Foam Integrated Innerspring Mattress And Method of Manufacture

Abstract

This invention relates to a foam integrated innerspring mattress and method of manufacture wherein a flexible polyurethane foam is adhered onto the top and bottom of individually wrapped pocket innersprings, and additional polyurethane foam is molded onto the sides of the mattress.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a group of three attached pocket coils.

FIG. 2 is a perspective view of attached pocket coils.

FIG. 3 is a perspective view of an aggregation of pocket coils, with a foam layer covering.

FIG. 4 is a perspective view of an aggregation of pocket coils, with foam layers affixed top and bottom.

FIG. 5 is a perspective view of various elements of the invention.

FIG. 6 is a perspective view of an embodiment of the invention.

Claims

1. A method of forming a mattress comprising: a. providing a plurality of independent spring coils, wherein each spring coil is enclosed in an individual pocket of material, each spring coil and its pocket material having a first end and second end;b. arranging the pocket coils in a generally side by side configuration, creating a generally rectangular shape;c. securing the first ends of each coil's pocket material to a first layer of flexible foam;d. securing the second ends of each coil's pocket material to a second layer of flexible foam;e. placing liquid foam material into contact with the periphery of the pocket coils and the periphery of the first and second foam layers; andf. allowing the liquid foam material to cure such that it at least partially adheres to at least one side of the mattress.

2. A method of forming a mattress comprising: a. providing a plurality of independent spring coils, wherein each spring coil is enclosed in an individual pocket of material, each spring coil and its pocket material having a first end and second end;b. arranging the pocket coils in a generally side by side configuration, creating a generally rectangular shape;c. enclosing the pocket coils in a layer of preformed foam;d. placing liquid foam material into contact with the periphery of the pre-formed foam layers; ande. allowing the liquid foam material to cure such that it at least partially adheres to at least one side of the mattress.

3. A mattress comprising: a. a plurality of independent spring coils, wherein each spring coil is enclosed in an individual pocket of material, each spring coil and its pocket material having a first end and second end;b. the pocket coils arranged in a generally side by side configuration;c. a first layer of flexible foam secured to the first ends of each coil's pocket material;d. a second layer of flexible foam secured to the second ends of each coil's pocket material; ande. foam edge support in contact with the pocket coils and first and second foam layers on the periphery of the mattress.

4. A mattress comprising: a. a plurality of independent spring coils, wherein each spring coil is enclosed in an individual pocket of material, each spring coil and its pocket material having a first end and second end;b. the pocket coils arranged in a generally side by side configuration;c. a layer of pre-formed foam enclosing the pocket coils;d. foam edge support in contact with the pre-formed foam layer on the sides of the mattress.

5. A product manufactured utilizing the process of claim 1 or 2.

6. The manufacturing methods of claims 1 and 2 wherein the flexible foam layer(s) are made from polyurethane.

7. The mattress of claims 3 or 4 wherein the flexible foam layer(s) are made from polyurethane.

8. The manufacturing methods of claims 1 and 2 wherein the material connecting the pocket coils along the periphery of the mattress is contiguous and resistant to penetration from contact with liquid foam.