Claims
- 1. A spring retainer having a longitudinal dimension and a transverse dimension, said longitudinal dimension being greater than said transverse dimension, said spring retainer comprising:
- a continuous piece of fabric folded so as to form longitudinally extending top, bottom and side portions, one side of said spring retainer being open, said continuous piece of fabric being overlapped in said top and bottom portions so that said top and bottom portions each have an upper ply and a lower ply defining a receptacle therebetween,
- a band of coil springs made of a single length of wire shaped to form a plurality of coil springs arranged in a row, each of said coil springs having an upper and lower end turn, said band of coil springs being located between said top and bottom portions of fabric with said end turns of said coil springs being inserted into said receptacles, said end turns of said coil springs of said band being held in place by multiple connections, each of said connections securing an upper ply to a lower ply.
- 2. The spring retainer of claim 1 wherein the end turns of two coil springs are located between adjacent connections.
- 3. The spring retainer of claim 1 wherein said connections are welds.
- 4. The spring retainer of claim 1 wherein said connections are sewn lines.
- 5. The spring retainer of claim 1 wherein said connections are lines of glue.
- 6. A spring retainer having a longitudinal dimension and a transverse dimension, said longitudinal dimension being greater than said transverse dimension, said spring retainer comprising:
- a band of coil springs made of a single length of wire shaped to form a plurality of coil springs arranged in a longitudinally extending row, each coil spring having an upper end turn located in a top face of the band and a lower end turn located in a bottom face of the band, adjacent end turns being connected by interconnecting segments in said top and bottom faces of said band,
- a continuous piece of fabric folded around said band of coil springs so as to form longitudinally extending top, bottom and side portions, one side of said spring retainer being open, said top and bottom portions of said continuous piece of fabric being overlapped so that said top and bottom portions each have an upper ply and a lower ply, the end turns of said coil springs of said band being located between said plies,
- said coil springs of said band being secured in place by multiple transversely extending connections, each of said connections securing one of said plies to the other of said plies in one of said top and bottom portions of said continuous piece of fabric.
- 7. The spring retainer of claim 6 wherein the end turns of two adjacent coil springs of said band are located between adjacent connections.
- 8. The spring retainer of claim 6 wherein said spring retainer is joined to other spring retainers in a spring assembly.
- 9. The spring assembly of claim 8 wherein said spring retainers are joined together with a plurality of supplemental fabric strips.
- 10. The spring assembly of claim 8 wherein said spring retainers are sewn together.
- 11. The spring assembly of claim 8 wherein said spring retainers are welded together.
- 12. The spring assembly of claim 8 wherein said spring retainers are glued together.
- 13. A method of constructing a spring retainer comprising the steps of:
- folding a piece of fabric longitudinally so as to form one side portion, an overlapped top portion and an overlapped bottom portion, leaving one side of said spring retainer open, said top and bottom portions each having an upper ply of fabric and a lower ply of fabric defining a receptacle therebetween,
- providing a band of coil springs made of a single length of wire shaped to form a plurality of coil springs arranged in a longitudinally extending row, each coil spring having an upper end turn located in a top face of the band and a lower end turn located in a bottom face of the band, adjacent end turns being connected by interconnecting segments in said top and bottom faces of said band,
- inserting said end turns of said coil springs into said receptacles,
- securing said end turns of said coil springs in place by attaching the plies of said top and bottom portions of fabric to each other.
- 14. The method of claim 13 wherein securing step comprises welding said plies of fabric at select locations.
- 15. The method of claim 13 wherein securing step comprises sewing said plies of fabric at select locations.
- 16. The method of claim 13 wherein securing step comprises glueing said plies of fabric at select locations.
- 17. A pocketed spring assembly for use in the manufacture of bedding and seating products, said pocketed spring assembly comprising:
- a plurality of pockets joined together, each pocket containing a spring retainer, said spring retainer comprising:
- a band of coil springs made of a single length of wire shaped to form a plurality of coil springs arranged in a row, each coil spring having an upper end turn located in a top face of the band and a lower end turn located in a bottom face of the band, adjacent end turns being connected by interconnecting segments in said top and bottom faces of said band,
- a continuous piece of fabric folded so as to form longitudinally extending top, bottom and side portions, one side of said fabric retainer being open, said top and bottom portions of said continuous piece of fabric being overlapped so that said top and bottom portions each have an upper ply and a lower ply defining a receptacle therebetween, the end turns of said coil springs of said band being located in said receptacles,
- said coil springs of said band being held in place by multiple connections, each of said connections securing an upper ply to a lower ply.
- 18. The pocketed spring assembly of claim 17 wherein said pockets are glued together.
- 19. The pocketed spring assembly of claim 17 wherein said pockets are integrally connected, each pocket being defined by two sheets of fabric joined together.
