Glueless pocketed spring cushioning unit assembler

Abstract

In described examples, a cushioning unit assembler includes first, second, third, and fourth rows of welding heads, a transport, and a feed module. The welding heads have a welding position and a retracted position. A main axis of the welding heads is oriented in a first dimension while in the welding position. The transport is disposed above the rows of welding heads. The transport has a main axis oriented in a second dimension perpendicular to the first dimension. The feed module includes a pocketed spring intake and a pocketed spring outflow. The transport is mechanically coupled to enable the feed module to move in the second dimension along a scope of movement. An exit aperture of the outflow vertically aligns with welding heads of the first row that are in the welding position, and vertically aligns with welding heads of the second row that are in the welding position.

1 - 46 . (canceled) 
     
     
         47 . A cushioning unit, comprising:
 a single continuously connected string of pocketed springs including more than two rows of pocketed springs, adjacent pairs of the rows thermally welded together.   
     
     
         48 . The cushioning unit of  claim 47 ,
 wherein the single continuously connected string includes no more than two cuts parallel to a main axis of the pocketed springs in a fabric connecting the pocketed springs of the single continuously connected string.   
     
     
         49 . The cushioning unit of  claim 48 ,
 wherein if there is one cut, then the cut is located at either the beginning of the string or the end of the string; and   wherein if there are two cuts, then one cut is located at the beginning of the string and the other cut is located at the end of the string.   
     
     
         50 . The cushioning unit of  claim 47 , wherein pocket fabric between non-consecutive adjacent pairs of pocketed springs in first ones of the rows is welded to pocket fabric between corresponding non-consecutive adjacent pairs of pocketed springs in second ones of the rows. 
     
     
         51 . The cushioning unit of  claim 47 , wherein each pocketed spring in the string is connected by continuous pocket fabric to two other pocketed springs, except a first pocketed spring in a first one of the rows and a last pocketed spring in a last one of the rows. 
     
     
         52 . The cushioning unit of  claim 47 , wherein each of multiple ones of the rows are connected by a continuous length of pocket fabric to at least one other one of the rows. 
     
     
         53 . The cushioning unit of  claim 47 , wherein the continuous lengths of pocket fabric are located on alternating sides of the cushioning unit. 
     
     
         54 . The cushioning unit of  claim 47 , wherein each of the adjacent pairs of rows are thermally welded together. 
     
     
         55 . A cushioning unit, comprising:
 one or more continuously connected strings of pocketed springs including more than two rows of pocketed springs, adjacent pairs of the rows thermally welded together;   wherein each of multiple ones of the rows are connected by a continuous length of pocket fabric to at least one other adjacent one of the rows, the continuous lengths of pocket fabric integral to respective connected ones of the rows.   
     
     
         56 . The cushioning unit of  claim 55 ,
 wherein the continuously connected string includes no more than two cuts parallel to a main axis of the pocketed springs in a fabric connecting the pocketed springs of the continuously connected string.   
     
     
         57 . The cushioning unit of  claim 56 ,
 wherein if there is one cut, then the cut is located at either the beginning of the string or the end of the string; and   wherein if there are two cuts, then one cut is located at the beginning of the string and the other cut is located at the end of the string.   
     
     
         58 . The cushioning unit of  claim 55 , wherein pocket fabric between non-consecutive adjacent pairs of pocketed springs in first ones of the rows is welded to pocket fabric between corresponding non-consecutive adjacent pairs of pocketed springs in second ones of the rows. 
     
     
         59 . The cushioning unit of  claim 55 , wherein each pocketed spring in the string is connected by continuous pocket fabric to two other pocketed springs, except a first pocketed spring in a first one of the rows and a last pocketed spring in a last one of the rows. 
     
     
         60 . The cushioning unit of  claim 55 , wherein the continuous lengths of pocket fabric are located on alternating sides of the cushioning unit. 
     
     
         61 . The cushioning unit of  claim 55 , wherein each of the adjacent pairs of rows are thermally welded together. 
     
     
         62 . A cushioning unit, comprising:
 multiple rows of continuously connected pocketed springs, adjacent pairs of the rows thermally welded together, the multiple rows forming a first pair of sides of the cushioning unit and a second pair of sides of the cushioning unit, the first pair of sides formed of a first one of the rows and a last one of the rows, the second pair of sides formed of pocketed springs at a first end of each of the rows and pocketed springs at a second end of each of the rows, each side of the second pair of sides including continuous pocket fabric connections between adjacent pairs of the rows.   
     
     
         63 . The cushioning unit of  claim 62 ,
 wherein the rows of continuously connected pocketed springs comprise a continuously connected string that includes no more than two cuts parallel to a main axis of the pocketed springs in pocket fabric connecting the pocketed springs of the continuously connected string.   
     
     
         64 . The cushioning unit of  claim 63 ,
 wherein if there is one cut, then the cut is located at either the beginning of the string or the end of the string; and   wherein if there are two cuts, then one cut is located at the beginning of the string and the other cut is located at the end of the string.   
     
     
         65 . The cushioning unit of  claim 62 , wherein each pocketed spring in rows of pocketed springs is connected by continuous pocket fabric to two other pocketed springs, except a first pocketed spring in the first row and a last pocketed spring in the last row. 
     
     
         66 . The cushioning unit of  claim 62 , wherein the continuous pocket fabric connections are located on alternating sides of the cushioning unit in sequential adjacent pairs of the rows.