Abstract: Machinery for automated manufacture of formed wire structures such as innerspring assemblies for mattresses and seating and flexible support structures includes one or more coil formation devices configurable to produce generally helical spring coils having a terminal convolution which extends beyond an end of the coil; a conveyor system having a plurality of flights slidably mounted upon a continuous track and connected to a chain and driven by an index driver; a coil transfer machine which removes a row of coils from the conveyor and inserts the coils into an innerspring assembler; an innerspring assembler having first and second sets of coil-engaging dies in a parallel arrangement, each set of dies having an upper row positioned over a lower row, the dies being mounted upon carrier bars which are vertically translated within the innerspring assembler to diverge the upper and lower dies of a set to allow positioning of a row of uncompressed coils between the upper and lower dies, and to converge the upper a

Abstract: A pocket coil spring structure assembling apparatus includes a feeder mechanism for supplying a group of pocket coil springs to a positioning transfer conveyor. A positioning transfer conveyor mechanism conveys the group of the pocket coil springs supplied from the feeder mechanism to a predetermined location. A cutter mechanism mounted between the feeder mechanism and the positioning transfer conveyor mechanism separates a group of the pocket coil springs from succeeding pocket coil springs by cutting to a given length. A press holding mechanism holds and lifts the group of the pocket coil springs on the positioning transfer conveyor by pressing the radial center of each pocket coil spring from opposite ends thereof. A press holding mechanism carrier mechanism moves the press holding mechanism in four, i.e. forward, backward, leftward, and rightward, directions. A spray mechanism including a spray nozzle applies a spray of an adhesive material to the group of the pocket coil springs.

Abstract: Disclosed herein is a coil spring forming machine and transfer conveyor assembly comprising a transfer conveyor operable through a succession of operational cycles and including and endless conveyor assembly and a conveyor drive servo-motor drivingly connected to the conveyor assembly and operative, upon each energization thereof, to drive the conveyor assembly through one operational cycle. A control system operative to automatically and non-selectively cause energization of the conveyor drive servo-motor.

Abstract: A method and an apparatus are provided for producing sequences of coil springs of more than one configuration, such as those differing in stiffness, shape, size or other property. At least two coiling stations are provided around different positions of a rotary index mechanism that has a plurality of angularly spaced spring holders that are sequentially moved through and rest simultaneously at a plurality of forming or other treating stations around a central axis. The coiling stations alternatively deliver coiled springs to each holder, while one or more post forming stations, preferably including two knotting stations and one heat treating station, sequentially operate on each of the springs of the different configurations. A transfer station transfers finished springs to a conveyor that transfers programmed sequences of springs, row by row, to a spring interior assembler. The stations are controlled to simultaneously perform different operations on different springs, including different types of springs.

Abstract: A pocket coil spring structure assembling apparatus for producing a pocket coil spring structure which includes a feeder mechanism to supply a group of pocket coil springs to a positioning transfer conveyor mechanism; a cutting mechanism between the feeding mechanism and the positioning transfer conveyor mechanism to cut the group of pocket coil springs to a predetermined length; a press holding mechanism to hold and lift the cut group of pocket coils springs on the positioning transfer conveyor mechanism by pressing the centers of opposite ends of each pocket coil springs; a pressing holding mechanism carrier mechanism to move the press holding mechanism in forward, backward, leftward, and rightward directions; a spray mechanism with a spray nozzle to apply adhesive to the cut group of pocket coil springs; a nozzle carrier to move the spray nozzle; and a controller mechanism for controlling each of the mechanisms.

Abstract: Device for transferring springs to an assembly machine, wherein the sprints to be transferred are retained in a guide device wherein for the transfer of the springs sliders are provided engaging at the end winds of the springs.

Abstract: A coil spring assembly machine for lacing coil springs together to form a coil spring assembly, which machine includes clamping jaws for clamping together portions of adjacent rows of coil springs in at least one of a top and bottom plane of the coil spring assembly, which clamping jaws include dies which cooperate with the end portions of the rows of coil springs to define a helical travel path for helical lacing wires as those lacing wires are moved through the helical travel path. The machine further includes a lacing wire forming and application mechanism for alternatively and selectively supplying lacing wires having two different physical characteristics to that helical travel path.

