Patent ID: 8141251
Filing Date: 2012-03-27
Classification: A47C,B29C,Y10T

Abstract:
1. A method for manufacturing a filling material having a layer of cylindrical foam springs having a desired length or lengths, said method comprising: providing cylindrical foam springs having opposed axial ends and extending axially between two support layers, wherein said cylindrical foam springs have a first length which is larger than said desired length; fixing said cylindrical foam springs at said axial ends to the support layers to obtain a first double support layered assembly, wherein the double support layered assembly comprises said support layers with said cylindrical foam springs extending lengthwise between the support layers; cutting said cylindrical foam springs fixed to said two support layers along a direction extending between said support layers to form a set of two single support layered assemblies, wherein each single support layered assembly has a layer of cylindrical foam springs having a free end and a support layered end attached to one of the two support layers, wherein at least one of the two single support layered assemblies comprises cylindrical foam springs having said desired length or lengths; attaching an additional support layer on said free end of at least one of the set of two single support layered assemblies to form a second double support layered spring assembly; cutting said second double support layered assembly along a direction extending between said support layers to form a second set of two single support layered assemblies; and then repeating said attaching of an additional support layer to a free end of a single support layered assembly to form another double support layered assembly and said cutting of the another double support layered assembly until the first double support layer covered assembly is divided into a desired number of single or double support layer covered assemblies.