U.S. patent application number 16/076911 was filed with the patent office on 2019-02-14 for resilient unit and method of manufacture.
The applicant listed for this patent is HS PRODUCTS LIMITED. Invention is credited to David CLARE, Michael GALLAGHER, Simon SPINKS.
Application Number | 20190045940 16/076911 |
Document ID | / |
Family ID | 55642090 |
Filed Date | 2019-02-14 |
United States Patent
Application |
20190045940 |
Kind Code |
A1 |
SPINKS; Simon ; et
al. |
February 14, 2019 |
RESILIENT UNIT AND METHOD OF MANUFACTURE
Abstract
A resilient unit (180), such as for a mattress, comprises a
folded pad containing rows of resilient elements (120) in discrete
pockets formed between superposed sheets of material joined at
locations between adjacent resilient elements. Between at least
some adjacent resilient elements the sheets form a gusset (160)
which acts as a hinge when the pad is folded to form the resilient
unit.
Inventors: |
SPINKS; Simon; (Leeds West
Yorkshire, GB) ; CLARE; David; (Leeds West Yorkshire,
GB) ; GALLAGHER; Michael; (Leeds West Yorkshore,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HS PRODUCTS LIMITED |
Leeds West Yorkshire |
|
GB |
|
|
Family ID: |
55642090 |
Appl. No.: |
16/076911 |
Filed: |
February 9, 2017 |
PCT Filed: |
February 9, 2017 |
PCT NO: |
PCT/GB2017/050331 |
371 Date: |
August 9, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 27/064
20130101 |
International
Class: |
A47C 27/06 20060101
A47C027/06 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 10, 2016 |
GB |
1602378.0 |
Claims
1. A resilient unit comprising a folded pad containing rows of
resilient elements in discrete pockets formed between superposed
sheets of material joined at locations between adjacent resilient
elements, wherein between at least some adjacent resilient elements
the sheets form a gusset which acts as a hinge when the pad is
folded to form the resilient unit.
2. A unit according to claim 1, wherein the pad comprises a
plurality of gussets, each between adjacent pairs of resilient
elements in a longitudinal direction of the pad.
3. A unit according to claim 1 or 2, wherein successive gussets are
located on alternate sides of the folded pad.
4. A unit according to any of the preceding claims, wherein at
least some of the resilient elements have axes that extend between
gussets.
5. A unit according to any of the preceding claims, wherein at
least some of the resilient elements have axes that are aligned in
a substantially parallel fashion in the folded pad.
6. A unit according to any of the preceding claims, wherein the
sheets are joined at two or more spaced locations between adjacent
resilient elements to form the gusset.
7. A unit according to any of the preceding claims, wherein a
single resilient element is located between successive gussets.
8. A unit according to any of the preceding claims, wherein a
plurality of resilient elements are located between successive
gussets in the pad.
9. A unit according to any of the preceding claims, wherein the
resilient elements comprise springs.
10. A unit according to any of the preceding claims wherein the
resilient elements comprise coil springs, which of metal wire.
11. A unit according to any of the preceding claims, wherein for at
least some of the springs the axial length of the spring exceeds
the maximum diameter of the spring.
12. A unit according to any of the preceding claims, wherein for at
least some of the springs the axial length of the spring is
substantially equal to, or less than, the maximum diameter of the
spring.
13. A unit according to any of the preceding claims, wherein in the
folded pad at least some adjacent resilient elements are attached
together.
14. A unit according to claim 13, wherein the adjacent elements are
attached together along an axially extending surface of the
resilient elements in the folded pad.
15. A unit according to any of the preceding claims, wherein the
folded pad is held in its folded configuration by a retention
member.
16. A unit according to claim 15, wherein the retention member
comprises a frame or envelope.
17. A unit according to claim 15 or 16, wherein the retention
member comprises a loop or band passing around the folded pad to
prevent it from unfolding.
18. A unit according to any of the preceding claims, wherein the
folded pad is held in its folded configuration by its attachment to
a cover sheet or sheets.
