Claims
- 1. A method of making a spring unit comprising the steps of:arranging a plurality of rows of pocketed coil springs, each row including a plurality of coil springs each encased in a fabric pocket, each fabric pocket having a top end, a bottom end and a sidewall between the top and bottom ends, the sidewalls of the fabric pockets of each row of pocketed coil springs being juxtaposed to the sidewalls of the fabric pockets of an adjacent row with the top and bottom ends of the fabric pockets combining to define top and bottom surfaces, respectively, of the spring unit; bonding a plurality of top sheets to the top ends of the fabric pockets of selected pocketed coil springs, each of the top sheets being generally perpendicular to the rows of pocketed coil springs and separated by a spacing from an adjacent top sheet; bonding a plurality of bottom sheets to the bottom ends of the fabric pockets of the selected pocketed coil springs, each of the bottom sheets being generally perpendicular to the rows of pocketed coil springs and aligned with one of the top sheets; bonding the sidewalls of the fabric pockets of the pocketed coil springs in the spacings between adjacent top sheets to the sidewalls of the fabric pockets of pocketed coil springs in an adjacent row to provide differing performance characteristics to the pocketed coil springs located in the spacings relative to the selected pocketed coil springs.
- 2. The method of claim 1, wherein the bonding of the top sheets, the bottom sheets and the sidewalls is accomplished by an adhesive spray applicator.
- 3. The method of claim 1 further comprising:serially inserting each of the rows of pocketed coil springs between spaced upper and lower conveyors; feeding the top and bottom sheets from respective supply rolls between the top ends and the upper conveyor and the bottom ends and the lower conveyor, respectively; spraying adhesive onto the top and bottom sheets for bonding to the respective top and bottom ends of the selected pocketed coil springs; and spraying adhesive onto the sidewalls of the pocketed coil springs in the spacings between the top sheets.
- 4. A method of making a spring unit comprising the steps of:arranging at least one string of interconnected pocketed coil springs into a plurality of rows, each row including a plurality of coil springs each encased in a fabric pocket, each fabric pocket having a opposed ends and a sidewall between the opposed ends, the sidewalls of the fabric pockets of each row of pocketed coil springs being juxtaposed to the sidewalls of the fabric pockets of an adjacent row with the corresponding ends of the fabric Dockets combining to define opposed surfaces; bonding at least one sheet to the corresponding ends of the fabric pockets of selected pocketed coil springs on a first one of the opposed surfaces; and bonding the sidewalls of at least some of the fabric pockets of the pocketed coil springs to the sidewalls of the fabric pockets of pocketed coil springs in an adjacent row; wherein the at least one sheet is bonded to less than all of the pocketed coil springs of the spring unit to provide differing performance characteristics for the spring unit relative to those pocketed coil springs that do not have the sheet bonded thereto.
- 5. A method of making a spring unit comprising the steps of:arranging at least one string of interconnected pocketed coil springs into a plurality of rows, each row including a plurality of coil springs each encased in a fabric pocket, each fabric pocket having a opposed ends and a sidewall between the opposed ends, the sidewalls of the fabric pockets of each row of pocketed coil springs being juxtaposed to the sidewalls of the fabric pockets of an adjacent row with the corresponding ends of the fabric pockets combining to define opposed surfaces; bonding at least one sheet to the corresponding ends of the fabric pockets of selected pocketed coil springs on a first one of the opposed surfaces; bonding the sidewalls of at least some of the fabric pockets of the pocketed coil springs to the sidewalls of the fabric pockets of pocketed coil springs in an adjacent row; and bonding at least one sheet to the corresponding ends of the fabric pockets of selected pocketed coil springs on a second one of the opposed surfaces; wherein a plurality of sheets are bonded to each of the first and second opposed surfaces and each of the sheets is spaced from an adjacent sheet on the corresponding surface.
- 6. A method of making a spring unit comprising the steps of:arranging a plurality of rows of pocketed coil springs, each row including a plurality of coil springs each encased in a fabric pocket, each fabric pocket having a opposed ends and a sidewall between the opposed ends, the sidewalls of the fabric pockets of each row of pocketed coil springs being juxtaposed to the sidewalls of the fabric pockets of an adjacent row with the corresponding ends of the fabric pockets combining to define opposed surfaces; bonding at least one sheet to the corresponding ends of the fabric pockets of selected pocketed coil springs on a first one of the opposed surfaces; and bonding the sidewalls of at least some of the fabric pockets of the pocketed coil springs to the sidewalls of the fabric pockets of pocketed coil springs in an adjacent row; wherein the at least one sheet is bonded to less than all of the pocketed coil springs of the spring unit to provide differing performance characteristics for the spring unit relative to those pocketed coil springs that do not have the sheet bonded thereto.