- 20. A pocketed spring assembly for use in the manufacture of bedding and seating products, said assembly having an upper and lower planar surface in top and bottom planes respectively and comprising:
- a plurality of hingedly connected fabric pockets, each pocket containing a spring retainer, wherein said pockets are defined between two sheets of fabric, a first sheet and a second sheet, each sheet containing a plurality of folds therein, said folds separating said pockets from one another and extending inwardly from one of said upper and lower planar surfaces, said spring retainer comprising:
- a band of coil springs made of a single length of wire shaped to form a plurality of coil springs arranged in a row, each coil spring having an upper end turn located in a top face of the band and a lower end turn located in a bottom face of the band, adjacent end turns being connected by interconnecting segments in said top and bottom faces of said band,
- a continuous piece of fabric folded so as to form longitudinally extending top, bottom and side portions, one side of said strip being open, said top and bottom portions of said continuous piece of fabric being overlapped so that said top and bottom portions each have an upper ply and a lower ply defining a receptacle therebetween, the end turns of said coil springs of said band being located in said receptacles,
- said coil springs of said band being held in place by multiple connections, each of said connections securing an upper ply to a lower ply.
- 21. The pocketed spring assembly of claim 20 wherein said first and second sheets are joined with lines of attachment.
- 22. The pocketed spring assembly of claim 21 wherein said lines of attachment are located in said upper and lower planar surfaces of said pocketed spring assembly.
- 23. A spring assembly for use in the manufacture of bedding and seating products, said assembly having an upper and lower planar surface in top and bottom planes respectively and comprising:
- a plurality of parallel, aligned spring retainers, each spring retainer comprising a band of coil springs made of a single length of wire shaped to form a plurality of coil springs arranged in a row, each coil spring having an upper end turn located in a top face of the band and a lower end turn located in a bottom face of the band, adjacent end turns being connected by interconnecting segments in said top and bottom faces of said band,
- a continuous piece of fabric folded so as to form longitudinally extending top, bottom and side portions, one side of said spring retainer being open, said top and bottom portions of said continuous piece of fabric being overlapped so that said top and bottom portions each have an upper ply and a lower ply defining a receptacle therebetween, the end turns of said coil springs of said band being inserted in said receptacles,
- said coil springs of said band being held in place by multiple connections, each of said connections securing an upper ply to a lower ply,
- said spring retainers being secured to each other with multiple supplemental fabric strips, said supplemental fabric strips being located in one of said upper and lower planar surfaces of said spring assembly.
- 24. The spring assembly of claim 23 wherein said assembly has a longitudinal dimension and a transverse dimension, said longitudinal dimension being greater than said transverse dimension, said supplemental fabric strips being longitudinally oriented and said spring retainers being transversely oriented.
- 25. The spring assembly of claim 23 wherein said supplemental fabric strips and said spring retainers are parallel.
- 26. The spring assembly of claim 23 wherein said supplemental fabric strips and said spring retainers are perpendicular.
- 27. The spring assembly of claim 23 wherein an open side of one retainer is adjacent a side portion of fabric of an adjacent retainer.
- 28. A method of making a spring assembly, said assembly having an upper and lower planar surface in top and bottom planes respectively, said method comprising the steps of:
- aligning a plurality of spring retainers in a parallel manner such that each spring retainer is similarly oriented, each spring retainer comprising a band of coil springs made of a single length of wire shaped to form a plurality of coil springs arranged in a row, each coil spring having an upper end turn located in a top face of the band and a lower end turn located in a bottom face of the band, adjacent end turns being connected by interconnecting segments in said top and bottom faces of said band, a continuous piece of fabric folded so as to form longitudinally extending top, bottom and side portions, one side of said spring retainer being open, said top and bottom portions of said continuous piece of fabric being overlapped so that said top and bottom portions each have an upper ply and a lower ply defining a receptacle therebetween, the end turns of said coil springs of said band being located in said receptacles, said coil springs of said band being held in place by multiple connections, each of said connections securing an upper ply to a lower ply,
- securing said spring retainers to each other with multiple supplemental fabric strips, said supplemental fabric strips being located in one of said upper and lower planar surfaces of said spring assembly.
- 29. The method of making a spring assembly of claim 28 wherein said securing step comprises welding said supplemental fabric strips to said spring retainers.
- 30. The method of making a spring assembly of claim 28 wherein said securing step comprises sewing said supplemental fabric strips to said spring retainers.
- 31. The method of making a spring assembly of claim 28 wherein said securing step comprises gluing said supplemental fabric strips to said spring retainers.
- 32. A spring assembly for use in the manufacture of bedding and seating products, said assembly having an upper and lower planar surface in top and bottom planes respectively and comprising:
- a plurality of parallel, aligned spring retainers, each spring retainer comprising a band of coil springs made of a single length of wire shaped to form a plurality of coil springs arranged in a row, each coil spring having an upper end turn located in a top face of the band and a lower end turn located in a bottom face of the band, adjacent end turns being connected by interconnecting segments in said top and bottom faces of said band,
- a continuous piece of fabric folded so as to form longitudinally extending top, bottom and side portions, one side of said retainer being open, said top and bottom portions of said continuous piece of fabric being overlapped so that said top and bottom portions each have an upper ply and a lower ply defining a receptacle therebetween and an extension flap, the end turns of said coil springs of said band being inserted into said receptacles,
- said coil springs of said band being held in place by multiple transversely extending connections, each of said connections securing a upper ply to a lower ply,
- said spring retainers being secured to each other with said extension flaps, said extension flaps of one retainer being secured to an adjacent spring retainer.
