Method of producing a spring core mattress

Claim 1

A METHOD OF PRODUCING A SPRING CUSION BODY IN WHICH A COIL SPRING CORE IS COVERED WITH AND SECURED TO FOAMED. ELASTOMERIC MATERIAL, SAID SPRING CORE BEING FORMED BY ASSEMBLING A PLURALITY OF COIL SPRINGS INTO A SPRING CORE HAVING END COILS DEFINING A SURFACE WITH A PARTIAL SEGMENTS OF THE ENDS COILS LYING ON THE PERIPHERY OF SAID SURFACE, SAID METHOD COMPRISING PLACING A SIDE WALL BAND AROUND THE SIDES OF SAID SPRING CORE WITH ONE PERIPHERAL EDGE ADJACENT SAID PERIPHERAL SEGMENTS OF SAID END COILS, POSITIONING SAID SPRING CORE WITH SAID SIDE WALL BAND IN A MOLD WITH A SHEET OF FORMED, ELASTOMERIC MATERIAL COVERING RHEE END COILS DEFINING SAID SURFACE AND WITH A SPACE BETWEEN THE SIDE WALLS OF THE MOLD AND SIDES OF SAID SPRING CORE COMPLETELY SURROUNDING THE SIDES OF THE SPRING CORE, SAID SPACE BEING CLOSED ON THE INNER SIDE BY SAID SIDE WALL BAND AND ON THE OTHER SIDES BY SAID MOLD TO PROVIDE A COMPLETELY ENCLOSED SPACE, ADMITTING A FOAMABLE AND SOLIDIIFIABLE ELASTOMERIC MATERIAL TO SAID SPACE AND PERMITTING THE MATERIAL TO FOAM AND SOLIDIFY TO FORM A FOAMED ELASTOMERIC MATERIAL FILLING SAID SPACE AND BONDED TO SAID SHEET OF FOAMED, ELASTOMERIC MATERIAL TO SAID SIDE WALL BAND, SO THAT SAID FOAMED MATERIAL FORMS AN INTEGRAL COVER OF SAID SURFACE OF SAID ENDS COILS AND THE SIDES OF SAID CORE, SAID PERIPHERAL SEGMENTS OF SAID END COILS BEING EMBEDDED IN THE FOAMED MATERIAL TO SECURE SAID END COILS TO THE CASING FORMED BY SAID FOAMED MATERIAL.

Claim 2

A METHOD OF PRODUCING A SPRING CUSION BODY IN WHICH A COIL SPRING CORE IS COVERED WITH AND SECURED TO FOAMED. ELASTOMERIC MATERIAL, SAID SPRING CORE BEING FORMED BY ASSEMBLING A PLURALITY OF COIL SPRINGS INTO A SPRING CORE HAVING END COILS DEFINING A SURFACE WITH A PARTIAL SEGMENTS OF THE ENDS COILS LYING ON THE PERIPHERY OF SAID SURFACE, SAID METHOD COMPRISING PLACING A SIDE WALL BAND AROUND THE SIDES OF SAID SPRING CORE WITH ONE PERIPHERAL EDGE ADJACENT SAID PERIPHERAL SEGMENTS OF SAID END COILS, POSITIONING SAID SPRING CORE WITH SAID SIDE WALL BAND IN A MOLD WITH A SHEET OF FORMED, ELASTOMERIC MATERIAL COVERING RHEE END COILS DEFINING SAID SURFACE AND WITH A SPACE BETWEEN THE SIDE WALLS OF THE MOLD AND SIDES OF SAID SPRING CORE COMPLETELY SURROUNDING THE SIDES OF THE SPRING CORE, SAID SPACE BEING CLOSED ON THE INNER SIDE BY SAID SIDE WALL BAND AND ON THE OTHER SIDES BY SAID MOLD TO PROVIDE A COMPLETELY ENCLOSED SPACE, ADMITTING A FOAMABLE AND SOLIDIIFIABLE ELASTOMERIC MATERIAL TO SAID SPACE AND PERMITTING THE MATERIAL TO FOAM AND SOLIDIFY TO FORM A FOAMED ELASTOMERIC MATERIAL FILLING SAID SPACE AND BONDED TO SAID SHEET OF FOAMED, ELASTOMERIC MATERIAL TO SAID SIDE WALL BAND, SO THAT SAID FOAMED MATERIAL FORMS AN INTEGRAL COVER OF SAID SURFACE OF SAID ENDS COILS AND THE SIDES OF SAID CORE, SAID PERIPHERAL SEGMENTS OF SAID END COILS BEING EMBEDDED IN THE FOAMED MATERIAL TO SECURE SAID END COILS TO THE CASING FORMED BY SAID FOAMED MATERIAL.