Abstract: A spring interior assembly method and apparatus produces spring interiors formed of a plurality of longitudinally connected columns of spring coils. Preferably, the spring interiors are formed as continuous wire bands each of alternating coils and bridging sections. Corresponding, coils of each column are laced together with transverse lacing wires as the columns are indexed longitudinally through a lacing station and are adjusted to correct lengths as the spring interiors are assembled. A measurement device or other form of sensor at a measurement station downstream of the lacing station in the assembly machine signals the length of a portion of the spring interior, preferably including a number of bridging sections. A processor in the assembly machine controller causes the last laced section to be longitudinally deformed to adjust its length in response to the measurement.

Abstract: A spring interior forming method and apparatus provides a spring interior assembler and a coil row transfer station upstream of the assembler having at least one conveyer extending therethrough. A coil former is provided at an upstream end of the conveyor and is operated through a plurality of cycles, each to feed one spring coil onto the conveyor. In one embodiment, a single former is provided with a single conveyor extending therefrom through the transfer station. In a second embodiment, two such coiler-conveyor combinations is provided. In a third embodiment, one conveyor through the transfer station is provided with two coilers, each having a feeder preferably in the form of a conveyor, that selectively feed spring coils, which may be of different types, to a cross-over station for feed onto the transfer station conveyor. In a fourth embodiment, each coiler accumulates springs at its output while awaiting queing by the cross-over station.

Abstract: An apparatus for forming springs for incorporation into an innerspring mattress is disclosed. The apparatus includes the use of change gears to facilitate the manufacture of a variety of innerspring sizes.

Abstract: An apparatus for forming and assembling spring interiors is provided in which, in the preferred embodiment, adjustable reforming dies adjacent a cutting station lengthen the supporting structure of a bridging portion of the coil band that interconnects coils near the end of the band to compensate for the change of length caused by the cutting of the endmost bridging portion separating spring assemblies. Adjustable dies are also provided to vary the length of the bridging portions when they are initially formed. The coils are interlaced at a lacing station from continuous lacing coil bands.

Abstract: Multiple coil springs, particularly springs of alternating right and left hand coils, are formed from a continuous wire, interconnected by spring heads formed of straight lengths of the wire, by a coiler having a stationary forming head which with a pair forming rollers which bend the wire to one side or the other, with the formed coils extending in the same direction from the forming head, thus producing a partially formed step-shaped spring. The partially formed spring is passed through a spin tube which damps out the alternating twists resulting from the coiling procedure. Downstream from the coiler, the partially formed spring is folded by imposing opposite 180.degree. twists to consecutive pairs of the interconnecting heads to reverse the direction of alternate ones of the coils.

Abstract: A machine in which butterfly clips are prebent and then punched out of steel strip and simultaneously finally bent, such that they fasten together a spring and the frame of a spring core. Thus, both the punching out of the clip and the final bending process, i.e. the connecting process between the frame and spring parts, are carried out in a single tool. The machine therefore operates particularly cost-effectively, because, in comparison with the prior art, the separately punched butterfly clips do not have to be inserted into a separate bending machine.

Abstract: A known kind of spring unit, for use in mattresses, seats and the like, is made as an assembly of spring bands which are disposed side by side and a plurality of helical wires (5,6) which extend transversely to the bands and are linked to them. Each spring band comprises a row of springs (1), and each pair of adjacent springs is integrally connected by a connector (2) which includes two spaced end portions (3), which are transverse to the band and are embraced by helical wires. Variations in manufacture lead to variations in the spacing between the end portions. The invention provides for the further bending of each connector (2), after initial formation of the spring band, to cause the end portions to take up a predetermined spacing. This is effected by reshaping corner portions of the connector between dies (31,42) so that the corner portions (8) are finally of more gentle curvature than they were (12) when initially formed.

Abstract: Apparatus for automatically securing borderwires on mattress innersprings, including a support member for maintaining a mattress innerspring and borderwires on edge in a substantially upright position as clips are automatically wrapped along the supported edge on each side thereof. A rotatable paddle-like member is provided for rotating the mattress innerspring and the borderwires on the support member to present another edge on which clips are to be wrapped. Control means is provided for carrying out, automatically, each operation performed by the apparatus.

Abstract: Apparatus for automatically wrapping clips on the borderwires and coils of a mattress innerspring which includes an adjustable alignment mechanism and adjustable clip wrapping tool mechanism for enabling the apparatus to accommodate borderwires and mattress innersprings of substantially any dimensions.