19. A unit according to claim 18, wherein the cover sheet or sheets
cover one or both sides of the folded pad.
20. A unit according to claim 18 or 19, wherein the or each cover
sheet is attached to the folded pad by adhesive or by welding to
one or more positions.
21. A unit according to any of claims 18 to 20, wherein the or each
cover sheet is attached to one or more gussets of the pad.
22. A unit according to any of the preceding claims, wherein the
folded pad is retained in a folded configuration by a case or
bag.
23. A unit according to claim 22, wherein the case or bag includes
padding or cushioning material.
24. A unit according to any of the preceding claims, wherein the
unit comprises a fan-folded, accordion-folded, concertina-folded or
pleated pad.
25. A unit according to any of the preceding claims, wherein the
pad is folded upon itself first one way and then the other such
that alternate gussets are located at first one side then the other
side of the folded unit.
26. A unit according to any of the preceding claims, wherein in the
folded unit at least some rows of resilient elements comprise a
first plurality of springs and a second plurality of springs
superposed on, and/or axially adjacent, the first plurality.
27. A unit according to claim 26, wherein the first and second
pluralities of springs differ in one or more characteristics
including, but not limited to: length, diameter, stiffness, shape,
number of coils and gauge of spring material.
28. A unit according to any of the preceding claims, wherein the
sheets of material on opposed sides of the unit differ from one
another in respect of at least one characteristic from a group
including optical, thermal, tactile, structural, chemical and
physical.
29. A resilient pad for forming a resilient unit, the pad
comprising plural rows of resilient elements in discrete pockets
formed between superposed sheets of material joined at locations
between adjacent resilient elements, wherein between at least some
adjacent resilient elements the sheets form a gusset which acts as
a hinge between resilient elements either side of the gusset when
the pad is folded to form a resilient unit.
30. A method of making a resilient unit, the method comprising
forming a resilient pad by encasing a plurality of resilient
elements in discrete pockets between superposed sheets of material
joined at locations between the resilient elements, forming between
at least some of the resilient elements a gusset, and fan-folding
the pad upon itself using the gussets as hinges, such that
alternate gussets become located on opposed sides of the folded
unit and axes of at least some of the resilient units become
substantially parallel.
31. A mattress comprising a resilient unit according to any of
claims 1 to 28 or made by a method according to claim 30.
Description
[0001] The present invention relates to a resilient unit, and to a
method of making a resilient unit, and is concerned particularly,
but not exclusively, with a resilient unit that can be used for
example in an upholstered article such as a mattress or
similar.
[0002] Pocketed springs, otherwise known as encased springs, are
used in upholstered articles such as mattresses. Most pocketed
spring units comprise coil springs encased individually in pockets
of fabric material formed by folding over a sheet of fabric to form
two leaves that envelope the springs, and then attaching the leaves
together between the springs so as to form a string of springs. The
strings are then joined to form an array of springs as a pocketed
spring unit. The joining of the strings together to form an array
is achieved either by gluing the strings together along the
cylindrical surfaces of the pocketed springs, one string to the
next, and so on until the unit is formed, or else by arranging the
strings beside each other in the manner of an array, and then
gluing sheets of fabric to the cylindrical ends of the pocketed
springs, above and below, so as to form the unit.
[0003] In view of its relatively high cost, there is a desire to
reduce the quantity of adhesive used in the manufacture of such
units.
[0004] An alternative method of forming an array of pocketed
springs is described in our European Patent No. EP 19939473 in
which springs are introduced between axially superposed sheets of
material that are then joined at locations between the springs.
[0005] The present invention is defined in the attached independent
claims, to which reference should now be made. Further, preferred
features may be found in the sub-claims appended thereto.
[0006] According to one aspect of the present invention, there is
provided a resilient unit comprising a folded pad containing rows
of resilient elements in discrete pockets formed between superposed
sheets of material joined at locations between adjacent resilient
elements, wherein between at least some adjacent resilient elements
the sheets form a gusset which acts as a hinge when the pad is
folded to form the resilient unit.
