Welding apparatus for strings of springs
A pocketed spring assembly comprises parallel strings, each string joined to at least one adjacent string. At least some of the strings have springs of different gauge wire and some of the pockets of the strings having springs of different gauge wire are spliced together. At least some of the strings have springs of different geometries and some of the pockets of the strings having springs of different geometries are spliced together. At least some strings may have end sections with springs different than a middle section therebetween, the springs of the end sections being firmer than the springs of the middle section.
1 . In combination, a first supply string of springs, a second supply string of springs and a welding apparatus, the combination comprising:
a first supply string of springs;
a second supply string of springs; and
a welding apparatus for joining two strings of pocketed coil springs, the welding apparatus comprising;
a first set of clamps for holding and moving an upstream tab of a starting string of pocketed coil springs, the starting string of pocketed coil springs being downstream of the clamps,
a second set of clamps for holding and moving a downstream tab of the first supply string of pocketed coil springs, the second set of clamps being offset from the first set of clamps,
a third set of clamps for holding and moving a downstream tab of the second supply string of pocketed coil springs, the third set of clamps being in-line with the first set of clamps,
a cutter movable between a raised position when it is not being used and a lowered position;
a welding horn, and
an anvil, the welding horn and anvil being moveable between the first and third sets of clamps.
2 . The combination of claim 1 wherein the second set of clamps may be interchanged with the third set of clamps.
3 . The combination of claim 1 further comprising first and second coilers.
4 . The combination of claim 1 wherein the welding horn and anvil are moved together between the first and third sets of clamps to weld overlapping tabs of fabric together in a weld.
5 . The combination of claim 1 wherein the welding horn and anvil are separated to allow a combined string of pocketed coil springs to move downstream.
6 . The combination of claim 5 wherein the first set of clamps are separated to allow the combined string of pocketed coil springs to move downstream.
7 . The combination of claim 1 further comprising an assembler downstream of the welding horn and anvil.
8 . In combination, a first supply string of springs, a second supply string of springs and a welding apparatus, the combination comprising:
a first supply string of springs;
a second supply string of springs; and
a welding apparatus comprising a welding horn,
an anvil, the welding horn and anvil being moveable between open and closed positions,
a first set of clamps for holding and moving an upstream tab of a starting string of pocketed coil springs, the starting string of pocketed coil springs being downstream of the welding horn and anvil,
a second set of clamps for holding and moving a downstream tab of a first supply string of pocketed coil springs, the second set of clamps being upstream from the welding horn and anvil,
a third set of clamps for holding and moving a downstream tab of a second supply string of pocketed coil springs, the third set of clamps being upstream from the welding horn and anvil; and
a cutter movable between a raised position when it is not being used and a lowered position.
9 . The combination of claim 8 wherein one of the second and third sets of clamps is in-line with the first set of clamps.
10 . The combination of claim 9 wherein the other of the second and third sets of clamps is offset from the first set of clamps.
11 . The combination of claim 8 wherein the cutter is upstream of the first set of clamps.
12 . The combination of claim 8 wherein the first set of clamps open and close with the welding horn and anvil.
13 . The combination of claim 8 further comprising first and second coilers.
14 . The combination of claim 8 wherein the springs within strings having tabs welded together come from different coilers.
15 . In combination, a first supply string of springs, a second supply string of springs and a welding apparatus, said combination comprising:
a first supply string of springs;
a second supply string of springs; and
a welding apparatus comprising a welding horn,
an anvil, the welding horn and anvil being moveable between open and closed positions,
a first set of clamps for holding and moving an upstream tab of a starting string of pocketed coil springs originating from a first coiler, the starting string of pocketed coil springs being downstream of the welding horn and anvil,
a second set of clamps for holding and moving a downstream tab of a first supply string of pocketed coil springs originating from the first coiler, the second set of clamps being upstream from the welding horn and anvil,
a third set of clamps for holding and moving a downstream tab of a second supply string of pocketed coil springs originating from a second coiler, the third set of clamps being upstream from the welding horn and anvil; and
a cutter movable between a first position when it is not being used and a second position.
16 . The combination of claim 15 wherein each of the second and third sets of clamps is movable between an offset position and an in-line position, in-line with the starting string of pocketed coil springs.
17 . The combination of claim 15 wherein the springs within strings having tabs welded together come from different coilers.
18 . The combination of claim 15 wherein the welding horn and anvil are moveable between the first set of clamps and one of the second and third sets of clamps.
19 . The combination of claim 15 wherein the welding horn and anvil create a combined string of springs comprising the starting string of pocketed coil springs and one of the other strings of pocketed coil springs.
20 . The combination of claim 19 wherein the welding horn and anvil are open allowing the combined string of pocketed coil springs to move to an assembler.