Flat Packed Mattress Spring Core Assemblies and Method of Packaging Such Assemblies

Abstract

Package and method of flat-packing multiple pocketed spring core assemblies wherein a stack of multiple pocketed spring assemblies are trapped between a pair of wooden frames. After compression of the stack including the wooden frames, bands are tightly wrapped around the compressed stack. Loops of wire are then inserted through the stack and wrapped about at least one cross element of the frame on each side of the stack. Each loop of wire is pulled taut and its opposite ends connected together so as to prevent the center portion of the stack from ballooning outwardly after removal of compression forces on the rigid frames.

1 . A method of flat-packing multiple pocketed spring core assemblies, each spring core assembly of which contains multiple springs encased within fabric pockets, which method comprises:
 stacking multiple pocketed spring core assemblies to create a stack of pocketed spring core assemblies;   entrapping the stack of pocketed spring core assemblies between a pair of frames, each of the frames including a pair of longitudinally extending side elements and at least one other element extending longitudinally parallel to the side elements, and at least one transversely extending cross element connected at its opposite ends to the side elements;   compressing the stack of pocketed spring core assemblies between the pair of frames;   tightly wrapping bands about the compressed stack of pocketed spring core assemblies and the frames;   inserting a wire through the stack of compressed of pocketed spring core assemblies at two spaced locations in the stack, which locations are separated by at least one of the cross elements of the frame on each side of the stack;   pulling opposite ends of the wire taut and connecting opposite ends of the wire on one side of the stack so as to prevent a center portion of the stack from ballooning outwardly after removal of compression forces on the frames.   
   
   
       2 . The method of  claim 1  wherein the method of inserting the wire through the stack of compressed pocketed spring core assemblies comprises rotatably threading a hollow threaded rod through the stack, inserting a wire through the rod and the stack and then withdrawing the rod from the stack while leaving the wire extending through the stack. 
   
   
       3 . The method of  claim 1  wherein the method step of connecting opposite ends of the wire on one side of the stack comprises forming a loop on opposite ends of the wire, connecting a loop of banding material between the loops on opposite ends of the wire, overlapping opposite ends of the loop of banding material extending between the loops on the opposite ends of the wire, and tightening and fastening the overlapping opposite ends of the loop of banding material. 
   
   
       4 . The method of  claim 3  wherein the method step of connecting a loop of banding material between the opposite ends of the wire further comprises connecting a D ring to the loop formed at each end of the wire and connecting the loop of banding material between the D rings on opposite ends of the wire. 
   
   
       5 . A method of flat-packing multiple pocketed spring core assemblies, each spring core assembly of which contains multiple springs encased within fabric pockets, which method comprises:
 stacking multiple pocketed spring core assemblies to create a stack of pocketed spring core assemblies;   entrapping the stack of pocketed spring core assemblies between a pair of wooden frames, each of the frames including a pair of longitudinally extending side boards located on opposite sides of the stack of pocketed spring core assemblies as well as at least one other board extending longitudinally parallel to the side boards, and at least one transversely extending cross board connected at its opposite ends to the side boards;   compressing the stack of pocketed spring core assemblies between the pair of wooden frames;   tightly wrapping metal bands about the compressed stack of pocketed spring core assemblies and the wooden frames;   inserting a metal wire through the compressed stack of pocketed spring core assemblies at two spaced locations in the stack, which locations are separated by at least one of the boards of the frame on each side of the stack;   pulling opposite ends of the metal wire taut and connecting opposite ends of the wire on one side of the stack so as to prevent the center portion of the stack from ballooning outwardly after removal of compression forces on the frames.   
   
   
       6 . The method of  claim 5  wherein the method of inserting the wire through the stack of compressed pocketed spring core assemblies comprises rotatably threading a hollow threaded rod through the stack, inserting the wire through the rod and the stack and then withdrawing the rod from the stack while leaving the wire extending through the stack. 
   
   
       7 . The method of  claim 5  wherein the method step of connecting opposite ends of the wire on one side of the stack comprises forming a loop on opposite ends of the wire, connecting a loop of metal banding material between the loops on opposite ends of the wire, overlapping opposite ends of the loop of banding material extending between the loops on the opposite ends of the wire, and tightening and fastening the overlapping opposite ends of the loop of banding material. 
   
   
       8 . The method of  claim 7  wherein the method step of connecting a loop of banding material between the opposite ends of the wire further comprises connecting a D ring to the loop formed at each end of the wire and connecting the loop of banding material between the D rings on opposite ends of the wire. 
   
   
       9 . A method of preventing the center portion of a flat package containing a plurality of compressed pocketed spring core assemblies entrapped between a pair of rigid frames from ballooning outwardly, which method comprises:
 inserting a metal wire through a stack of a plurality of compressed pocketed spring core assemblies at two spaced locations in the stack, which locations are separated by at least one element of the rigid frame on each side of the stack; and   pulling opposite ends of the metal wire taut and connecting opposite ends of the wire on one side of the stack.   
   
   
       10 . The method of  claim 9  wherein the method of inserting a wire through the stack of pocketed compressed pocketed spring core assemblies comprises rotatably threading a hollow threaded rod through the stack, inserting a wire through the rod and the stack and then withdrawing the rod from the stack while leaving the wire extending through the stack, 
   
   
       11 . The method of  claim 9  wherein the method step of connecting opposite ends of the wire on one side of the stack comprises forming a loop on opposite ends of the wire, connecting a loop of banding material between the loops on opposite ends of the wire, overlapping opposite ends of the loop of banding material extending between the loops on the opposite ends of the wire, and tightening and fastening the overlapping opposite ends of the loop of banding material. 
   
   
       12 . The method of  claim 11  wherein the method step of connecting a loop of bonding material between the opposite ends of the wire further comprise connecting a D ring to the loop formed at each end of the wire and connecting the loop of banding material between the D rings on opposite ends of the wire. 
   
   
       13 . A method of preventing the center portion of a flat package containing a plurality of compressed pocketed spring core assemblies entrapped between a pair of rigid wooden frames from ballooning outwardly, which method comprises:
 inserting a metal wire through a stack of the plurality of compressed pocketed spring core assemblies at two spaced locations in the stack, which locations are separated by at least one board of the rigid frame on each side of the stack; and   pulling opposite ends of the metal wire taut and connecting opposite ends of the wire on one side of the stack.   
   
   
       14 - 15 . (canceled)