Abstract: A method of packaging spring units in which first and second webs of insulator material are fixedly located against the top and bottom surfaces of the spring units. The webs are folded around outermost coil springs along longitudinal edges of the spring units. The reverse sides of the webs are glued, welded or otherwise permanently secured together. In another embodiment, side portions of the webs are secured together, sandwiching the spring units therebetween. The resultant bedding products are then roll-packed.

Abstract: A string (12) of pocketed coil springs (14) is formed by inserting compressed springs between upper and lower plies of a folded, preferably thermally weldable fabric (16). The springs are maintained in a compressed configuration while a longitudinal seam (54) joins the free edges of the thermally welded fabric (16) together. Subsequently, the compressed springs (14) are allowed to relax into an expanded configuration after which a transverse seam (80) is formed in the fabric (16) between the adjacent springs (14) thereby encapsulating each spring (14) within a fabric pocket (86). The string (12) of pocketed coil springs (14) is advantageously formed without the need for reorienting the springs (14) after being inserted between the plies (24, 26) of the fabric (16) and thereby avoiding the disadvantages and complications associated with turning or reorienting the pocketed coil spring (14).

Abstract: A method of packaging spring units in which at least one web of insulator material is fixedly located against one of the top and bottom surfaces of the spring units. Each web of insulator material is secured to the outermost coil springs along longitudinal edges of the spring units with securing elements. The resultant bedding products are then roll-packed.

Abstract: A non-woven fiber pad having a convoluted surface formed by cutting a non-woven fiber batt having a plurality of low melt synthetic fibers. The non-woven batt is compressed generally toward a cutting device by a pair of counter-rotating drums having convoluted surfaces.

Abstract: A system and method for manufacturing pocketed compound nested coil springs includes inserting a compressed, preferably pocketed, smaller coil spring into a vertically oriented larger coil spring either prior to compressing and inserting the outer coil spring into pocket material or after the larger coil spring has been compressed and prior to being encapsulated in the pocket. Alternative systems and methods are also contemplated which include forming the outer coil spring around the inner coil spring and pocketing the resulting nested spring unit.

Abstract: A method of packaging spring units in which first and second webs of insulator material are fixedly located against the top and bottom surfaces of the spring units. The webs are folded around outermost coil springs along longitudinal edges of the spring units. The reverse sides of the webs are glued, welded or otherwise permanently secured together. In another embodiment, side portions of the webs are secured together, sandwiching the spring units therebetween. The resultant bedding products are then roll-packed.

Abstract: A method of packaging spring units in which first and second webs of insulator material are fixedly located against the top and bottom surfaces of the spring units. The webs are folded around outermost coil springs along longitudinal edges of the spring units. The reverse sides of the webs are glued, welded or otherwise permanently secured together. In another embodiment, side portions of the webs are secured together, sandwiching the spring units therebetween. The resultant bedding products are then roll-packed.

Abstract: A string (12) of pocketed coil springs (14) is formed by inserting compressed springs between upper and lower plies of a folded, preferably thermally weldable fabric (16). The springs are maintained in a compressed configuration while a longitudinal seam (54) joins the free edges of the thermally welded fabric (16) together. Subsequently, the compressed springs (14) are allowed to relax into an expanded configuration after which a transverse seam (80) is formed in the fabric (16) between the adjacent springs (14) thereby encapsulating each spring (14) within a fabric pocket (86). The string (12) of pocketed coil springs (14) is advantageously formed without the need for reorienting the springs (14) after being inserted between the plies (24, 26) of the fabric (16) and thereby avoiding the disadvantages and complications associated with turning or reorienting the pocketed coil spring (14).

Abstract: A roll of roll-packed bedding products is created by permanently securing spaced spring units between first and second webs of insulator material. The bedding products are compressed and wound into a roll for shipping. During shipment and handling, the spring units are maintained within the roll in a similar orientation spaced from one another by the first and second webs of insulator material until the roll is unrolled and the insulator web material cut between the spring units to create spring units having the insulator web material thereon.

Abstract: A method of assembling strings of pocketed coil springs into an innerspring core which may be used as the core of a mattress, cushion or similar body support foundation uses a reinforcing material, preferably having an adhesive component, between rows of pocketed coil springs. The reinforcing, adhesive material serves to bond the rows of springs to each other and to reinforce the pockets to prevent wear between coils in frictional relation.

Abstract: A method of packaging a bedding product in order to create a plastic film package in which the bedding product is individually packaged. First and second webs of extruded plastic film are unwound from first and second web rolls, passed between rollers and across opposed first and second surfaces of the bedding product before being cut and joined together in order to create a plastic film package. Each of the first and second webs have a uniform width and a varying thickness across the width in order to provide increased protection along the ends of the packaged bedding product.

