A comfort layer for a bedding or seating product has slow-acting pockets characterized by the individual springs of the comfort layer being pocketed with either semi-impermeable or impermeable fabric. Each seam joining opposed plies of fabric around each of the coil springs of the comfort layer may be segmented, allowing air to flow between the segments, thereby increasing the luxury feel of the comfort layer. The method of making the comfort layer includes compressing the springs and creating pockets with a welding horn and an anvil.

A comfort layer for a bedding or seating product has slow-acting pockets characterized by the individual springs of the comfort layer being pocketed with either semi-impermeable or non-permeable fabric. Each seam joining opposed plies of fabric around each of the coil springs of the comfort layer may be segmented, allowing air to flow between the segments, thereby increasing the luxury feel of the comfort layer. The method of making the comfort layer includes compressing the springs and creating pockets with a welding horn and an anvil.

A comfort layer for a bedding or seating product has slow-acting pockets characterized by the individual springs of the comfort layer being pocketed with either semi-impermeable or non-permeable fabric. Each seam joining opposed plies of fabric around each of the coil springs of the comfort layer may be segmented, allowing air to flow between the segments, thereby increasing the luxury feel of the comfort layer. The method of making the comfort layer includes compressing the springs and creating pockets with a welding horn and an anvil.

An automatic bagged spring production apparatus comprising a spring treatment assembly including first and second treatment subassemblies, a spring bagging assembly, and a spring welding assembly. The first treatment subassembly includes a first longitudinally axis representing a direction of travel for springs being transported and processed and the second treatment subassembly includes a second longitudinal axis representing a direction of travel for springs being transported and processed, the first longitudinal axis and second longitudinal axis are oriented at an angle relative to each other. The automatic bagged spring production apparatus also includes an apparatus housing in which the spring treatment assembly, the spring bagging assembly and the spring welding assembly are positioned.

An automatic bagged spring production apparatus comprising a spring treatment assembly including first and second treatment subassemblies, a spring bagging assembly, and a spring welding assembly. The first treatment subassembly includes a first longitudinally axis representing a direction of travel for springs being transported and processed and the second treatment subassembly includes a second longitudinal axis representing a direction of travel for springs being transported and processed, the first longitudinal axis and second longitudinal axis are oriented at an angle relative to each other. The automatic bagged spring production apparatus also includes an apparatus housing in which the spring treatment assembly, the spring bagging assembly and the spring welding assembly are positioned.

A system for manufacturing a string of pocketed coil springs comprising: a coil-forming subsystem that produces two coil springs; a spring transporter subsystem that receives the two coil springs at a first position and conveys the two coil springs to a second position; a spring compressor subsystem that compresses the two coil springs; a fabric-folding subsystem that receives a piece of fabric and folds the fabric to create an open side; a spring inserter subsystem that receives the two compressed coil springs and inserts the two compressed coil springs between top and bottom surfaces of a folded piece of fabric; two welder subsystems that form first and second welds between top and bottom surfaces of the folded piece of fabric, the first welds and the second welds forming a plurality of pockets in the fabric, each of the plurality of pockets comprising a compressed coil spring.

A system for manufacturing a string of pocketed coil springs comprising: a coil-forming subsystem that produces two coil springs; a spring transporter subsystem that receives the two coil springs at a first position and conveys the two coil springs to a second position; a spring compressor subsystem that compresses the two coil springs; a fabric-folding subsystem that receives a piece of fabric and folds the fabric to create an open side; a spring inserter subsystem that receives the two compressed coil springs and inserts the two compressed coil springs between top and bottom surfaces of a folded piece of fabric; two welder subsystems that form first and second welds between top and bottom surfaces of the folded piece of fabric, the first welds and the second welds forming a plurality of pockets in the fabric, each of the plurality of pockets comprising a compressed coil spring.

An apparatus for assembling a bedding foundation having spring modules and a frame includes a support configured to receive the frame, a bridge disposed over the support, and staplers movably coupled to the bridge and positioned over the support, each stapler configured to staple a spring module to the frame. The apparatus also includes cameras coupled to the bridge and positioned over the support. Each stapler is operatively associated with one of the cameras and each camera is positioned to provide a field of view toward the support. The apparatus also includes a driver configured to move the frame relative to the support and a controller in communication with the cameras and the driver, the controller configured to receive vision guidance signals from one of the cameras to direct movement of the driver and of the stapler operatively associated with the one of the cameras.

A comfort layer for a bedding or seating product has slow-acting pockets characterized by the individual springs of the comfort layer being pocketed with either semi-impermeable or impermeable fabric. Each seam joining opposed plies of fabric around each of the coil springs of the comfort layer may be segmented, allowing air to flow between the segments, thereby increasing the luxury feel of the comfort layer. The method of making the comfort layer includes compressing the springs and creating pockets with a welding horn and an anvil.

A bed mesh combination device includes a first loading mechanism, a feeding mechanism, a second loading mechanism, and a combination mechanism. In a first direction, the first feeding mechanism transports the first spring strings of a set length to a first position, and the feeding mechanism transfers the first spring strings from the first position to a second position. At the second position, the first spring strings are parallel to the first direction. The second loading mechanism can reciprocate in the first direction, so as to continuously arrange the second spring string back and forth in the first direction at the second position. At the second position, there is one first spring string between two adjacent sections of the second spring string. The combination mechanism welds or sews the first spring strings at the second position and the adjacent second spring string to form a bed mesh.