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: Disclosed are methods, apparatus, devices, and other implementations, including a method for the production of a pocketed spring unit that includes compressing a plurality of springs, moving the springs to positions between upper and lower layers of fabric or other material, step-wise advancing the material and the springs in a spring unit output direction, and welding together the lengths of fabric or other material at each step-wise advancement to produce a pattern of welds in which are formed a plurality of discrete pockets, each containing a spring.

Abstract: A complex spring unit (10) comprises at least a first spring portion (12) and a second spring portion (14), which first and second spring portions are integrally formed, wherein the first spring portion is arranged in use to be placed under compression, and the second spring portion is arranged in use to be placed under tension, during compression of the complex spring unit.

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 method and apparatus for the production of a pocketed spring unit by compressing and feeding a plurality of springs (42) into troughs (2A, 4A) or castellations in opposed conveyor belts (2,4), moving the springs (42) from the troughs (2A, 4A) or castellations to a position between upper and lower layers of fabric or other material (16A, 18A), step-wise advancing the material (16A, 18A) and the springs (42) in the direction of the output of the apparatus and welding together the lengths of fabric or other material (16A, 18A) 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).

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 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.