- 33. The spring assembly of claim 32 wherein the extension flaps of said one spring retainer are secured to a top and bottom portion of fabric of said adjacent spring retainer.
- 34. The spring assembly of claim 32 wherein the extension flaps of said one spring retainer are secured to a side portion of fabric of said adjacent spring retainer.
- 35. A method of making a spring assembly, said assembly having an upper and lower planar surface in top and bottom planes respectively, said method comprising the steps of:
- aligning a plurality of spring retainers in a parallel manner such that each spring retainer is similarly oriented, each spring retainer comprising a band of coil springs made of a single length of wire shaped to form a plurality of coil springs arranged in a row, each coil spring having an upper end turn located in a top face of the band and a lower end turn located in a bottom face of the band, adjacent end turns being connected by interconnecting segments in said top and bottom faces of said band, a continuous piece of fabric folded so as to form longitudinally extending top, bottom and side portions, one side of said retainer being open, said top and bottom portions of said continuous piece of fabric being overlapped so that said top and bottom portions each have an upper ply and a lower ply defining a receptacle therebetween and extension flaps, the end turns of said coil springs of said band being located in said receptacles, said coil springs of said band being held in place by multiple transversely extending connections, each of said connections securing an upper ply to a lower ply,
- securing said spring retainers to each other with fasteners, said fasteners securing an extension flap of one spring retainer to the fabric of an adjacent spring retainer.
- 36. The method of making a spring assembly of claim 35 wherein said securing step comprises welding said extension flaps of said one spring retainer to the fabric of said adjacent spring retainer.
- 37. The method of making a spring assembly of claim 35 wherein said securing step comprises sewing said extension flaps of said one spring retainer to the fabric of said adjacent spring retainer.
- 38. The method of making a spring assembly of claim 35 wherein said securing step comprises gluing said extension flaps of said one spring retainer to the fabric of said adjacent spring retainer.
- 39. A spring assembly for use in the manufacture of bedding and seating products, said assembly having an upper and lower planar surface in top and bottom planes respectively and comprising:
- a plurality of parallel, aligned spring retainers, each spring retainer comprising a band of coil springs made of a single length of wire shaped to form a plurality of coil springs arranged in a row, each coil spring having an upper end turn located in a top face of the band and a lower end turn located in a bottom face of the band, adjacent end turns being connected by interconnecting segments in said top and bottom faces of said band,
- a continuous piece of fabric folded so as to form longitudinally extending top, bottom and side portions, one side of said spring retainer being open, said top and bottom portions of said continuous piece of fabric being overlapped so that said top and bottom portions each have an upper ply and a lower ply defining a receptacle therebetween, the end turns of said coil springs of said band being inserted in said receptacles,
- said coil springs of said band being held in place by multiple connections, each of said connections securing an upper ply to a lower ply,
- said spring retainers being secured to each other with sheets, said sheets being located in said upper and lower planar surfaces of said spring assembly.
- 40. A method of making a spring assembly, said assembly having an upper and lower planar surface in top and bottom planes respectively, said method comprising the steps of:
- aligning a plurality of spring retainers in a parallel manner such that each spring retainer is similarly oriented, each spring retainer comprising a band of coil springs made of a single length of wire shaped to form a plurality of coil springs arranged in a row, each coil spring having an upper end turn located in a top face of the band and a lower end turn located in a bottom face of the band, adjacent end turns being connected by interconnecting segments in said top and bottom faces of said band, a continuous piece of fabric folded so as to form longitudinally extending top, bottom and side portions, one side of said spring retainer being open, said top and bottom portions of said continuous piece of fabric being overlapped so that said top and bottom portions each have an upper ply and a lower ply defining a receptacle therebetween, the end turns of said coil springs of said band being located in said receptacles, said coil springs of said band being held in place by multiple connections, each of said connections securing an upper ply to a lower ply,
- securing said spring retainers to each other with at least one sheet, said at least one sheet being located in one of said upper and lower planar surfaces of said spring assembly.
- 41. The method of making a spring assembly of claim 40 wherein said securing step comprises welding said at least one sheet to said spring retainers.
- 42. The method of making a spring assembly of claim 40 wherein said securing step comprises sewing said at least one sheet to said spring retainers.
- 43. The method of making a spring assembly of claim 40 wherein said securing step comprises gluing said at least one sheet to said spring retainers.
Parent Case Info
This application is a continuation application of Provisional Patent Application, Ser. No. 60/073,633, filed Feb. 4, 1998, entitled SPRING RETAINER ASSEMBLY and assigned to L&P Property Management Co. which is incorporated by reference herein.
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