Claim 3

A method of producing a spring cushion body in which a coil spring core is covered with and secured to foamed, elastomeric material, said spring core being formed by assembling a plurality of coil springs into a spring core having end coils defining a surface with partial segments of the end coils lying on the periphery of said surface, said method comprising placing a side wall band around the sides of said spring core with one peripheral edge adjacent the peripheral segments of said end coils and with said segments projecting outwardly beyond the peripheral edge of said band, covering the surface defined by the end coils with a cover sheet of foamed, elastomeric material, moving said peripheral segments toward the opposite ends of said springs and retaining them in such position under stress, enclosing a space surrounding the sides of said spring core with the side band and peripheral edge of said cover sheet of foamed material forming one side of said space and forming the other sides of said space to enclose completely said space with said peripheral segments projecting beyond said side into with said space, admitting a foamable and solidifiable elastomeric material into said space and permitting the material to foam and solidify to form a wall of foamed, elastomeric material surrounding the sides of said spring core and bonded to said side band and the peripheral edge of said cover sheet, so that said foamed material forms an integral cover of said surface of said coils and the sides of said core, with said peripheral segments of the end coils embedded in the foamed material to secure the end coils to said casing.

Claim 4

A method of producing a spring cushion body in which a coil spring core is covered with and secured to foamed, elastomeric material, said spring core being formed by assembling a plurality of coil springs into a spring core having end coils defining a surface with partial segments of the end coils lying on the periphery of said surface, said method comprising placing a side wall band around the sides of said spring core with one peripheral edge adjacent the peripheral segments of said end coils and with said segments projecting outwardly beyond the peripheral edge of said band, covering the surface defined by the end coils with a cover sheet of foamed, elastomeric material, moving said peripheral segments toward the opposite ends of said springs and retaining them in such position under stress, enclosing a space surrounding the sides of said spring core with the side band and peripheral edge of said cover sheet of foamed material forming one side of said space and forming the other sides of said space to enclose completely said space with said peripheral segments projecting beyond said side into with said space, admitting a foamable and solidifiable elastomeric material into said space and permitting the material to foam and solidify to form a wall of foamed, elastomeric material surrounding the sides of said spring core and bonded to said side band and the peripheral edge of said cover sheet, so that said foamed material forms an integral cover of said surface of said coils and the sides of said core, with said peripheral segments of the end coils embedded in the foamed material to secure the end coils to said casing.

Claim 5

A method of producing a spring cushion body in which a coil spring core is covered with and secured to foamed, elastomeric material, said spring core being formed by assembling a plurality of coil springs into a spring core having end coils defining a surface with partial segments of the end coils lying on the periphery of said surface, said method comprising placing a side wall band around the sides of said spring core extendiNg between the end coils of the opposite ends of the coil springs to surround said spring core completely between the end coils of the springs, positioning said spring core with said side wall band in a mold with a sheet of material in the bottom of the mold, and with a second sheet of material covering the ends of the coil springs defining said surface at the top of the mold, at least one of said sheets being of foamed, elastomeric material, the side walls of said mold being spaced from the sides of said spring core to provide a space surrounding said spring core enclosed by said side wall band and edges of said sheets and by the walls of said mold with said partial segments projecting into said space, moving said partial segments of the end coils defining said surface covered by the sheet of foamed, elastomeric material toward the opposite ends of said springs defining the opposite surface and retaining them in such position under stress, admitting a foamable and solidifiable elastomeric material into said space and permitting the material to foam and solidify to form a wall of foamed, elastomeric material surrounding said spring core bonded to said side wall band and to said sheet of foamed material with said partial segments embedded in said foamed material, so that said spring core is enclosed on at least one surface of the end coils and sides by an integral cover of foamed, elastomeric material with the partial segments of the end coils defining said surface embedded in said foamed material.

