Abstract: A demountable wire carrier 100 is for supporting loops of wire W and comprises a lower end-stop 110, an upper end-stop 120 and a plurality of frame members 130 extending between the end-stops. The carrier is shown standing inside a cylindrical loop-forming container 140 into which the wire W has been fed in the direction of Arrow A, so that the wire forms loops around the inside of the container wall. The introduction of the wire takes place when, prior to assembly of the carrier, only the lower end-stop 110 is positioned inside the container, so that the loops of wire rest on the lower end-stop 110. After all the wire has been introduced into the container 140, the frame members are connected to the lower end-stop, and the upper end stop is then connected to the frame members to complete assembly of the carrier.

Abstract: Apparatus for forming a pocketed spring unit, comprising a plurality of strings of pocketed springs and at least one cover sheet, comprises welding tools for welding together the pocketing material and the sheet. One of the welding tools is provided with a cutter for cutting the pocket prior to welding. The tool travels in the direction of Arrow A1, so that the cutter penetrates the pocketing material substantially centrally at the circular proximal end face of the pocket. Once inside the pocket, the tool moves axially through the centre of the spring until it reaches the distal end face of the pocket. Before the end face is reached, the piercing member becomes retracted in the direction of Arrow A2, so that the blade does not pierce the distal end face of the pocket.

Abstract: A pocketed spring unit comprising an array of springs 120 located in pockets 180 formed by discrete superposed webs 140 of pocketing material joined together by welds W between the springs, wherein the welds are located at alternately opposite ends of the pocketed springs. FIG. 1 shows generally a pocketed spring unit at a first stage of manufacture. A row of coil springs 120 (only the end one of which is visible) is introduced by an inserter mechanism 130 into position between axially disposed webs 140a and 140b of pocketing material. The webs 140a and 140b are fed from supply reels (not shown via guide rollers 150. The springs 120 are partly compressed and are pushed between plates 160 towards the webs 140 by the inserter 130 in the direction of Arrow A1. Once the springs are between the webs 140 a pair of ultrasonic welding tools 170a and 170b joins the webs together at weld locations W between the springs to form individual pockets 180 for the springs.

Abstract: A pocketed spring unit comprises a plurality of strings of pocketed springs and a cover sheet, wherein each string comprises a flap of material located along an edge of the string and extending longitudinally of the string. The cover sheet is attached to the flaps at welds W.

Abstract: A method of forming a pocketed spring unit for an upholstered article comprises taking successive strings of pocketed springs and welding at least one sheet of material to at least a first end of the pocketed springs. Anvils 46 are moved from a non-operative position to an operative position, in which they are located between adjacent pockets at upper and lower ends of the springs. This embodiment makes use of the surplus material that is formed at the ends of the pockets in the form of flaps or “ears” of material. These flaps protrude upwardly initially, and then become folded flat as the spring unit advances between the rolls 48 of material. The external anvils are then made to apply heat and pressure to the material flaps trapped between them and the internal anvils at the sides of the pockets, between the springs to weld them to the material from the rolls 48.

Abstract: A wire supply station comprises a container 34 in which the wire is retained in a multitude of loops (not shown) of substantially the same diameter around a cylindrical inside surface of the drum. The wire 16 emerges from the drum 34 under no tension and substantially straight. It is then fed between guide or feed rollers 20 into the coiling head 12. The wire 16 is formed into a continuous coil, from which lengths are cut by a cutter (not shown) to form individual coil springs 24. The individual coil springs 24 are then carried by the spring transfer station 26 to the fabric pocket welding station 28 where they become encased in individual pockets when the welding heads 30 weld the material. Pre-straightening the wire before storing it in loops inside the cylindrical drum 34 allows for a more consistent pocket spring, and ultimately a flatter spring unit/mattress as any pre-stressing of the wire, caused by the drawing process used to manufacture it, is neutralised leaving the wire largely stress-free.

Abstract: A method of forming a pocketed spring unit for an upholstered article comprises taking successive strings of pocketed springs and welding at least one sheet of material to at least a first end of the pocketed springs. Anvils 46 are moved from a non-operative position to an operative position, in which they are located between adjacent pockets at upper and lower ends of the springs. This embodiment makes use of the surplus material that is formed at the ends of the pockets in the form of flaps or “ears” of material. These flaps protrude upwardly initially, and then become folded flat as the spring unit advances between the rolls 48 of material. The external anvils are then made to apply heat and pressure to the material flaps trapped between them and the internal anvils at the sides of the pockets, between the springs to weld them to the material from the rolls 48.