[0007] Preferably the pad comprises a plurality of gussets, each
between adjacent pairs of resilient elements in a longitudinal
direction of the pad.
[0008] Preferably successive gussets are located on alternate sides
of the folded pad.
[0009] Preferably at least some of the resilient elements have axes
that extend between gussets in the folded pad. Preferably at least
some of the resilient elements have axes that are aligned in a
substantially parallel fashion in the folded pad.
[0010] In a preferred arrangement, the sheets are joined at two or
more spaced locations between adjacent resilient elements to form
the gusset.
[0011] A single resilient element may be located between successive
gussets. Alternatively, or in addition, a plurality of resilient
elements may be located between successive gussets in the pad.
[0012] The resilient elements may comprise springs. Preferably the
resilient elements comprise coil springs, which may be of metal
wire.
[0013] The springs may be substantially cylindrical in shape.
Preferably, the springs comprise plural coils and in at least some
springs the coil at one end, more preferably the coils at each end,
is of a reduced diameter. The springs may be other than
cylindrical, such as conical or barrel-shaped for example. This is
so that, when the pad is in the folded configuration the free end
or ends of the endmost coils of adjacent springs do not interfere
with or catch upon one another.
[0014] For at least some of the springs the axial length of the
spring may exceed the maximum diameter of the spring. Alternatively
or in addition, for at least some of the springs the axial length
of the spring may be substantially equal to, or may be less than,
the maximum diameter of the spring.
[0015] In the folded pad at least some adjacent resilient elements
may be attached together. The adjacent elements may be attached
together along an axially extending surface, more preferably a
substantially cylindrical surface, of the resilient elements in the
folded pad. Adjacent elements may be attached together for example
by gluing or welding, such as ultrasonic welding, of the sheet of
material to itself.
[0016] Alternatively, or in addition, the folded pad may be held in
its folded configuration by a retention member, which may comprise
a frame or envelope. The retention member may comprise a loop or
band passing around the folded pad to prevent it from
unfolding.
[0017] Alternatively or in addition, the folded pad may be held in
its folded configuration by its attachment to a cover sheet or
sheets. The cover sheet or sheets may cover one or both sides of
the folded pad, and may be attached to the folded pad by adhesive
or more preferably by welding, preferably to one or more positions
which may comprise the gussets of the pad.
[0018] Alternatively, or in addition, the folded pad may be
retained in a folded configuration by a case or bag. The case or
bag may include padding or cushioning material and the folded pad
inside the case may substantially comprise a mattress.
[0019] In a preferred arrangement the folded unit comprises a
fan-folded, accordion-folded, concertina-folded or pleated pad. The
pad may be folded upon itself first one way and then the other such
that alternate gussets are located at first one side then the other
side of the folded unit.
[0020] The sheets are preferably of a thermally weldable material,
such as spun-bonded polyester.
[0021] In the folded unit at least some rows of resilient elements
comprise a first plurality of springs and a second plurality of
springs superposed on, and/or axially adjacent, the first
plurality.
[0022] The first and second pluralities of springs may differ in
one or more characteristics including, but not limited to: length,
diameter, stiffness, shape, number of coils and gauge of spring
material.
[0023] The resilient unit may comprise plural rows of resilient
elements arranged in an array.
[0024] In the unfolded pad, adjacent rows of resilient elements may
be offset from one another. This is so that, when folded, the
springs are able to fit together more closely, for example to nest,
which helps to form a more stable pad.
[0025] The sheets of material on opposed sides of the unit may
differ from one another in respect of at least one characteristic
from a group including optical, thermal, tactile, structural,
chemical and physical.
[0026] The at least one characteristic may comprise the presence,
absence or degree of at least one property from a group including,
waterproof, probiotic, antibacterial, antistatic, flavour,
fragrance, flame-retardance, elasticity, wear resistance and
permeability.
