Abstract: Apparatus for forming wire components, which are in this example springs, comprises a supply station (202), for supplying spring forming material, such as metallic wire W. The supply station includes a pair of guide rollers (204) and pair of driven feed rollers (206), mounted on a heavy support plate (216). The wire is fed through a flexible sheath FS to a remotely located wire shaping device, in particular a spring forming device 208, comprising forming tools (210), a pitch control tool (212) and a cutter (214). The forming tools (210) and the pitch control tool (212) form the wire into a spring S, which is cut from the supply of wire when it is complete. The tools (210, 212) and cutter (214) are controlled remotely from a control station (220) via a bundle of flexible control cables (222), which may include a power cable.

Abstract: A pocketed resilient unit (130), such as for a mattress core, comprises integral pocketed resilient elements (110) arranged in clusters (240), wherein each integral pocketed resilient element in a cluster is attached to at least one other integral pocketed resilient element, and wherein the clusters define interstices (250), in at least some of which are located independent resilient elements (260).

Abstract: Apparatus for forming a resilient unit comprises a conveyor 210 and first and second spring supply stations 212 and 214, arranged in use to deposit respectively first and second spring types 216 and 218 under compression onto the conveyor. The conveyor is arranged in use to convey a row of the springs 216, 218 in a direction shown by Arrows A4 towards pocketing station 220. At the pocketing station 220 the springs are urged from the conveyor into positions between upper and lower sheets 222 and 224, by a plurality of inserter devices 226 that move together in a reciprocating fashion in the direction of arrow A5, before retracting to the position shown. After each row of springs is inserted between the sheets 222, upper and lower computer-controlled welding tools (not shown) come together at positions P between the springs to join the sheets together, forming pockets in which the springs are encased.

Abstract: A resilient unit has strings of individual coil springs (not shown) inside pockets 120 are arranged in an array. The strings together form a spring unit and are each secured to a common cover sheet S, which comprises a non-woven elastic fabric. It is welded ultrasonically or thermally whilst under tension in one or both of its major dimensions—i.e. in-plane—to the pockets 120, the material of which is substantially inelastic and non-woven. In this example the welds, labelled W, are located substantially centrally with respect to the generally circular end surfaces of the pockets.

Abstract: A conveyor (400) for transporting articles, such as coils springs, is described. The conveyor comprises a substrate (420) for supporting articles during transportation, and a plurality of retaining members (520) located on the substrate for retaining the articles during transportation. The retaining members (520) each comprise a mounting portion (530) for mounting to the substrate (420). A containment portion (540) comprises proximal and distal parts (540a) and (540b) define a space therebetween for receiving a coil spring (100) under compression. Slots (550a) and (550b) in the containment parts are aligned for receiving pushers.

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 spring forming apparatus is shown generally at 200, in which metal wire 220 is fed from a supply (not shown) by feed rollers 230, via irregularity-effecting rollers 240 to a forming station 250. The forming station comprises a first deflector 260 and a second deflector 270. When the spring S is complete, it separates automatically from the rest of the wire 220 due to the presence of an irregularity 280, without the need for a cutter device.

Abstract: Apparatus for forming a resilient unit comprises a conveyor (210) and first and second spring supply stations (212 and 214), arranged in use to deposit respectively first and second spring types (216 and 218) under compression onto the conveyor. The conveyor is arranged in use to convey a row of the springs (216, 218) in a direction shown by Arrows A4 towards pocketing station (220). At the pocketing station (220) the springs are urged from the conveyor into positions between upper and lower sheets (222 and 224), by a plurality of inserter devices (226) that move together in a reciprocating fashion in the direction of arrow A5, before retracting to the position shown. After each row of springs is inserted between the sheets (222), upper and lower computer-controlled welding tools (not shown) come together at positions P between the springs to join the sheets together, forming pockets in which the springs are encased.

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 resilient unit has strings of individual coil springs (not shown) inside pockets 120 are arranged in an array. The strings together form a spring unit and are each secured to a common cover sheet S, which comprises a non-woven elastic fabric. It is welded ultrasonically or thermally whilst under tension in one or both of its major dimensions—i.e. in-plane—to the pockets 120, the material of which is substantially inelastic and non-woven. In this example the welds, labelled W, are located substantially centrally with respect to the generally circular end surfaces of the pockets.

