Note: Descriptions are shown in the official language in which they were submitted.
CA 02291036 1999-11-23
Method and Device for Producing Pocket Spring Cores
The object of this invention is a method and a device for generating pocket
spring cores.
Such methods and devices have become known in a plurality of different forms
of
embodiment. Essentially, first constructed for this are individual coils of
pocket springs.
These coils contain a series of pockets. Accommodated in each pocket are one
or more
springs. The pockets are closed with respect to each other, e.g. by cementing
or welding.
The jacketing consists of a fabric or a substance displaying different
material properties,
based on requirements. In principle, any suitable material is capable of being
used here; the
concept of a fabric is not to be considered limiting.
For production of the pocket spring cores, first produced according to prior
art is a series of
coils that are next joined with one another. This is done, for example, by
cementing (gluing).
However, the known methods and devices are relatively ineffective and require
high outlays
for equipment, since the individual coils must be positioned exactly in
relation to each other.
Therefore, the object of this invention is to provide a method and a device by
which pocket
spring cores can be produced quickly, in a cost-effective fashion and at low
expense, in
practically random dimensions (sizes).
This objective is satisfied in accordance with the invention by the technical
teaching of the
independent claims.
The invention proposes a completely new way for producing pocket spring cores.
Now.
individual coils that have to be tediously joined together will no longer be
produced first;
rather, taking place first is the joining of the jackets or fabric of the
individual coils, and the
springs subsequently inserted. If required, the separation into pockets can be
performed
downstream.
The result of this is the significant advantage that already from the start
the desired number
of coils to be used, which is essentially predetermined by the width of the
pocket spring
core, is supplied. The length of the pocket spring core can be easily set; as
a measurement
for this the consumption of jacketing or the number of inserted springs can be
used.
It is preferred to have the jacketing material for each coil available already
pre-sorted into the
correct sizes. The individual jackets are then arranged next to each other and
joined with
one another. A welded connection is preferred here but, obviously, also
possible is
cementing or some other means of joining, such as stitching.
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Next, the jackets are converted into a closed tube by overlapping the free
ends and
connecting them together. Again preferred here is welding; however, the other
connection
possibilities mentioned above can also be employed.
In order to obtain a desired form, and simultaneously be able to grip onto the
inside space of
the thus-structured tube, the jacketing is preferably looped about a pipe, the
pipe being
adapted in size to the springs being processed.
The springs are now conveyed in, this preferably being done by inserting the
springs into the
inner space of the appropriate tube. The springs are then pushed torward
inside this inner
space, in the conveying direction, for a certain distance or up to a stop.
The springs need not be forcibly introduced after the forming of the jacketing
into a tube. It
is likewise possible to place the springs in the tube beforehand and then,
after forming the
tube, tacking them in.
In the event that a pocketing is to be provided. a separation is formed behind
the introduced
spring or springs in each coil. This separation can consist of a penetrating
weld seam, of an
interrupted weld seam or of weld points. Used in the following is only the
concept of weld
seam, which includes all the possibilities mentioned. Alternatively, a gluing,
a stitching or
some other possibility can again be selected.
Self-evident is the fact that the fabric forming the jacketing must be moved
in the conveying
direction. Driven rollers can be used for this purpose, but it is likewise
possible to achieve
the movement of the fabric together with the displacement of the springs. A
combination is
also possible.
After reaching the desired length for the pocket spring cores, applied for the
pocketing is not
one but two weld seams that display a certain, relatively small spacing
between each other,
depending upon conditions. The already-completed pocket spring in this region
between the
weld seams is next separated from the one yet to be produced. Preferred here
is that a hot
separation (cutting) be done, e.g. by means of a heated, mobile wire.
Obviously, an
alternative possibility is the use of shears or other mechanical separation
means.
The finished pocket spring core is removed via a suitable contrivance, and
possibly reworked
to some measure to achieve a uniform surface.
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The entire finishing process can run off in continuous or cyclic fashion, with
cyclic finishing
being preferred. Preferred here is to perform the three welding processes at
the same time.
Next, the welding elements are withdrawn and the jacketing moved. As mentioned
at the
beginning, this preferably takes place by introducing the springs, which are
pushed up to the
forward end of the coil concerned, and then farther by an amount that
corresponds
approximately to the maximum diameter of the spring. Rollers or spools that
act upon the
jacketing can support this movement.
The object of this invention results not only from the object of the
individual claims, but also
from the combination of the individual claims among one another.
All data and features disclosed in the documentation, including the abstract,
in particular the
spatial structuring represented in the drawings, are claimed as invention-
essential, insofar as
they are new individually or in combination relative to the prior art.
The invention will be explained in more detail in the following with the aid
of the drawings
representing just one method of embodiment. In this, resulting from the
drawings and their
description are other features essential to the invention.
Shown are:
Figure 1 : a side view of a device in accordance with the invention
Figure 2. a plan view according to arrow II in Figure 1
Figure 3. a side view according to arrow III in Figure 1
Figure 4: detail X from Figure 1
Figure 5: detail Y from Figure 1
Figure 6: detail Z from Figure 1
Figures 7 to 9: Views according to Figures 4 to 6 in which the fabric forming
the jacketing is
represented
Figures 1-3 show schematically overall views of a device 1 in accordance with
the
invention. In the implementation example represented, the device 1 includes an
upright 2 on
which are mounted several spools (reels, cylinders). These spoofs can be
arranged one
above the other as represented, and carry the fabric 23 in the required
dimensions.