Abstract: A single continuous length of wire is formed into a continuous length spiral or helix, which is subsequently placed onto a moving chain conveyor having pins upstanding therefrom. The helix then is folded into a wave configuration for establishing a row of parallel coils by folding the links so as to move further apart a pair of adjacent pins of adjacent links while simultaneously moving closer together other pins on the same adjacent links. Thereby, the individual spring coils are arranged in generally parallel alignment one with the other within the row. Each coil in the row is thereby connected at its opposite ends to adjacent coils by three-dimensional looped connector segments.

Abstract: A spring coil has an open-ended terminal convolution which is connected to the body of the coil through a gradient arm. The gradient arm can be readily varied in length in manufacture to alter the compression and thereby the firmness of the spring coil. Offset portions are advantageously formed on terminal convolutions with a major straight part which is outwardly spaced from minor straight parts. This provides a three point engagement for the offset portion when connected to a border wire with a border wire helical spring. The offset portions of the spring coils have inside and outside shoulders adjacent their ends. The pitch of cross-helicals which join overlapped offset portions is chosen so that a cross-helical simultaneously engages the outside shoulders of one of a pair of overlapped offset portions to firmly hold the spring coil against rotation. The cross-helical preferably also catches the inside shoulders of the other overlapped portion to additionally hold that spring coil against rotation.

Abstract: The coil spring assembly method comprises forming a series of coil spring rows, each row being formed from a single continuous length of spring wire. Each intermediate spring within a row has an adjacent coil spring on one side directly connected at one end of that intermediate spring, and an adjacent coil spring on the other side directly connected at the other end of that coil spring, through use of connector sections that are part of the single continuous length of spring wire used to form that row. The pre-formed rows thereafter are connected in matrix form. After the rows have been connected in matrix configuration, the connector sections are selectively cut between adjacent springs on both sides of each intermediate spring. This results in a coil spring product having individual or separate coil springs not directly connected one with the other in which each such coil spring's end loops terminate in free ends, i.e.

Abstract: A spring element for bedding and furniture which can be constructed in a simple manner but will not tend to come apart in ordinary use. The spring element includes a laterally extending pair of parallel wires and a longitudinally extending pair of parallel wires atop the laterally extending wires. The pairs of wires are welded to one another at their crossing points to form a seat for engaging the open top loop of a coil spring, and the ends of the wires are connected to a framework. Each longitudinally extending wire has a depressed portion between the crossing points extending beneath the laterally extending wires. The top loop of the spring is snapped into engagement with the pairs of wires, so that the top loop is sealed above the depressed portions of the longitudinally extending wires and beneath the laterally extending wires and so that the top of the free end portions of the top loop is biased against the bottom of one of the laterally extending wires.

Abstract: A machine for connecting successive rows of coil springs together into a coil spring assembly. The machine, in preferred form, initially picks up a row of coil springs by inserting a pick up finger into the barrel of each coil and moving the springs onto a support platen. In the course of transporting the coils between pick up and the support platen, the pick up fingers change the spacing of the coils. The springs are then compressed against the support platen to a desired height through use of a reciprocable compression bar. Thereafter, and through use of rotatable transfer fingers on a transfer shaft, the springs are removed from under the compression bar, and are moved into clamping dies. Leading rotary transfer fingers on the transfer shaft first pull the row of springs out from under the compression bar, and trailing rotary fingers then push the springs into the downstream one of upper and lower clamping dies.

Abstract: A machine for connecting rows of coil springs together into a coil spring assembly. The machine initially picks up a row of coil springs by inserting a pick up finger into the barrel of each coil and moving the springs onto a support platen. While transporting the coils, the pick up fingers change the spacing of the coils. The springs are then compressed against the support platen to a desired height through use of a reciprocable compression bar. Thereafter, rotatable transfer fingers remove the springs from under the compression bar, and move them into clamping dies. Leading rotary transfer fingers on the transfer shaft first pull the row of springs out from under the compression bar, and trailing rotary fingers then push the springs into the downstream one of upper and lower clamping dies. The rows of clamping dies clamp together the upper and lower end loops of the leading and trailing rows of coil springs.