Abstract: Spring sets each include a pair of coil springs joined together by a connecting wire and are encased in individual fabric pockets such that the connecting wire joining the coil springs spans an otherwise empty fabric pocket. A spring unit, mattress or the like includes a number of such pocketed spring sets with the connecting wire being alternately positioned near a top face or a bottom face of the spring unit. The pocketed coil spring unit can be used to form a mattress or other spring assembly of pocketed coil springs wherein every third pocket is left empty. The connecting wire spreads the load across the empty pocket and distributes the load to the adjacent springs. The absence of one-third of the springs that are normally in a mattress drastically reduces material costs without diminishing performance.

Abstract: A bedding or seating product comprising a spring core made up of a plurality of parallel strings of springs joined to each other. Each of the strings of springs comprises a row of interconnected pocketed coil springs. The pocket of fabric surrounding each of these coil springs is divided into at least two subpockets by at least one line of attachment of opposite sides of the fabric to each other. Each of these subpockets contains one portion of the coil spring, thus resulting in a multilayered product.

Abstract: A bedding or seating product comprising a centrally located spring core, edge support means located around the perimeter of the spring core, filling material located above and below the spring core and an upholstered covering. The edge support may be either a string of springs, a pair of spiral edge supports or plastic edge reinforcements. The edge support means extends above and below the upper and lower surfaces of the spring core thus creating a higher peripheral edge than the central portion of the spring core. Layers of filling material are inserted over the central portion of the spring core in order to create a uniform upper and lower surface.

Abstract: A method of packaging a bedding product in order to create a plastic film package in which the bedding product is individually packaged. First and second webs of extruded plastic film are unwound from first and second web rolls, passed between rollers and across opposed first and second surfaces of the bedding product before being cut and joined together in order to create a plastic film package. Each of the first and second webs have a uniform width and a varying thickness across the width in order to provide increased protection along the ends of the packaged bedding product.

Abstract: A method and system for manufacturing a spring core by adhesively bonding strings of pocketed coil springs together utilizes a moving adhesive applicator for depositing adhesive onto a moving string of pocketed coil springs. Subsequently, individual strings are adhesively bonded to similar strings to form the spring core of pocketed coil springs. The moving applicator may take one of any number of various embodiments which include reciprocating movement, rotational movement, pivotal movement and/or linear translational movement for spraying a pattern of adhesive onto the moving string of pocketed coil springs. The adhesive may be dispensed in a plurality of parallel lines from a set of nozzles. The nozzles may be moved and turned on and off under the control of a programmed controller.

Abstract: A method and system for manufacturing a spring core by adhesively bonding strings of pocketed coil springs together utilizes a moving adhesive applicator for depositing adhesive onto a moving string of pocketed coil springs. Subsequently, individual strings are adhesively bonded to similar strings to form the spring core of pocketed coil springs. The moving applicator may take one of any number of various embodiments which include reciprocating movement, rotational movement, pivotal movement and/or linear translational movement for spraying a pattern of adhesive onto the moving string of pocketed coil springs.

Abstract: A method of assembling strings of pocketed coil springs into an innerspring core which may be used as the core of a mattress, cushion or similar body support foundation uses plastic netting reinforced nonwoven webs supplied between a pair of spaced apart heated rolls. Strings of pocketed coil springs are fed in seriatim into the nip between the rolls to heat the netting and activate an integral adhesive to bond the webs to the top and bottom surfaces of the pockets of each string. The core formed thus has reinforced webs on the top and bottom of the strings. The process overcomes the problems encountered when hot melt spraying is utilized to bond the pocketed coil strings together.

Abstract: A method and apparatus for forming a mattress having a core formed from a plurality of elongated rows of interconnected coil spring containing fabric pockets, each row having a plurality of spaced apart pockets with a spring encased in each pocket, and having a reinforcing and/or adhesive material between adjacent rows. A first row of spring encased pockets is placed in a tray in a horizontal position and held in the tray by fingers which engage the fabric of the pockets at the ends of each spring, there being a finger at each end of each pocket. An adhesive, if necessary, may be placed on the upper surface of the row. The tray is mounted on a pivotable plate which is then rotated to a vertical position and moved linearly toward a table containing prior rows of the core to bond the row carried in the tray to the last row on the table.

Abstract: A method and system for manufacturing a spring core by adhesively bonding strings of pocketed coil springs together utilizes a moving adhesive applicator for depositing adhesive onto a moving string of pocketed coil springs. Subsequently, individual strings are adhesively bonded to similar strings to form the spring core of pocketed coil springs. The moving applicator may take one of any number of various embodiments which include reciprocating movement, rotational movement, pivotal movement and/or linear translational movement for spraying a pattern of adhesive onto the moving string of pocketed coil springs.