length of folded fabric which are employed for carrying out the bonding operations.

Apparatus for producing string of pocket coils

An encapuslated spring for use with mattresses, cushions, or the like, including a spring enclosed within flexible sheet material, the material being formed in a tubular configuration such that its longitudinal edges are in a flat overlap configuration. The flat overlap configuration reduces a phenomenon known as false loft.

Pocketed coil strings having a flat overlap side seam

An improved array of spring units. In a preferred embodiment, the spring units are composed of polyurethane which are blow molded such that a string of bellows-like springs are provided, with the axial ends of each spring being free for axial compression, while the sides of the springs are left attached to each other during the blow molding process. In another embodiment, the blow molded springs each include a vent hole which affects the dynamic cushioning properties of the springs. In another embodiment, extruded tubes of particular configurations are slotted at spaced-apart intervals such that independent spring units are provided, with the axial ends of each spring being free for axial compression. The array of spring units does not require a fabric covering as do strings of pocketed coils, but may be as easily handled, and may be connected in side-to-side abutting relationship to provide a mattress, cushion, or box spring inner construction.

Mattress or cushion spring array

An improved method and apparatus for constructing an improved pocketed coil string, in which a tube of fabric is formed, a transverse seam is provided across the tube, a partially compressed coil spring is inserted adjacent to the seam, and a second seam is provided, thus encapsulating the spring. The fabric is guided around the outer surface of a tubular mandrel, thus forming a tube, and the spring is inserted into the mandrel such that as the spring exits the opposite side of the mandrel, it is within the tube of fabric. Excessive spring compression is avoided.

Method for providing pocketed coil strings having a flat overlap side

An innerspring construction including adhered strings of pocketed coil springs is provided together with a method of manufacture. Each string is defined by a series of coil springs connected and encased by a fabric cover. The strings are connected to each other by an adhesive applied between the lines of tangency of adjacent coil springs. A method is provided for assembling such a construction. A hot melt adhesive applicator traverses a string of pocketed coil springs depositing a precise amount of adhesive on each coil jacket. A second string is positioned on the first and pressure applied thereto. The applicator then traverses the second string in the same manner as the first. For purposes of efficiency, it may traverse the second string in the opposite direction from which it originally moved with respect to the first. The sequence is repeated until an innerspring construction of desired size is created.

Innerspring construction

A method and apparatus are provided for assembling innerspring constructions from rows of pocketed coil springs. The apparatus includes a surface for supporting the rows and a pressure plate which compresses them slightly while holding them in straight lines. After each row is positioned between the surface and the plate, a hot melt applicator is passed thereby and deposits a selected amount of bonding material to the fabric encasing each coil spring. New rows are pushed into contact with the treated rows and each displaces them by about one coil spring diameter. A plurality of rows are maintained under compression at all times to insure they remain in alignment with adequate frictional contact therebetween. A bar having markings corresponding to each pocketed coil spring within a row is mounted to the apparatus. A beam switch or the like is provided for detecting these markings and actuating the applicator at a selected time as it passes each spring.

Method and apparatus for manufacturing innerspring constructions

An apparatus for manufacturing pocketed coil springs is provided. The apparatus includes a pair of weld heads and an adjustment assembly for moving the heads longitudinally or transversely from each other. The relative position of the weld lines in a fabric passing beneath the heads can accordingly be set with precision. This is accomplished by rotating one of the heads about two axes, one extending through the head and a second axis extending parallel to the first at a selected distance therefrom.

Apparatus for manufacturing pocketed coil springs

A spring assembly is provided including a plurality of interconnected longitudinal blocks of pocketed coil springs. Each block includes a pair of interconnected strips of pocketed springs which are preferably arranged in a square array. Each pair of strips is tightly encased by a flexible cover. The covers are connected to each other along longitudinal hinge lines which allows the assembly to bend easily in at least one direction.

Independent block assembly of springs

A boxspring is provided with stop members for limiting the amount the springs therein can be compressed. The stop members may be light weight hollow cylindrical members fitted within or about a selected number of springs. Supporting braces having a height sufficient to prevent overstressing of the springs when compressed may also be employed. The braces also have the advantage of providing additional stiffness to the boxspring frame. Areas of the boxspring most vulnerable to damage are protected by selective positioning of the stop members.

Boxspring having coil compression stops

An ultrasonic separation apparatus is disclosed which provides simultaneous cutting and sealing of thermoplastic materials. Both relatively thin and thick materials may be cut and sealed. The apparatus includes a cutting mechanism having a cutting blade mounted for oscillatory movement along its longitudinal axis. Cutting takes place at a controlled rate to allow sufficient time for simultaneous sealing to occur. The apparatus may be particularly adapted for cutting strings of pocketed coil springs to length.

Ultrasonic separation apparatus

A coil spring construction is provided for incorporation within a mattress or cushion. The construction includes a plurality of independently mounted pocketed coil springs. Resilient stabilizers are provided between the springs to maintain their axial positions. The spring pockets are formed by the sealing of first and second sheets to each other in a substantially circular configuration about the axis of each spring. Spring height is determined by the inside diameter of the seal.

Coil spring construction

The pocketed upholstery springs of the disclosed assembly, made from strips of pocketed springs and intended for use in mattresses or cushions, are connected together in 'square' array, i.e., each spring disposed in mutually perpendicular rows, by connecting the pocket sheeting of adjacent strips together between adjacent springs of each strip, the firmness of the assembly being increased by the nature of the interstrip connection, namely, an elongated connection centered at mid-height of the spring coils.

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Dunwoody, GA, United States of America

Walter Stumpf