Abstract: A machine for connecting successive rows of coil springs together into a coil spring assembly. The machine, in preferred form, initially picks up a row of coil springs by inserting a pick up finger into the barrel of each coil and moving the springs onto a support platen. In the course of transporting the coils between pick up and the support platen, the pick up fingers change the spacing of the coils. The springs are then compressed against the support platen to a desired height through use of a reciprocable compression bar. Thereafter, and through use of rotatable transfer fingers on a transfer shaft, the springs are removed from under the compression bar, and are moved into clamping dies. Leading rotary transfer fingers on the transfer shaft first pull the row of springs out from under the compression bar, and trailing rotary fingers then push the springs into the downstream one of upper and lower clamping dies.

Abstract: A machine for connecting successive rows of coil springs together into a coil spring assembly. The machine, in preferred form, initially picks up a row of coil springs by inserting a pick up finger into the barrel of each coil and moving the springs onto a support platen. In the course of transporting the coils between pick up and the support platen, the pick up fingers change the spacing of the coils. The springs are then compressed against the support platen to a desired height through use of a reciprocable compression bar. Thereafter, and through use of rotatable transfer fingers on a transfer shaft, the springs are removed from under the compression bar, and are moved into clamping dies. Leading rotary transfer fingers on the transfer shaft first pull the row of springs out from under the compression bar, and trailing rotary fingers then push the springs into the downstream one of upper and lower clamping dies.

Abstract: A machine for connecting rows of coil springs together into a coil spring assembly. The machine initially picks up a row of coil springs by inserting a pick up finger into the barrel of each coil and moving the springs onto a support platen. While transporting the coils, the pick up fingers change the spacing of the coils. The springs are then compressed against the support platen to a desired height through use of a reciprocable compression bar. Thereafter, rotatable transfer fingers remove the springs from under the compression bar, and move them into clamping dies. Leading rotary transfer fingers on the transfer shaft first pull the row of springs out from under the compression bar, and trailing rotary fingers then push the springs into the downstream one of upper and lower clamping dies. The rows of clamping dies clamp together the upper and lower end loops of the leading and trailing rows of coil springs.

Abstract: An inner spring assembly embodying a generally channel-shaped border wire of the type which is provided with a continuous groove with straight sides and into which the end convolutions of the helical bedsprings of the assembly project in tangential fashion and about which the border wire is crimped to form a loose self-aligning non-rigid interconnection between springs and border wire. The border wire is formed from solid rod-like wire stock by a cold rolling operation in a shaping mill thereby obviating the necessity of resorting to machining and heat treating and eliminating waste material that is a consequence of machining. The rolling operation includes a reshaping of the solid cylindrical stock to a grooved border wire that offers a greater bending strength than like diameter solid border wire of the like weight per unit length.

Abstract: Rows of springs are periodically supplied to a mattress spring core assembly machine 7 by a transfer system 6. The springs are taken, in turn, from one of two conveyor belt pairs 4, 5 by the transfer system. The individual springs are produced by spring coiling machines 1, 2 with each machine feeding one conveyor belt pair. By periodically shifting the transfer system 6 its gripping arms 20 can alternately take a row of springs from one or the other conveyor belt pair, thus doubling the overall production rate.

Abstract: A system is provided for handling a strip of pocketed coil springs in an organized manner. An accumulator bin receives the strip from a conveyor assembly which oscillates about a pivot axis to feed the strip evenly across the width of the bin. The bin is designed to urge the first manufactured portions of the strip to the front portion thereof where it may be removed by a second conveyor assembly. Photosensitive devices may be provided to control the feeding of the strip to the bin and its removal therefrom.

Abstract: A coil spring assembly, and a method of forming that assembly, in which the assembly's edgemost coil springs are connected to a border wire by a single continuous spiral lacing wire. The method involves the steps of guiding a rotation spiral lacing wire completely around the periphery of a spring coil matrix and border wire through use of helical path defining dies until the leading and trailing ends of the lacing wire are overlapped. During the lacing operation, the helical path defining dies cooperate to deflect a peripheral segment of each corner and edge coil into juxtaposition with the border wire. The resulting final coil spring assembly includes corner coil springs in which the deflected peripheral segments of the corner coils are retained contiguous to the corner of the border wire by the lacing wire.

Abstract: A clinch tool and method for clamping a grid frame to a coil in which a clinch component is fed automatically into a space formed by the tool between the grid frame and coil with the clinch component saddled in position on the grid frame to be bent to retain the coil in a locked condition to the grid frame.