[0027] The first and second sheets of material may differ from one
another in thickness and/or weight.
[0028] In a preferred arrangement the first and second sheets may
differ from one another in one or more defined zones on one or both
layers, such that the layers may have substantially identical
characteristics in parts and may have different characteristics in
other parts.
[0029] The sheets are preferably joined around the periphery of the
unit.
[0030] According to a second aspect of the invention there is
provided a resilient pad for forming a resilient unit, the pad
comprising plural rows of resilient elements in discrete pockets
formed between superposed sheets of material joined at locations
between adjacent resilient elements, wherein between at least some
adjacent resilient elements the sheets form a gusset which acts as
a hinge between resilient elements either side of the gusset when
the pad is folded to form a resilient unit.
[0031] The resilient pad may be in accordance with any statement
herein.
[0032] The invention also includes a method of making a resilient
unit, the method comprising forming a resilient pad by encasing a
plurality of resilient elements in discrete pockets between
superposed sheets of material joined at locations between the
resilient elements, forming between at least some of the resilient
elements a gusset, and fan-folding the pad upon itself using the
gussets as hinges, such that alternate gussets become located on
opposed sides of the folded unit and axes of at least some of the
resilient units become substantially parallel.
[0033] The invention also includes an article having at least one
resilient unit according to any statement herein.
[0034] The invention also includes a mattress comprising a
resilient unit according to any statement herein, or made according
to a method according to any statement herein.
[0035] In accordance with the invention there is provided a seat
comprising a resilient unit according to any statement herein.
[0036] The seat may be a seat for use in relation to a vehicle,
such as a wheeled vehicle, an aircraft, spacecraft or a ship or
boat, or a saddle for an animal. The seat may comprise a chair,
stool, bench, sofa or settee.
[0037] In accordance with another aspect there is provided a table
comprising a resilient unit according to any statement herein. The
table may be an operating table or massage table, for example.
[0038] In accordance with a further aspect of the present invention
there is provided an article of flooring comprising a resilient
unit according to any statement herein. The article of flooring may
comprise a carpet, or carpet underlay, or a sport mat or exercise
mat, or may be a leisure or sports surface either for indoor use or
for outdoor use.
[0039] In accordance with a still further aspect of the invention
there is provided a protective member, comprising a resilient unit
according to any statement herein. The protective member may
comprise an article of clothing or headgear, or may be a protective
shield to be worn on the body of a user, or for attachment to an
article.
[0040] According to a still further aspect of the invention there
is provided an article of packaging, comprising a resilient unit
according to any statement herein.
[0041] The invention may include any combination of the features or
limitations referred to herein, except such a combination of
features as are mutually exclusive, or mutually inconsistent.
[0042] A preferred embodiment of the present invention will now be
described. By way of example only, with reference to the
accompanying diagrammatic drawings, in which:
[0043] FIG. 1 is a side view of a first embodiment of resilient
unit at a first stage of manufacture;
[0044] FIG. 2 is a side view of the unit of FIG. 1 at a second
stage of manufacture,
[0045] FIG. 3 is a side view of the unit at a third stage of
manufacture;
[0046] FIG. 4 is a perspective view of the unit of FIG. 3;
[0047] FIG. 5 is a side view of an alternative embodiment of
resilient unit at a second stage;
[0048] FIG. 6 is a side view of the unit of FIG. 5 at a third stage
of manufacture; and
[0049] FIG. 7 shows a further alternative embodiment of resilient
unit in accordance with the present invention.
[0050] Resilient units for various uses, in accordance with
embodiments of the present invention, comprise pocketed coil
springs, which are sometimes referred to as encased springs. The
units typically comprise an array of metallic coil springs
individually encased in pockets formed by bonding or otherwise
joining together layers of material.
[0051] Turning to FIG. 1, this shows, generally at 100, a pad for
making into a resilient panel, in accordance with an embodiment of
the present invention. The pad 110 is shown in side view, and only
a single set of pocketed springs can be seen extending in a
longitudinal direction indicated by arrow X, which is also the
direction in which the newly formed pad is fed from the pocketing
station (not shown).
