Method of packaging spring units

Abstract

A method of packaging spring units in which at least one web of insulator material is fixedly located against one of the top and bottom surfaces of the spring units. Each web of insulator material is secured to the outermost coil springs along longitudinal edges of the spring units with securing elements. The resultant bedding products are then roll-packed.

We claim:  
     
         1 . A method of packaging a plurality of spring units, each spring unit comprising a plurality of coil springs, each of said coil springs having a top turn and a bottom turn, said top turns of said coil springs defining a generally planar first surface and said bottom turns of said coil springs defining a generally planar second surface, said method comprising the steps of: 
 providing first and second webs of insulator material, each of said webs of insulator material being adapted to separate said spring units from padding to be applied to said spring units,    locating said first and second webs of insulator material against said first and second surfaces, respectively, of said spring units;    permanently securing said first and second webs of insulator material to said spring units with securing elements; and    roll-packing said spring units and said webs of insulator material such that said spring units are at least partially compressed and upon unrolling, said webs of insulator material remain permanently connected to said spring units.    
     
     
         2 . The method of  claim 1  wherein said step of permanently securing said first and second webs of insulator material to said spring units comprises taping said top and bottom turns of outermost coil springs of said spring units to said first and second webs of insulator material.  
     
     
         3 . The method of  claim 1  wherein said step of permanently securing said first and second webs of insulator material to said spring units comprises hog ringing said top and bottom turns of select coil springs of said spring units to said first and second webs of insulator material.  
     
     
         4 . The method of  claim 1  further comprising the steps of: 
 providing first and second web rolls carrying said first and second webs of insulator material, respectively; and  
 passing said first and second webs of insulator material between respective first and second rollers before locating said first and second webs of insulator material against said first and second surfaces, respectively, of said spring units.  
 
     
     
         5 . The method of  claim 1  further comprising the step of unrolling said spring units, said spring units remaining connected to said webs of insulator material.  
     
     
         6 . The method of  claim 5  further comprising the step of cutting said webs of insulator material between adjacent spring units.  
     
     
         7 . The method of  claim 1  wherein said step of permanently securing said first and second webs of insulator material to said spring units comprises extruding plastic to secure said top and bottom turns of select coil springs of said spring units to said first and second webs of insulator material.  
     
     
         8 . A method of packaging a plurality of spring units, each of said spring units comprising a plurality of coil springs, each of said coil springs having a top turn and a bottom turn, each of said spring units having a generally planar first surface defined by said top turns and a generally planar second surface defined by said bottom turns, a longitudinal dimension and a transverse dimension, said method comprising the steps of: 
 providing first and second web rolls of insulator material, each of said web rolls comprising a web of insulator material carried upon a core and each of said webs of insulator material having inner and outer surfaces, each of said webs of insulator material being adapted to separate said spring units from padding to be applied to said spring units;    passing said first and second webs of insulator material over said first and second surfaces of said spring units, respectively;    applying securing elements around said first and second webs of insulator material and edgemost springs of said spring units; and    roll-packing said spring units with said first and second webs of insulator material secured to said spring units such that said spring units are at least partially compressed and upon unrolling said spring units, said webs of insulator material remain permanently secured to said spring units.    
     
     
         9 . The method of  claim 8  further comprising the step of unrolling said spring units.  
     
     
         10 . The method of  claim 8  further comprising the step of cutting said webs of insulator material between adjacent spring units before roll-packing said spring units.  
     
     
         11 . The method of  claim 8  further comprising the step of cutting said webs of insulator material between adjacent spring units after said spring units are roll-packed.  
     
     
         12 . A method of packaging a plurality of spring units, each spring unit comprising a plurality of coil springs, each of said coil springs having a top turn and a bottom turn, said top turns of said coil springs defining a generally planar first surface and said bottom turns of said coil springs defining a generally planar second surface, said method comprising the steps of: 
 providing a web of insulator material, said web of insulator material being adapted to separate said spring units from padding to be applied to said spring units,    locating said web of insulator material against one of said first and second surfaces, respectively, of said spring units;    applying securing elements to permanently secure said web of insulator material to said spring units; and    roll-packing said spring units and said web of insulator material such that said spring units are at least partially compressed and upon unrolling, said web of insulator material remains permanently connected to said spring units.    
     