Abstract: Apparatus for receiving a row of spaced coils in which the coils are at a predetermined spacing and transferring them to a coil assembly machine at a different spacing.

Abstract: A coil spring assembly having increased firmness in a preselected area of the assembly through use of a novel spring connector structure and method. The increased firmness is provided by, during fabrication, overlapping joint segments of a pair of adjacent coil springs' top loops, positioning a levelizer wire across the overlapped joint so formed, deflecting at least one of the overlapped joint segments out of its normal arcuate attitude toward a linear attitude, and wrapping a helical lacing wire around the overlapped joint segments and levelizer wire in a sufficiently tight manner to prevent the deflected joint segment from returning fully to its normal arcuate attitude, thereby maintaining the spring joint so established in a prestressed state. Preferably, this structure and method employs a single levelizer wire and a single lacing wire to connect adjacent springs in adjacent parallel rows from one end of the rows to the other.

Abstract: A single continuous length of spring wire is formed into a continuous length spiral or helix which is subsequently folded into a wave configuration for establishing in row form, a plurality of individual spring coils disposed generally parallel one to another. Each coil in the row is connected at its opposite ends to adjacent coils by head or connector end sections. The head or connector end sections are then formed, preferably into a planar Z-shaped configuration such that the formed connector sections at the same ends of the coils are disposed in a common plane normal to the axes of the coils which they interconnect. During forming of the end sections or heads of the coils, each connector section is deformed from a looped three-dimensional attitude into the planar Z-shaped attitude by interengagement with novel forming pins and forming dies.

Abstract: Automatic machinery for producing assemblies of coil springs wherein wire is fed to a coiling station for the formation of individual coil springs and wherein transport equipment delivers the coil springs to an assembly station where the springs are tied together into complete assemblies. Indentation means are located for forming indentations in the opposite end convolutions of each coil spring prior to delivery to the assembling station. The indentation means include dies positioned in the path of movement of the transport equipment, and the movement of the transport equipment is stopped as each spring is positioned in the area of the dies. The dies then operate to form the indentations in the respective convolutions.

Abstract: This invention is concerned with manufacture of spring interior units using known machinery for the manufacture of hour-glass shaped spring members wherein a plurality of the hour-glass shaped spring members are conveyed to a locality whereat a plurality of said hour-glass shaped spring members are displaced in a form of a row located adjacent to another row of springs whence the two rows of springs are joined together at both their end convolutions and the process repeated until a spring interior unit with a predetermined number of rows of springs is formed automatically.

Abstract: A box spring grid which includes coil spring engaging ears and a plurality of support wires secured to the grid and each including an ear. The ends of each support wire may be reversely bent around one end coil of a coil spring. Also disclosed is a method of manufacturing a box spring support grid wherein ears are formed in all longitudinal wires, between each pair of transverse wires, and, subsequently, selected portions of certain longitudinal wires are removed.

Abstract: The method of making a grid of a predetermined length embodying crossing longitudinally and transversely extending spaced parallel wires welded at their crossings wherein the portions of the longitudinally extending wires between the transversely extending wires contain depressions for receiving attaching elements at the ends of coiled springs, comprising forming the grid with the transverse wires spaced in the longitudinal direction of the grid so that any whole number of spaces in the longitudinal direction exceed the length of the assembly and then forming the depression in the portion of the longitudinally extending wires between the transversely extending wires by an amount such that collectively they reduce the distance between the transversely extending wires so that a whole number of the spaces between the transversely extending wires correspond to the length of the assembly desired.

Abstract: A spring interior forming method and apparatus provides a spring interior assembler and a coil row transfer station upstream of the assembler having at least one conveyer extending therethrough. A coil former is provided at an upstream end of the conveyor and is operated through a plurality of cycles, each to feed one spring coil onto the conveyor. In one embodiment, a single former is provided with a single conveyor extending therefrom through the transfer station. In a second embodiment, two such coiler-conveyor combinations is provided. In a third embodiment, one conveyor through the transfer station is provided with two coilers, each having a feeder preferably in the form of a conveyor, that selectively feed spring coils, which may be of different types, to a cross-over station for feed onto the transfer station conveyor. In a fourth embodiment, each coiler accumulates springs at its output while awaiting queing by the cross-over station.