U.S. patent application number 10/143377 was filed with the patent office on 2002-09-12 for method of packaging spring units.
This patent application is currently assigned to L&P Property Management Company. Invention is credited to Mossbeck, Niels S., Wells, Thomas J..
Application Number | 20020124531 10/143377 |
Document ID | / |
Family ID | 29418446 |
Filed Date | 2002-09-12 |
United States Patent
Application |
20020124531 |
Kind Code |
A1 |
Mossbeck, Niels S. ; et
al. |
September 12, 2002 |
Method of packaging spring units
Abstract
A method of packaging spring units in which at least one web of
insulator material is fixedly located against one of the top and
bottom surfaces of the spring units. Each web of insulator material
is secured to the outermost coil springs along longitudinal edges
of the spring units with securing elements. The resultant bedding
products are then roll-packed.
Inventors: |
Mossbeck, Niels S.;
(Carthage, MO) ; Wells, Thomas J.; (Carthage,
MO) |
Correspondence
Address: |
J. Dwight Poffenberger, Jr.
Wood, Herron & Evans, L.L.P.
2700 Carew Tower
441 Vine Street
Cincinnati
OH
45202-2917
US
|
Assignee: |
L&P Property Management
Company
South Gate
CA
|
Family ID: |
29418446 |
Appl. No.: |
10/143377 |
Filed: |
May 10, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10143377 |
May 10, 2002 |
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10034823 |
Dec 27, 2001 |
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10034823 |
Dec 27, 2001 |
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09712503 |
Nov 14, 2000 |
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09712503 |
Nov 14, 2000 |
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09397337 |
Sep 15, 1999 |
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Current U.S.
Class: |
53/430 ; 53/436;
53/450 |
Current CPC
Class: |
B65B 9/02 20130101; B65B
63/024 20130101; B65B 63/04 20130101; B65B 63/026 20130101 |
Class at
Publication: |
53/430 ; 53/450;
53/436 |
International
Class: |
B65B 063/04; B65B
009/00 |
Claims
We claim:
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.
11. 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.
12. 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.
13. The method of claim 12 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 1 6 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.
Description
FIELD OF THE INVENTION
[0001] 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
[0002] 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.
[0003] 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.
[0004] 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.
[0005] 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.
[0006] Another machine for packing bedding springs is seen in U.S.
Pat. 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. Pat. No. 2,114,008,
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.
[0007] 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.
[0008] Applicant's U.S. Pat. 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.
[0009] 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.
[0010] It has been a further objective of the present invention to
facilitate and ease the manufacture of spring mattresses by the
mattress manufacturer.
[0011] 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
[0012] 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.
[0013] 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.
[0014] 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.
[0015] 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.
[0016] 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.
[0017] 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.
[0018] 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.
[0019] 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.
[0020] 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.
[0021] 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.
[0022] 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
[0023] FIG. 1 is a perspective view of a first preferred embodiment
of the present inventive method of packaging resilient spring
units;
[0024] FIG. 1A is a cross-sectional view of a spring unit being
compressed in a transverse direction prior to application of the
securing elements;
[0025] FIG. 1B is a cross-sectional view similar to FIG. 1A,
illustrating securing elements being applied to join the insulator
pad or pads and edgemost coil springs of the spring units;
[0026] FIG. 1C is a cross-sectional view taken along line 1C-1C of
FIG. 1
[0027] FIG. 2 is a side view of bedding products being roll
packed;
[0028] FIG. 3 is a perspective view of an alternative embodiment of
the present inventive method of packaging resilient spring
units;
[0029] FIG. 4 is a cross-sectional view of a bedding product
produced by the method illustrated in FIG. 3;
[0030] FIG. 5 is a flow chart of the method illustrated in FIG.
6;
[0031] FIG. 6 is a perspective view similar to FIG. 3 but
illustrating an alternative embodiment of the present invention;
and
[0032] FIG. 7 is a flow chart of a portion of the method of the
present invention;
[0033] FIG. 8 is a cross-sectional view similar to FIG. 1C,
illustrating hog rings to secure the insulator pad or pads to
select coil springs of the spring units;
[0034] FIG. 9 is a cross-sectional view similar to FIG. 1C,
illustrating extruded plastic to secure the insulator pad or pads
to selected edgemost coil springs of the spring units;
[0035] 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
[0036] As can be seen in FIGS. 1 and 1A, 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. 1C, the spring unit 10 has a thickness T defined
between the first surface 12 and the second surface 14. As
illustrated in FIG. 1 , the spring unit 10 also has opposing end
surfaces 16a, 16b and opposing side surfaces 18a, 18b.
[0037] 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 12 and a bottom
turn 24 comprising a portion of the second surface 14.
[0038] The first and second surfaces 12, 14 of the spring unit 10
are covered with first and second webs 26, 28, respectively, of
insulator material. The insulator material used to cover the first
and second surfaces 12, 14 of the spring unit 10 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 12, 14 of the spring
unit 10, respectively.
[0039] As seen in FIGS. 1A, 1B and 1C, 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 10 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 10. The lengths of the
first and second webs 26, 28 are considerably longer than the
longitudinal dimension L of a single spring unit 10 so that plural
spring units 10 may be packaged by the inventive method described
in further detail below.
[0040] In the present inventive method of packaging a spring unit
10, 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 10 may be received therebetween. A conveyor 48 transports the
spring unit 10 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 12, 14, respectively, of the
spring unit 10.
[0041] In a first embodiment, after the first and second webs of
insulator material 26, 28 are located against the respective first
and second surfaces 12, 14 of the spring unit 10, 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. 1B and 1C.
[0042] In one embodiment of the present invention illustrated in
FIGS. 1A-1C, the spring unit 10 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 10 are moved temporarily from their at rest position
illustrated in dashed lines to a compressed position illustrated in
solid lines in FIG. 1A. As illustrated in FIG. 1B, after webs of
insulator material 26,28 are located against surfaces 12, 14 of the
spring unit 10, 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 10,
thereby securing the side portions 36 of each of the first and
second webs 26, 28 to the spring unit 10. As illustrated in FIG.
1C, 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 10 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.
[0043] After the first and second webs 26, 28 have been located
against the first and second surfaces 12, 14 of the spring unit 10
and permanently secured thereto by application of the securing
elements 57 as described above, the spring unit 10 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.
[0044] 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.
[0045] 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 12, 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 10. 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.
[0046] 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.
[0047] 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.
[0048] 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.
[0049] 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.
[0050] 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.
[0051] 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.
[0052] 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.
[0053] 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.
[0054] 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.
[0055] 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.
[0056] 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.
[0057] 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.
* * * * *