Customizable elastic unit and method of manufacturing the same

Abstract

A pocketed elastic unit (130), such as for a mattress core, comprises integral pocketed elastic elements (110) arranged in clusters (240), wherein each integral pocketed elastic element in a cluster is attached to at least one other integral pocketed elastic element, and wherein the clusters define voids (250) in at least some of which are provided independent elastic elements (260).

Description

Technical Field

[0001] This invention relates to an elastic element, such as an elastic element that can be used in a mattress, and more particularly to a customizable elastic element. Background Technology

[0002] Mattress cores are typically formed from coiled springs encased in pockets. (Reference) Figure 1 The spring 10 is initially placed between sheets or layers of bag-like material, which may be a single sheet 20 folded into two pieces. The sheets are then glued, spliced, or welded along their edges and between the springs to encapsulate the springs in a separate bag. Figure 2 and Figure 3 These are schematic side and perspective views of the so-called spring "string" 30 formed in this way.

[0003] Then, the strings 30 are glued together along the cylindrical surface of the pocket spring to form a shape as shown. Figure 4 The array 40 shown. Such an array, with appropriate length and width, is used as a mattress core.

[0004] Glue is expensive and not easily recycled, so efforts have recently been made to find alternative devices to hold the strings together. However, so far, many of these alternatives have proven to be inflexible or expensive to manufacture, or both.

[0005] In addition, it may be desirable to be able to easily change the appearance or elasticity characteristics of the mattress during the manufacturing process. Summary of the Invention

[0006] Embodiments of the present invention aim to provide an elastic unit suitable for mattresses, which may have at least one modified or customized feature, while using little or no glue, thereby allowing it to be easily recycled.

[0007] The invention is defined in the appended independent claims, which should now be referred to. Furthermore, preferred features can be found in the appended dependent claims.

[0008] According to one aspect of the invention, a bag elastic unit is provided, comprising a cluster of integral bag elastic elements, wherein each integral bag elastic element in the cluster is attached to at least one other integral bag elastic element, and wherein the cluster defines spaces or gaps in which individual elastic elements are disposed.

[0009] Preferably, the elastic unit comprises multiple strings of integral bagged elastic elements, each integral bagged elastic element being connected to at least one other integral bagged elastic element in the same string via a mesh of shared bag-like material.

[0010] Each string of integral bag elastic elements is preferably coupled to at least one other string of integral bag elastic elements.

[0011] The integral bagged elastic element preferably comprises an elastic element encapsulated in a separate bag. The string of integral bagged elastic elements preferably comprises a plurality of integral bagged elastic elements arranged with substantially parallel axes.

[0012] The elastic element may include a spring, and more preferably a helical spring, such as a helical spring made of metal (such as steel).

[0013] Individual elastic elements may not be connected to other elastic elements. In a preferred arrangement, individual elastic elements do not form part of a string. Preferably, individual elastic elements do not share the mesh of the bag-like material with integral elastic elements.

[0014] Individual elastic elements can be pouched or unpouched. Elastic units can include combinations of pouched and unpouched individual elastic elements.

[0015] Independent elastic elements may differ from integral elastic elements in at least one characteristic (such as, but not limited to, length, width, stiffness, color, and material composition). An elastic unit may include one or more independent elastic elements that differ from at least one other independent elastic element in the elastic unit in one or more characteristics, including but not limited to: length, width, stiffness, color, and material composition.

[0016] Independent elastic elements can be arranged to create regions with different characteristics within the elastic unit.

[0017] The elastic unit may include an elastic core for padded articles, such as mattresses.

[0018] The present invention includes a mattress comprising elastic elements according to any statement herein.

[0019] According to another aspect of the invention, a method for manufacturing an elastic element is provided, the method comprising: arranging integral bagged elastic elements into a cluster, wherein each integral bagged elastic element in the cluster is attached to at least one other integral elastic element, and wherein the cluster defines a space or gap; and inserting individual elastic elements into one or more of the spaces or gaps.

[0020] Preferably, an inserter mechanism is used to insert the individual resilient element into the gap, and the inserter mechanism may include an insertion tube. The inserter mechanism may include a funnel.

[0021] The method may include: introducing an inserter mechanism at least partially into a gap, placing an independent elastic element into the inserter mechanism, and withdrawing the inserter mechanism such that the independent elastic element is at least partially located within the gap.

[0022] An individual elastic element can be introduced into the gap using an actuator, which may include a piston. Alternatively or additionally, the individual elastic element can be inserted into the gap by fluid pressure (e.g., by blowing).

[0023] Alternatively or additionally, the method may include placing an independent elastic element near at least one member in the partially formed cluster, and enclosing the independent elastic element in a gap, for example, by joining one or more additional integral elastic elements to the elastic unit.