     
         13 . The method of  claim 12  wherein said step of applying securing elements comprises taping one of said top and bottom turns of outermost coil springs of said spring units to said web of insulator material.  
     
     
         14 . The method of  claim 12  wherein said step of applying securing elements comprises applying a bead of extruded plastic to select coil springs of said spring units to said web of insulator material.  
     
     
         15 . The method of  claim 12  wherein said step of applying securing elements comprises hog ringing select coil springs of said spring units to said web of insulator material.  
     
     
         16 . A method of packaging a plurality of spring units, each spring unit comprising a plurality of coil springs, each of said coil springs having a top turn and a bottom turn, said top turns of said coil springs defining a generally planar first surface and said bottom turns of said coil springs defining a generally planar second surface, said method comprising the steps of: 
 providing first and second webs of insulator material, each of said webs of insulator material being adapted to separate said spring units from padding to be applied to said spring units,    locating said first and second webs of insulator material against said first and second surfaces, respectively, of said spring units;    permanently securing said first and second webs of insulator material to said spring units with securing elements,    locating at least one web of separator material against one of said webs of insulator material; and    roll-packing said spring units and said webs of insulator material such that said spring units are at least partially compressed and upon unrolling, said webs of insulator material remain permanently connected to said spring units.    
     
     
         17 . The method of  claim 1   6  wherein said step of permanently securing said first and second webs of insulator material to said spring units comprises taping said top and bottom turns of outermost coil springs of said spring units to said first and second webs of insulator material.  
     
     
         18 . The method of  claim 16  further comprising cutting said webs of insulator material between adjacent spring units prior to locating said at least one web of separator material against one of said webs of insulator material.  
     
     
         19 . The method of  claim 16  wherein said step of permanently securing said first and second webs of insulator material to said spring units comprises hog ringing said top and bottom turns of outermost coil springs of said spring units to said first and second webs of insulator material.  
     
     
         20 . A method of packaging a plurality of spring units, each spring unit comprising a plurality of coil springs, each of said coil springs having a top turn and a bottom turn, said top turns of said coil springs defining a generally planar first surface and said bottom turns of said coil springs defining a generally planar second surface, said method comprising the steps of: 
 providing a web of insulator material, said web of insulator material being adapted to separate said spring units from padding to be applied to said spring units,    locating said web of insulator material against one of said first and second surfaces, respectively, of said spring units;    applying securing elements to said web of insulator material and said spring units to permanently secure said web of insulator material to said spring units,    locating at least one web of separator material against said web of insulator material; and    roll-packing said spring units and said web of insulator material such that said spring units are at least partially compressed and upon unrolling, said web of insulator material remains permanently connected to said spring units.    
     
     
         21 . The method of  claim 20  further comprising cutting said web of insulator material between adjacent spring units prior to locating said at least one web of separator material against said web of insulator material.  
     
     
         22 . A method of packaging a plurality of spring units, each spring unit comprising a plurality of coil springs, each of said coil springs having a top turn and a bottom turn, said top turns of said coil springs defining a generally planar first surface and said bottom turns of said coil springs defining a generally planar second surface, said method comprising the steps of: 
 compressing each of said spring units in a transverse direction;    providing a web of insulator material, said web of insulator material being adapted to separate said spring units from padding to be applied to said spring units,    locating said web of insulator material against one of said first and second surfaces of said transversely compressed spring units, respectively, of said spring units;    applying securing elements to said web of insulator material and said spring units to permanently secure said web of insulator material to said spring units;    allowing each of said spring units to expand in a transverse direction to tighten said web of insulator material; and    roll-packing said spring units and said web of insulator material such that said spring units are at least partially compressed and upon unrolling, said web of insulator material remains permanently connected to said spring units.