Depending upon circumstances, it can be required that the spools be arranged
one above the
other. Obviously, each spool 3 is as wide as the total dimension of the
associated fabric
23, so that by mounting the spools 3 right next to each other a very great
width would be
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achieved. To decrease this width, the spools can be mounted above one another,
as
represented.
The device 1 further includes a forming and welding station 4, a pocketing
station 5, a
cutting tseparation) station 6, as well as a packer/transporter7.
The forming and welding station in the implementation example includes a pipe
8 that can
be provided with a funnel 9 on its end facing toward the spools 3. This funnel
serves to
facilitate winding the fabric 23 about the pipe 8.
Disposed inside the pipe 8 is a pusher (slider) for moving the spring 27.
These springs 27,
in the implementation example shown, are supplied from below via a pipe 11 and
another
pusher 12.
Overall feeding of the springs 27 can, for example, be accomplished laterally,
hence from
the top or bottom in Figure 2.
Available for producing the appropriate connection are three sonotrodes 13.
14, 15, whose
exact method of operation is represented in the more detail in Figures 4-9.
One or more conveying stations 16 can be provided with one or more driven
rollers for
conveying the fabric in the conveying direction 29. Obviously, it is likewise
possible to
achieve this conveying via the pusher 10.
The cutting station 6 includes a wire 19 that is heatable and movable in the
arrow direction
20, 21 . Here, the wire is structured such, and brought to such a temperature,
that it can
cut through the fabric 23 without difficulties.
The packer 7, in the implementation example shown, consists of two rotating
belts 17, 18,
between which the finished pocket spring core is picked up. Preferred is to
have the
distance between the belts 17, 18 be adjustable in order to be able to exert
pressure on the
pocket spring core for smoothing out roughness.
In the implementation example shown, carried out are essentially three joining
(connecting)
processes. As already explained in the general part of the description, a
welded connection
is preferred, in comparison to a cemented or stitched connection. The
principal reason is
that no additional material must be supplied.
Figures 4 and 7 show the connection of individual jackets 23 and, therewith,
connection of
the individual coils. Here, every other pipe 8 is provided with a recess 22
which a first
CA 02291036 1999-11-23
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sonotrode 13 engages. As represented in Figure 7, this sonotrode 13 is movable
in order to
enable an adaptation to different rim conditions. The sonotrode in the
implementation
example shown generates three weld points 24, which can be placed above one
another,
next to each other or also diagonally. The distance between individual weld
points can
essentially be freely selected. The distance between the individual
connections, from weld
points 24 in Figure 7 to the sonotrode 13, can be essentially freely selected
also.
Figures 5 and 8 show the subsequent forming of the fabric 23 into a closed
tube. For this,
as represented schematically in Figure 8, the overhanging ends of the fabric
23 are folded in
so that they overlap one another. A weld seam 25 is produced in this
overlapping region by
means of the sonotrode 14. The sonotrode 14 can be constructed to be mobile.
Figures 6 and 9 show the pocketing. An assumption for pocketing is that the
closed tubes,
that is the coils without springs, first be closed at their forward end. Next,
a spring 27 is
moved forward in each coil up to this non-represented seam, via the pipes 8, 1
7 and the
pushers 10, 12.
All coils 30 are then moved forward a certain, predetermined distance. This
can be done
either by the pusher 10 or the conveying station 16 or a combination thereof.
It is self-evident that for the appropriate movement, the sonotrodes 15 that
are provided for
are driven downward. Now, as soon as the first picked-up spring has passed
sonotrodes
15, these latter again travel upwardly and generate a .weld seam 26, so that a
pocket is
formed. Here, the weld seam 26 can, as represented, _be interrupted.
Obviously, it is also
possible to produce a penetrating weld seam, or simply only one or more weld
points.
Next, the sonotrodes 15 again travel downward. the next spring 27 is placed in
a pocket,
the coils 30 move in the conveying direction 29. The sonotrodes 15 drive
upwardly,
generate the next weld seam, and so forth.
As soon as a certain number of springs 27 have been processed or a certain
length of fabric
has been supplied, the sonotrodes 15 apply two weld seams 26 a short distance
apart from
one another. The cutting station, by means of the wire 19, then does the
cutting between
the weld seams.
The completed pocket spring core is picked up by the packer 7, if need be
smoothed, and
then processed and sent to a warehouse.
Here, the sequence and/or the type of springs to be processed can be varied.
For each coif
its own type of spring can be used; several different springs can also be used
for each coil.
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In particular, this is important in the production of pocket spring cores,
since these latter are
usually divided into areas having different requirements, especially different
weight loading.
With this invention, it is readily possible to pre-program and then supply
particular spring
sequences.
The entire construction and sequence of the method are, moreover, very fluid
and enable a
rapid and cost-effective production
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Drawing Legends
1. Device
2. Upright
3. Spool
4. Forming and Welding Station
5. Pocketing /pocket-forming? Station
6. Separating/Cutting Station
7. Packer/Transporter
8. Pipe
9. Funnel
10. Pusher, Slide
11. Pipe
12. Pusher, Slide
13. Sonotrode
14. Sonotrode
15. Sonotrode
16. Conveying Station
17. Belt
18. Belt
19. Wire
20. Arrow Direction
21 . Arrow Direction
22. Recess
23. Fabric, Jacket, Jacketing
24. Weld Point
25. Wefd Seam
26. Weld Seam
27. Spring
28. Pocket
29. Conveying Direction
30. Coil