[0052] In fact the pocketed springs are formed in an array, made up
of plural rows of springs side by side.
[0053] The pad comprises a number of springs 120 of coiled metallic
wire (shown in broken lines) encased in individual pockets, one
spring to a pocket in the example shown, formed between superposed
sheets 140 or layers of material joined at positions P between the
springs, preferably by welding. The sheets 140 are joined at least
at two spaced apart positions P between each pair of adjacent
springs 120, so that a gusset 160, or pleat, is formed between each
pair of springs.
[0054] An example of an apparatus and a method for making the pad
shown in FIG. 1 can be seen in our European Patent No. EP 1 993 947
B1, the entire contents of which are incorporated herein by
reference.
[0055] FIG. 2 shows a next step in the forming of the resilient
unit. The springs 120 have been turned within their pockets, so
that their axes A extend longitudinally, between the weld points P.
Turning the springs within their pockets is achieved readily,
particularly with tall springs, as they have a tendency to turn in
any case and need only be urged to do so, for example by vibrating
the pad, or else by utilising a lip or ridge to catch an upper
leading edge of the spring, or a lower trailing edge, thereby
causing it to flip.
[0056] The pad is then folded, or pleated, in the manner of a fan,
concertina or accordion, so that alternate adjacent pocketed
springs are made to extend first one way, and then the other way,
to form a resilient unit 180. During folding, the gussets act as
hinges between rows of springs. When the pad has been folded in
this way the axes of substantially all of the springs become
aligned in a direction that is generally transverse to the
longitudinal extent L of the unit 180.
[0057] Before folding, adhesive is applied at positions G on the
cylindrical surfaces of the pocketed springs. When the pad has been
folded into the configuration depicted in FIG. 3 the pocketed
springs can be urged together, causing the adhesive to join
adjacent springs, thereby retaining the pad in the folded
configuration.
[0058] In one embodiment not shown, in the unfolded pad adjacent
rows of springs are offset from one another in a direction across
the pad, transverse to the axes of the springs, so that when the
pad is folded the springs nest, each between two adjacent springs
of a neighbouring row. This provides for a more stable pad.
[0059] The resultant unit is as shown in FIG. 4, which is a
perspective view in which the plural rows of springs can be seen.
The gussets 160 extend across the width of the unit, alternately
above and below adjacent springs.
[0060] The pad can initially be formed with other combinations of
springs, and an example of an alternative embodiment is shown in
FIGS. 5 and 6.
[0061] FIG. 5 shows a pad in which two different types of spring
are encased in individual pockets. The diagram shows the springs
after they have been turned so that their axes extend
longitudinally, along the length of the pad, between welding
positions P. A set 120a of long springs is formed with a second set
120b of shorter springs. The springs are each located within their
own pockets, created by joining the sheets 140 together at
positions P. Between adjacent pairs of springs a gusset 160 is
formed by spaced apart welds at positions P, and successive pairs
are oriented alternately so that when the pad is folded in the
manner of a fan, and glued, all of the shorter springs 120b are
located above the longer springs 120a in an integrated stack.
[0062] The effect, in the finished unit 200, is of a layer of short
springs above a layer of long springs. Other combinations of
springs can be employed in the pad.
[0063] The springs can be chosen for their characteristics such as
stiffness and size and, as well as controlling the stacking of
different springs, the springs can be grouped into zones along the
extent of the unit, and combined in such a way as to provide
specifically desired performance characteristics. These
characteristics can be determined by the intended use of the
resilient unit.
[0064] This versatility comes from the way in which the initial pad
is produced, in which the positions of the weld points can be
programmed using computer-controlled means to produce whatever
pattern is required.