Claim 6

A method of producing a spring cushion body in which a coil spring core is covered with and secured to foamed, elastomeric material, said spring core being formed by assembling a plurality of coil springs into a spring core having end coils defining a surface with partial segments of the end coils lying on the periphery of said surface, said method comprising placing a side wall band around the sides of said spring core extendiNg between the end coils of the opposite ends of the coil springs to surround said spring core completely between the end coils of the springs, positioning said spring core with said side wall band in a mold with a sheet of material in the bottom of the mold, and with a second sheet of material covering the ends of the coil springs defining said surface at the top of the mold, at least one of said sheets being of foamed, elastomeric material, the side walls of said mold being spaced from the sides of said spring core to provide a space surrounding said spring core enclosed by said side wall band and edges of said sheets and by the walls of said mold with said partial segments projecting into said space, moving said partial segments of the end coils defining said surface covered by the sheet of foamed, elastomeric material toward the opposite ends of said springs defining the opposite surface and retaining them in such position under stress, admitting a foamable and solidifiable elastomeric material into said space and permitting the material to foam and solidify to form a wall of foamed, elastomeric material surrounding said spring core bonded to said side wall band and to said sheet of foamed material with said partial segments embedded in said foamed material, so that said spring core is enclosed on at least one surface of the end coils and sides by an integral cover of foamed, elastomeric material with the partial segments of the end coils defining said surface embedded in said foamed material.

Claim 11

A method of producing a spring core cushion body which includes the steps of: fabricating a spring core assembly of a plurality of coil springs so that at least portions of the end coils of said springs define the top and bottom of said core assembly and include partial segments of said end coils lying at outer edge locations of said spring core assembly, placing side wall cover means of approximately the same height as said coil springs around the outer periphery of said coil spring assembly and placing elastomeric cover sheets over the top and bottom of said spring core assembly, positioning said spring core assembly, said side wall cover means, and said elastomeric cover sheets in a mold having an open space surrounding the sides of the spring core assembly, said space being bounded on the inner side by said side wall cover means and on an outer side by the inside surfaces of said mold, moving at least the peripheral portions of said cover sheets toward each other so as to preload at least said partial segments of said coil springs, and while holding said side wall cover means and said cover sHeets in their thus established relative positions during maintained preload of said partial segments, filling said space with foamable and solidifiable elastomeric material, and permitting said material to foam and solidify to form foamed elastomeric side walls united to said cover sheets and firmly interconnected with said partial segments of said coil springs.

Claim 12

A method of producing a spring core cushion body which includes the steps of: fabricating a spring core assembly of a plurality of coil springs so that at least portions of the end coils of said springs define the top and bottom of said core assembly and include partial segments of said end coils lying at outer edge locations of said spring core assembly, placing side wall cover means of approximately the same height as said coil springs around the outer periphery of said coil spring assembly and placing elastomeric cover sheets over the top and bottom of said spring core assembly, positioning said spring core assembly, said side wall cover means, and said elastomeric cover sheets in a mold having an open space surrounding the sides of the spring core assembly, said space being bounded on the inner side by said side wall cover means and on an outer side by the inside surfaces of said mold, moving at least the peripheral portions of said cover sheets toward each other so as to preload at least said partial segments of said coil springs, and while holding said side wall cover means and said cover sHeets in their thus established relative positions during maintained preload of said partial segments, filling said space with foamable and solidifiable elastomeric material, and permitting said material to foam and solidify to form foamed elastomeric side walls united to said cover sheets and firmly interconnected with said partial segments of said coil springs.

Claim 13

A method of producing a spring core cushion body which includes the steps of: fabricating a generally rectangular spring core assembly of a plurality of coil springs so that the end coils of said springs define the top and bottom of said spring core assembly and include partial segments of said end coils lying at outer edge locations of said spring core assembly, placing side wall cover means of approximately the same height as said coil spings around the outer periphery of said coil spring assembly and placing elastomeric foam material cover sheets over the top and bottom of said spring core assembly, positioning said spring core assembly, said side wall cover means, and said elastomeric cover sheets in a mold having an open space surrounding the sides of the spring core assembly, said space being bounded on the inner side by said side wall cover means and on an outer side by the inside surfaces of said mold, moving at least the peripheral portions of said cover sheets toward each other so as to preload at least said partial segments of said coil springs and while holding said side wall cover means and said cover sheets in their thus established relative positions during maintained preload of said partial segments, filling said space with foamable and solidifiable elastomeric material, and permitting the same to foam and solidify and form foamed elastomeric side walls united to said foam sheets and said partial segments of said coil springs.