- 7. A method of making a spring unit comprising the steps of:arranging a plurality of rows of pocketed coil springs, each row including a plurality of coil springs each encased in a fabric pocket, each fabric pocket having a opposed ends and a sidewall between the opposed ends, the sidewalls of the fabric pockets of each row of pocketed coil springs being juxtaposed to the sidewalls of the fabric pockets of an adjacent row with the corresponding ends of the fabric pockets combining to define opposed surfaces; bonding at least one sheet to the corresponding ends of the fabric pockets of selected pocketed coil springs on a first one of the opposed surfaces; bonding the sidewalls of at least some of the fabric pockets of the pocketed coil springs to the sidewalls of the fabric pockets of pocketed coil springs in an adjacent row; and bonding at least one sheet to the corresponding ends of the fabric pockets of selected pocketed coil springs on a second one of the opposed surfaces; wherein a plurality of sheets are bonded to each of the first and second opposed surfaces and each of the sheets is spaced from an adjacent sheet on the corresponding surface.
- 8. A method of making a spring unit comprising the steps of:arranging a plurality of rows of pocketed coil springs, each row including a plurality of coil springs each encased in a fabric pocket, each fabric pocket having a top end, a bottom end and a sidewall between the top and bottom ends, the sidewalls of the fabric pockets of each row of pocketed coil springs being juxtaposed to the sidewalls of the fabric pockets of an adjacent row with the top and bottom ends of the fabric pockets combining to define top and bottom surfaces, respectively, of the spring unit; bonding a top sheet to the top ends of the fabric pockets of a first set of pocketed coil springs; bonding a bottom sheet to the bottom ends of the fabric pockets of a second set of pocketed coil springs; bonding the sidewalls of the fabric pockets of a third set of pocketed coil springs to the sidewalls of the fabric pockets of pocketed coil springs in an adjacent row.
- 9. The method of claim 8 further comprising:orienting the top and bottom sheets generally perpendicular to the rows of pocketed coil springs.
- 10. The method of claim 8 further comprising:bonding a plurality of top sheets to the top ends of the first set of pocketed coil springs; spacing each of the top sheets from an adjacent top sheet; bonding a plurality of bottom sheets to the bottom ends of the second set of pocketed coil springs; and spacing each of the bottom sheets from an adjacent bottom sheet.
- 11. The method of claim 8 wherein the first and second sets of pocketed coil springs are identical so that the top and bottom sheets are aligned and bonded to the same coil springs.
- 12. The method of claim 8 wherein the top and bottom ends of the third set of pocketed coil springs are not bonded to the top and bottom sheets, respectively.
- 13. The method of claim 8 wherein the bonding of the top sheet, the bottom sheet and the sidewalls is accomplished by an adhesive spray applicator.
- 14. The method of claim 8 further comprising:serially inserting each of the rows of pocketed coil springs between spaced upper and lower conveyors; feeding the top and bottom sheets from respective supply rolls between the top ends and the upper conveyor and the bottom ends and the lower conveyor, respectively; spraying adhesive onto the top and bottom sheets for bonding to the respective top and bottom ends of the first and second sets of pocketed coil springs; and spraying adhesive onto the sidewalls of the third set of pocketed coil springs.
- 15. A method of making a spring unit comprising the steps of:arranging at least one string of interconnected pocketed coil springs into a plurality of rows, each row including a plurality of coil springs each encased in a fabric pocket, each fabric pocket having a opposed ends and a sidewall between the opposed ends, the sidewalls of the fabric pockets of each row of pocketed coil springs being juxtaposed to the sidewalls of the fabric pockets of an adjacent row with the corresponding ends of the fabric pockets combining to define opposed surfaces; bonding at least one sheet to the corresponding ends of the fabric pockets of selected pocketed coil springs on a first one of the opposed surfaces; and bonding the sidewalls of at least some of the fabric pockets of the pocketed coil springs directly to the sidewalls of the fabric pockets of pocketed coil springs in an adjacent row.
- 16. The method of wherein the bonding of the at least one sheet and the bonding of the sidewalls are accomplished in combination with one another.
- 17. The method of claim 15 wherein the bonding of the at least one sheet and the bonding of the sidewalls are accomplished concurrently.
- 18. The method of claim 15 further comprising:bonding at least one sheet to the corresponding ends of the fabric pockets of selected pocketed coil springs on a second one of the opposed surfaces.
- 19. The method of claim 18 wherein the sheets bonded to the first and second opposed surfaces are generally aligned with one another and are bonded to the same pocketed coil springs.
- 20. The method of claim 15 further comprising:orienting the at least one sheet generally perpendicular to the rows of pocketed coil springs.
Parent Case Info
This is a divisional of U.S. patent application Ser. No. 09/493,380, filed Jan. 28, 2000 and issued as U.S. Pat. No. 6,374,442 on Apr. 23, 2002.
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