[0065] Since the gusset 160 joins or connects pairs of adjacent
springs at one end, they need only be joined at a minimum of one
other place, which in the example (FIG. 3) is the adhesive point G
on the cylindrical surface of the pocketed spring. This leads to a
significant saving, possibly up to 50%, on adhesive.
[0066] In an alternative embodiment, shown in FIG. 7, the folded
pad may be held in its folded configuration by a retention member
in the form of a loop or band B passing around the folded pad to
prevent it from unfolding. The band B may be of the same material
as the sheets 140, but does not have to be. As an alternative (not
shown) the retention member may comprise a frame or envelope.
[0067] In another alternative embodiment (not shown), the folded
pad may be held in its folded configuration by its attachment to a
cover sheet or sheets. The cover sheet or sheets may cover one or
both sides of the folded pad, and may be attached to the folded pad
by adhesive or more preferably by welding, preferably to one or
more positions which may comprise the gussets of the pad.
[0068] In a further alternative embodiment, the folded pad may be
retained in a folded configuration by a case or bag. The case or
bag may include padding or cushioning material and the folded pad
together with the case may substantially comprise a mattress. The
pad would be compressed axially with respect to the springs and
possibly also transversely to this, between the edges, before being
fed into the padded case to form a complete mattress.
[0069] Reducing or even eliminating the glue usage has a beneficial
effect on the cost of production, and also makes recycling more
feasible. The glueless resilient mattress can give up its steel
springs easily and all of the pockets remain joined together.
[0070] An additional substrate layer may be placed on top of the
pocketed springs, or below them, to improve comfort and/or
performance of the pad. The additional layer preferably comprises
natural materials such as hemp, cotton or wool, to assist in the
recyclability of the pad.
[0071] At least some of the springs may have coils of different
diameters at opposed ends. Such springs have a number of advantages
over springs in which the coils at each end of the spring are of
substantially the same diameter. Firstly, the springs can be
compressed to a substantially flat configuration, with the smaller
diameter coils lying within the larger diameter coils. If the
springs can be compressed entirely within themselves, such that no
touching of adjacent coils takes place, this also provides a much
quieter panel than is the case when the coils repeatedly abut one
another.
[0072] Furthermore, the stiffness of a wire spring can be increased
by reducing coil diameter, for a given gauge of wire. Therefore a
narrower gauge spring can be made which uses less material to
produce the same spring stiffness. A spring consisting of coils
which reduce in diameter has a desirable characteristic, in that
its stiffness increases progressively as it is compressed.
[0073] In an embodiment not shown, coils at one, or more preferably
both, ends of the spring are of a reduced diameter. This can help
to avoid interference between adjacent the free end coils of
adjacent springs when the pad is folded. The springs may be other
than cylindrical, and may be, for example, conical, or
barrel-shaped.
[0074] Various types of material are used in the manufacture of the
above-described pocketed springs, and particularly common is the
use of non-woven, spun-bonded polyester, as this can readily be
welded to itself using electrical welding apparatus.
[0075] Many other combinations of springs and spring types may be
utilised in the resilient pad. These include, but are not limited
to: spring-within-spring arrangements, superposed springs in stacks
of two, three, four or more high, multi-stage or multi-phase
springs, such as hybrid springs of different coil types, and
springs of different heights alternating along the top of the
folded pad, in the manner of castellations (sometimes referred to
in the bed-making industry as a "Hi-Lo" unit). All of these
combinations can also be combined with springs of different gauge,
shape, height and with different degrees of pre-tensioning within
the pockets.
[0076] The invention described above allows for an easy
incorporation of large numbers of springs in a resilient unit. A
higher spring count means that the desired characteristics of the
unit can be achieved using springs of a lesser gauge and of a
lesser diameter, which in turn requires less filling material.
[0077] Whilst endeavouring in the foregoing specification to draw
attention to those features of the invention believed to be of
particular importance, it should be understood that the applicant
claims protection in respect of any patentable feature or
combination of features referred to herein, and/or shown in the
drawings, whether or not particular emphasis has been placed
thereon.
* * * * *