Abstract: A conveyor (400) for transporting articles, such as coils springs, is described. The conveyor comprises a substrate (420) for supporting articles during transportation, and a plurality of retaining members (520) located on the substrate for retaining the articles during transportation. The retaining members (520) each comprise a mounting portion (530) for mounting to the substrate (420). A containment portion (540) comprises proximal and distal parts (540a) and (540b) define a space therebetween for receiving a coil spring (100) under compression. Slots (550a) and (550b) in the containment parts are aligned for receiving pushers.

Abstract: Apparatus for forming wire components, which are in this example springs, comprises a supply station (202), for supplying spring forming material, such as metallic wire W. The supply station includes a pair of guide rollers (204) and pair of driven feed rollers (206), mounted on a heavy support plate (216). The wire is fed through a flexible sheath FS to a remotely located wire shaping device, in particular a spring forming device 208, comprising forming tools (210), a pitch control tool (212) and a cutter (214). The forming tools (210) and the pitch control tool (212) form the wire into a spring S, which is cut from the supply of wire when it is complete. The tools (210, 212) and cutter (214) are controlled remotely from a control station (220) via a bundle of flexible control cables (222), which may include a power cable.

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.

Abstract: A resilient unit is shown generally at 10, and comprises a structural portion (12) and a support portion (14). The structural portion is formed by rows of large pocketed metallic coil springs (16). In particular two rows of slightly longer pocketed springs (16a) form the side walls (S) of the structural portion, whilst an array of slightly shorter ones (16b) form a base (B) of the structural portion. The support portion (14) is formed of a pocketed spring unit (18) comprising a plurality of metal coil springs individually encased in pockets formed by layers of thermally weldable, non-woven material that are joined together at locations between the springs. The raised side walls (S) formed by the rows of tall springs (16a) form a recess within which the pocketed spring unit (18) rests on the springs of the base (B). No adhesive is used in the resilient unit (10). The tall springs are formed in rows by welding layers of the pocket material together along seams that run axially beside the springs.

Abstract: A resilient unit comprises a number of wire coil springs 12, each of which is located within its own discrete pocket 14 formed by first, upper and second, lower layers 14a and 14b of material, preferably of non-woven material. The two layers 14a and 14b have been thermally, or ultrasonically, welded together at points 16 between the adjacent springs to create the pockets. The upper layer of material 14a differs from the lower layer of material 14b in respect of at least one characteristic.

Abstract: A spring transfer apparatus, shown generally at 10, is positioned adjacent a spring coiling machine 12 (shown only schematically). The transfer apparatus comprises a conveying substrate in the form of a belt 14 arranged in an endless loop and driven in a direction A by a motor 16. The belt comprises a plurality of magnetic spring holders 18 which are arranged in use to accept steel wire springs 20 from the coiling machine 12. Each of the magnetic spring holders has a pair of ferro-magnets 18a for holding the steel springs. The magnets are arranged such that identical poles are adjacent. The apparatus is arranged such that the magnets begin to attract the formed springs before they are cut from the length of wire by the spring coiling machine.

Abstract: A resilient unit is fed as a continuous web 18 through first and second tensioning rollers 20, 22 to a winding roller 24. The winding roller is driven at a first speed, and one or both of the tensioning rollers is also driven, but at a second speed which is less than the first speed—i.e. slower than that of the winding roller. The difference is speeds causes tension to be applied to the material of the resilient unit which stretches the resilient unit and in turn compresses the resilient elements in their pockets. The result is that the resilient unit becomes compressed in its through thickness direction—the axial direction of the springs—before it is wound into the winding roller. The resilient unit extends in length in a longitudinal direction in which tension is applied. The extension in length is substantially proportional to a reduction in a thickness of the resilient unit.

Abstract: A method of packaging a mattress for storage and/or transportation comprises the steps of wrapping said mattress around a core and maintaining the mattress in position around said core. The method may include the additional steps of compressing the mattress prior to and/or during wrapping of the mattress around said core and the insertion of a topper for said mattress inside said core. In an alternative arrangement, the core may be constituted by a topper for the mattress. A mattress packaged according to the method is also disclosed.