[0024] This invention may include any combination of the features or limitations mentioned herein, unless such combination of features is mutually exclusive or inconsistent. Attached Figure Description

[0025] Preferred embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which:

[0026] Figures 1 to 3 The diagram shows several pocket springs in series at different manufacturing stages, based on a previously considered structure.

[0027] Figure 4 A schematic perspective view shows multiple strings joined together to form a resilient core unit according to a previously considered structure;

[0028] Figure 5 A schematic plan view illustrates two strings of pocket springs in the early manufacturing stage of an elastic core unit according to an embodiment of the present invention.

[0029] Figure 6 and Figure 7 The illustration shows the process for production. Figure 5 Further method steps for the elastic core unit;

[0030] Figure 8 and Figure 9 yes Figures 5 to 7 Schematic plan view of further subsequent manufacturing stages of the elastic core unit; and

[0031] Figure 10 The illustration schematically shows the process for manufacturing in subsequent stages. Figures 5 to 9 The device is a flexible unit. Detailed Implementation

[0032] Go to Figure 5The illustration shows two single-strand pocket springs 130, each pocket spring comprising a linear array of metal (e.g., steel) helical springs 110 encapsulated in a separate pouch formed of a sheet 120 of a weldable pouch-like material, which may include, for example, a spunbond polymer, such as polyester or polypropylene. It should be noted that the strand shown as an example contains only six individual pocket springs, while in reality, depending on the desired size of the elastic core unit being manufactured, the strand will include more than six pocket springs.

[0033] Sheets 120 (which may include a single sheet already folded onto a spring, or may include two separate sheets) are joined along their edges (not shown), in this example by ultrasonic welding. In this example, the sheets are also joined between springs 110 by ultrasonic welding to form a connecting portion 122, thereby defining a separate pouch 124 for the springs 110. The connecting portion is a portion of sheet or sheet material already joined between springs during pouch formation. Prior to the next step of the method, the two strings are aligned in parallel, in which multiple sets of ultrasonic welding tools, including an ultrasonic generator (or welding head) 150 and an anvil 160, are brought together to weld every other connecting portion of the connecting portion 122 together in the direction of arrow A1, thereby joining the strings 130.

[0034] Figure 6 The two strings are shown after the welding operation. Where welding has occurred, the connecting portions 122 of the two strings 130 are joined by an ultrasonic weld W. The weld W is located between the strings 130 and effectively binds the four bags 124 together. Welding tools 150 and 160 have been pushed together and engage the spaced pairs of connecting portions 122 of the bag springs. In doing so, the bags on either side of the weld W have been slightly rotated so that the unwelded connecting portions have been pushed outward in the direction of arrow A2 and are now present on the outward-facing side of the string pair P.

[0035] Figure 7 The next step is shown, in which the new string 130 is placed next to the joined string pair P. The welding tool has been positioned laterally offset by a spring distance along the string 130, such that the unwelded connection portion 122 of the string pair P is aligned with the corresponding connection portion 122 of the new string 130 for welding. Again, the welding tool sets 150, 160 are placed together, and the new string 130 is joined to the string pair P. As a result, in Figure 8 The partially formed pocket spring unit 140 is shown in the figure.

[0036] Repeat the process, each time rotating the bag spring unit 140 and moving the welding tool back and forth in a reciprocating manner to weld every other connection part to the new string, until a sufficient number of strings or rows have been added.

[0037] The joining of the strings occurs on a support surface, which may include devices (not shown) for clamping and moving the individual strings 130 and / or for indexing the pocket spring unit 140. Two sets of welding tools 150 and 160 may be inserted from above and / or below the unit next to the connecting portion 122 (i.e., in a direction parallel to the axis of the spring itself) or at least one set of welding tools (e.g., 160) may be introduced in a direction substantially transverse to the spring axis (e.g., in the direction where a new string exists (i.e., transverse to the extent of the string)). Although tools 150 and 160 are described in this example as an ultrasonic generator and an anvil, respectively, their positions / functions may be reversed.

[0038] In practice, examples of ultrasonic welding equipment can be replaced by heat bonding tools or heat sealing tools.

[0039] Figure 8 The elastic unit 130 is shown in a schematic plan view, from which it can be seen that the joined strings produce clusters or modules 240 of springs (one cluster or module is shown in shaded), and these clusters or modules of springs define spaces or gaps 250 between the springs in the cluster.

[0040] Figure 9 The elastic element 130 in the later manufacturing stage is shown in a schematic plan view.

[0041] An independent elastic unit 260 is provided within the gap 250, in this case, the elastic unit being a separate pocketed coil spring. The independent spring 260 is not integral with the rest of the elastic unit and does not share the pocket material / net with any integral spring 110. Specifically, the independent springs have been inserted into the space 250 such that their axes are substantially parallel to the integral spring 110.