Claim 14

A method of producing a spring core cushion body which includes the steps of: fabricating a generally rectangular spring core assembly of a plurality of coil springs so that the end coils of said springs define the top and bottom of said spring core assembly and include partial segments of said end coils lying at outer edge locations of said spring core assembly, placing side wall cover means of approximately the same height as said coil spings around the outer periphery of said coil spring assembly and placing elastomeric foam material cover sheets over the top and bottom of said spring core assembly, positioning said spring core assembly, said side wall cover means, and said elastomeric cover sheets in a mold having an open space surrounding the sides of the spring core assembly, said space being bounded on the inner side by said side wall cover means and on an outer side by the inside surfaces of said mold, moving at least the peripheral portions of said cover sheets toward each other so as to preload at least said partial segments of said coil springs and while holding said side wall cover means and said cover sheets in their thus established relative positions during maintained preload of said partial segments, filling said space with foamable and solidifiable elastomeric material, and permitting the same to foam and solidify and form foamed elastomeric side walls united to said foam sheets and said partial segments of said coil springs.

Claim 18

A method of producing a spring core cushion body which includes the steps of: fabricating a generally rectangular spring core assembly of a plurality of coil springs so that at least portions of the end coils of said springs are approximately located in two spaced parallel planes and include partial segments of said end coils lying at outer edge locations of said spring core assembly, placing side wall cover means of approximately the same height as said coil springs around the outer periphery of said coil spring assembly and placing elastomeric foam material cover sheets over the top and bottom of said spring core assembly, positioning said spring core assembly, said side wall cover means, and said elastomeric cover sheets in a mold having an open space surrounding the sides of the spring core assembly, said space being bounded on the inner side by said side wall cover means and on an outer side by the inside surfaces of said mold, and while holding said spring core assembly, said side wall cover means, said cover sheets and said mold in their thus established relative positions, filling said space with foamable and solidifiable elastomeric material, and permitting said material to foam and solidify and form foamed elastomeric side walls uniteD to said foam cover sheets and firmly interconnected with said partial segments of said coil spring.

Claim 19

A method of producing a spring core cushion body which includes the steps of: fabricating a generally rectangular spring core assembly of a plurality of coil springs so that at least portions of the end coils of said springs are approximately located in two spaced parallel planes and include partial segments of said end coils lying at outer edge locations of said spring core assembly, placing side wall cover means of approximately the same height as said coil springs around the outer periphery of said coil spring assembly and placing elastomeric foam material cover sheets over the top and bottom of said spring core assembly, positioning said spring core assembly, said side wall cover means, and said elastomeric cover sheets in a mold having an open space surrounding the sides of the spring core assembly, said space being bounded on the inner side by said side wall cover means and on an outer side by the inside surfaces of said mold, and while holding said spring core assembly, said side wall cover means, said cover sheets and said mold in their thus established relative positions, filling said space with foamable and solidifiable elastomeric material, and permitting said material to foam and solidify and form foamed elastomeric side walls uniteD to said foam cover sheets and firmly interconnected with said partial segments of said coil spring.

Claim 22

A method of producing a spring core cushion body which includes the steps of: fabricating a spring core assembly of a plurality of coil springs so that at least portions of the end coils of said springs are approximately located in two spaced parallel planes and include partial segments of said end coils lying at outer edge locations of said spring core assembly, placing side wall cover means around the outer periphery of said coil spring assembly and placing an elastomeric foam material cover sheet over the top of said spring core assembly, positioning said spring core assembly, said side wall cover means, and said elastomeric cover sheet in a mold having an open space surrounding the sides of the spring core assembly, said space being bounded on the inner side by said side wall cover means and on an outer side by the inside surfaces of said mold, and while holding said spring core assembly, said side wall cover means, said cover sheet and said mold in their thus established relative positions filling said space with foamable and solidifiable elastomeric material, and permitting said material to foam and solidify and form side walls united with said foam cover sheet and firmly interconnected with said partial segments of said coil springs.

Claim 23

A method of producing a spring core cushion body which includes the steps of: fabricating a spring core assembly of a plurality of coil springs so that at least portions of the end coils of said springs are approximately located in two spaced parallel planes and include partial segments of said end coils lying at outer edge locations of said spring core assembly, placing side wall cover means around the outer periphery of said coil spring assembly and placing an elastomeric foam material cover sheet over the top of said spring core assembly, positioning said spring core assembly, said side wall cover means, and said elastomeric cover sheet in a mold having an open space surrounding the sides of the spring core assembly, said space being bounded on the inner side by said side wall cover means and on an outer side by the inside surfaces of said mold, and while holding said spring core assembly, said side wall cover means, said cover sheet and said mold in their thus established relative positions filling said space with foamable and solidifiable elastomeric material, and permitting said material to foam and solidify and form side walls united with said foam cover sheet and firmly interconnected with said partial segments of said coil springs.