Pocketed spring units

Abstract

A method and apparatus for the production of a pocketed spring unit, the method comprising the steps of compressing and feeding a plurality of springs ( 42 ) into troughs ( 2 A, 4 A) or castellations in opposed conveyor belts ( 2, 4 ), moving said springs ( 42 ) from said troughs ( 2 A, 4 A) or castellations to a position between upper and lower layers of fabric or other material ( 16 A, 18 A), step-wise advancing said material ( 16 A, 18 A) and said springs ( 42 ) in the direction of the output of the apparatus and welding together said lengths of fabric or other material ( 16 A, 18 A) at each step-wise advancement by a plurality of sequentially controlled welding anvils ( 10 ) so as to form a plurality of discrete pockets ( 46 ) each containing a spring ( 42 ). Apparatus for carrying out the method is disclosed.

1 . A method for the production of a pocketed spring unit comprising the steps of compressing and feeding a plurality of springs into positions between upper and lower layers of fabric or other material, step-wise advancing said fabric or other material and said springs in the direction of the output of the apparatus and welding together said lengths of fabric or other material at each step-wise advancement so as to form a plurality of discrete pockets each containing a spring, using a welding means having a plurality of individually controllable, selectively actuated movable welding anvils and plurality of co-operating welding horns to sequentially weld said layers together at each sequential movement of said layers and said springs to produce a variable grid pattern of welds so as to form said discrete pockets. 
     
     
         2 . A method according to  claim 10 , including the step of forming the springs immediately prior to the springs being compressed and fed into said troughs or castellations. 
     
     
         3 . Apparatus for forming a pocketed spring unit comprising means for compressing and feeding springs in the direction of the output of the apparatus to positions between upper and lower lengths of fabric or other material, means for sequentially advancing said lengths and said springs in said direction, and welding means for sequentially welding together said lengths so as to form a plurality of discrete pockets each containing a spring, wherein said welding means is a plurality of individually controllable, selectively actuated movable welding anvils and a plurality of co-operating welding horns, said welding means being adapted to sequentially weld said layers together at each sequential movement of said layers and said springs to produce a variable grid pattern of welds so as to form said discrete pockets. 
     
     
         4 . (canceled) 
     
     
         5 . Apparatus according to  claim 11 , wherein the opposed conveyor belts each consist of an endless castellated or troughed belt, each belt being indexable, and one at least of said belts being positively drawn. 
     
     
         6 . (canceled) 
     
     
         7 . (canceled) 
     
     
         8 . Apparatus according to  claim 3 , wherein the welding anvils are movable by associated air cylinders and are operable, in conjunction with the welding horns, to work in a predetermined and preprogrammed manner so as to form a required pattern and entrap individual springs between the layers of fabric or other material. 
     
     
         9 . Apparatus according to  claim 3 , including a spring coiler adapted to form individual springs for delivery to said means for compressing and feeding springs. 
     
     
         10 . Apparatus according to  claim 4 , wherein the opposed conveyor belts each consist of an endless castellated or troughed belt, each belt being indexable, and one at least of said belts being positively drawn. 
     
     
         11 . Apparatus according to  claim 4 , wherein said welding means is a plurality of movable welding anvils and a plurality of co-operating welding horns, said welding means being adapted to sequentially weld said layers together at each sequential movement of said layers and said springs so as to form said discrete pockets.