[0042] Figure 10 A device for inserting an individual spring 260 into a gap formed by the spring cluster 240 is schematically shown. In this example, the individual spring 260 is a pocket coil spring having approximately the same axial length as the springs 110 constituting the cluster 240, but with a smaller diameter. For inserting the individual spring 260, a plastic or metal insertion device 270 is positioned substantially vertically above the gap. The device 270 includes a tube 270a with a truncated conical funnel portion 270b at its upper end.

[0043] To insert the individual springs into the cluster, first insert device 270 into gap 250, then insert spring 260 into device 270. This can be achieved by blowing spring 260, as it is a pocket spring. Alternatively, a pusher device such as a piston can be used, and this would be more efficient in the case of non-pocket individual springs. Once spring 260 is fully inserted into the gap, device 270 can be withdrawn.

[0044] Another way to incorporate individual springs into the gaps formed by the cluster is to place the individual springs into predetermined gap positions when forming the elastic units (i.e., when creating the string, such as during the joining of spring strings). In this embodiment, the springs are placed next to the previous string of integral springs before the next string is introduced.

[0045] Individual springs can be pocketed or unpocketed and can have characteristics such as length, diameter, stiffness, material composition, or color. These characteristics are selected to give the elastic unit specific features. For example, it may be desirable for certain parts, areas, or zones of the elastic unit to be stiffer or more elastic than others. This can be achieved by carefully selecting the type, number, and location of the individual springs.

[0046] In the examples shown and described herein, the cluster consists of four elastic elements. However, the cluster can be composed of other numbers of elastic elements.

[0047] While efforts have been made in the foregoing description to draw attention to those features of the invention that are considered particularly important, it should be understood that the applicant claims protection for any patentable features or combinations thereof mentioned herein and / or shown in the drawings, whether or not they are specifically emphasized.

Claims

1. A bagged elastic unit comprising a string of integral bagged springs, each integral bagged spring comprising an array of metal helical springs encapsulated in individual bags formed of a sheet of weldable bag-like material, the sheet being joined along its edges and also joined between the springs by ultrasonic welding to form a connecting portion, the springs being arranged in clusters, wherein, Each integral pocket spring in the cluster is attached to at least one other integral pocket spring, and wherein the cluster defines gaps in which at least some of the gaps are provided independent springs not connected to other springs, wherein two strings are aligned in parallel and every other connecting portion of the two strings is joined together by an ultrasonic weld located between the strings to combine the four bags together.

2. The bagged elastic unit according to claim 1, wherein, The bagged elastic unit includes multiple strings of integral bagged springs, each of which is connected to at least one other integral bagged spring in the same string via a mesh of shared bag-shaped material.

3. The bagged elastic unit according to claim 1 or 2, wherein, The independent spring differs from the integral pocket spring in at least one characteristic, including but not limited to one or more of the following: length, width, stiffness, color, and material composition.

4. The bagged elastic unit according to claim 1 or 2, wherein, The bagged elastic unit includes one or more independent springs that differ in one or more features from at least one other independent spring in the bagged elastic unit, including but not limited to: length, width, stiffness, color, and material composition.

5. The bagged elastic unit according to claim 1 or 2, wherein, The individual springs are arranged to create regions with different characteristics within the bagged elastic unit.

6. A mattress comprising a pocketed elastic unit according to any one of claims 1 to 5.

7. A method for manufacturing an elastic element, the method comprising: One-piece pocket springs are arranged in clusters, wherein each one-piece pocket spring in the cluster is attached to at least one other one-piece pocket spring, and wherein the clusters define gaps; and An independent spring is inserted into one or more of the gaps, and this independent spring is not connected to the other springs. The method includes forming a string of integral pocket springs, each integral pocket spring comprising an array of metal helical springs encapsulated in individual bags formed of a sheet of weldable bag-like material joined along their edges and also joined between the springs by ultrasonic welding to form a connecting portion, wherein two strings are aligned in parallel and every other connecting portion of the two strings is joined together by an ultrasonic weld located between the strings to combine four bags together.

8. The method according to claim 7, wherein, The individual spring is inserted into the gap using an inserter mechanism that includes a tube or funnel.

9. The method according to claim 8, wherein, The method includes: introducing the inserter mechanism at least partially into the gap; placing the independent spring into the inserter mechanism; and withdrawing the inserter mechanism such that the independent spring is at least partially located within the gap.

10. The method according to claim 7, wherein, The individual spring is introduced into the gap using a pusher.

11. The method according to claim 10, wherein, The actuator is a piston.

12. The method according to claim 7, wherein, The independent spring is inserted into the gap by fluid pressure.

13. The method according to claim 12, wherein, The individual spring is inserted into the gap by blowing.

14. The method according to any one of claims 7 to 13, wherein, The method includes: placing the individual spring as at least one component in a cluster formed by adjacent portions; and enclosing the individual spring in a gap by joining one or more additional integral pocket springs to the elastic unit.

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