Patent Application
20090183315
The invention is in the general field of reflexive support systems, springs and spring systems, including support systems for humans such as seating and bedding.
Different types of springs and spring systems are commonly used as the reflexive core of seating and support products such as chairs and mattresses. A common spring system which is used in mattresses and some upholstered furniture is the so-called “innerspring” which can be in one form a plurality of similarly or identically formed springs which are interconnected in an array or matrix. An innerspring provides a distributed generally homogeneous reflexive support system to give underlying support to an expanse such as the sleep surface of a mattress. The uniform spring rate across the expanse results from the common configuration of each of the interconnected springs. Attempts to alter the spring rate and feel of an entire innerspring or support areas of an innerspring involve the use of different types and amounts of materials such as foam, textiles and natural fibers as overlays on the innerspring. While the use of such materials does alter the feel and performance of the support system, it does not of course alter the spring rate of the underlying or internal innerspring.
Innersprings which are made of formed steel wire are manufactured by wire forming machinery which forms the individual springs or coils, and then connects them together by smaller lacing wires or other fasteners. Once the machines are set up to make a particular spring or coil design and interconnection, large runs are made and it is difficult to change the form of the springs and innerspring. Therefore, with current innerspring production technology, it is not practical to produce a single innerspring which has variable or non-homogeneous spring rates and support characteristics in different areas of the innerspring.
The invention provides dampened innersprings for use in support systems such as mattresses and furniture, by the provision of dampening inserts in the form of foam pieces which fit integrally with the springs or coils of an innerspring. In accordance with one principal aspect of the disclosure, a dampened innerspring is provided in which a foam dampener is inserted between springs or coils of an innerspring, and more particularly foam dampener inserts which are configured to extend across multiple adjacent or aligned springs or coils, and which also have parts which fit between individual turns or convolutions of each spring or coil with which the insert is engaged. Mechanical engagement of the innerspring by the foam dampening inserts insures alignment and registration of the cooperative components, with or without interposed fasteners.
In accordance with one aspect of the disclosure and invention, there is provided a foam dampened innerspring which includes an innerspring formed by a plurality of springs connected together in an array wherein the springs are arranged in rows and columns, each spring having a body with a first end and a second end, the body of each spring being generally cylindrical and having a longitudinal axis and an outer diameter, the springs being spaced apart in the rows and columns and connected together in a spaced apart arrangement with each spring being spaced from each adjacent spring in the array; at least one foam dampening insert located in the innerspring in spaces between springs of the innerspring, the foam dampening insert having a central core which fits between the bodies of adjacent springs, and a first segment which extends from the central core and into an opening region of a first spring to at least partially intersect a longitudinal axis of the first spring, and a second segment which extends from the central core and into an opening region of a second spring which is adjacent to the first spring and to at least partially intersect a longitudinal axis of the second spring.
These and other aspects of the disclosure and invention are described in further detail herein with reference to the accompanying drawing Figures.
In the Drawings which constitute a part of the disclosure:
As shown in the drawings Figures, an innerspring, generally referenced at 10, has a plurality of springs or coils 20 (herein referred to alternatively as “coils” or “springs”, although the disclosure and invention is not limited to any one particular type or form of spring or coil or other spring or reflexive device). The coils 20 are arranged in an array, such as an orthogonal array of columns and rows, and interconnected by lacing wires 30 which in one form or helical wires which are laced about turns of adjacent coils and typically run transverse across a width of the innerspring, but which can be run in other directions. The lacing wires can be located at either or both ends of the coils 20, as shown for example in
The coils 20 are shown as helical type coils, wherein each coil has a helical and cylindrical form coil body formed by multiple helical turns of wire about a generally linear coil axis A. The generally cylindrical coil body is defined by the outer radial extent of each of the turns of the wire helix. For each coil, the areas which are within the turns of the wire helix which form the coil body are within the coil body. As illustrated in
In a conventional innerspring the openings between the coils are generally uniform in each lateral direction, i.e., the longitudinal and transverse directions of the innerspring. Therefore, the foam dampening inserts 50 can be installed in the innerspring in transverse or longitudinal directions, or both, as illustrated by the Figures. In the Figures, the lacing wires 30 are shown oriented in a transverse direction in the innerspring 10 as the conventional arrangement, although longitudinal orientation of the lacing wires 30 is also possible. Accordingly, the foam dampening inserts 50 may be oriented traverse (perpendicular) to or parallel with the lacing wires 30. For example,
The foam dampening inserts 50 have a cross-sectional configuration which includes segments which fit between the coils, in the gaps or openings 40 formed between the spaced-apart coils, and segments or parts which fit within the coil bodies of adjacent coils. As shown for example in
One representative cross-sectional form of a foam dampening insert 50 of the disclosure includes a central core 50i and segments 50a, 50b, 50c, 50d and 50e as labeled, which extend from the central core 50i in generally opposing and first and second directions, and fit respectively within opening regions 40a, 40b, 40c, 40d and 40e of an opening 40 between two adjacent coils or rows of adjacent coils. Because the different segments 50a-50e of the foam dampening insert 50 are preferably located at different or unique elevations relative to the central core 50i and respective the coil axis A, and because they project laterally from central core 50i of the insert into the adjacent coil bodies and intersect the coil axes A, the foam dampening insert 50 is thereby held securely in place by engagement with the coils for permanent installation and spring dampening performance. As further shown in
Also, because the number of openings 40 may be greater than the number of segments 50a-n of the foam dampening insert 50, the foam dampening insert 50 may be configured with any number of segments, including fewer than or greater than five, as shown. In the case where there are a greater number of openings 40 than segments 50a-n of the foam dampening insert 50, the foam dampening insert 50 can be located equidistant, or closer to one or the other side of the innerspring, as defined by the planes in which the coil ends 23, 24 are located.
A further design aspect and feature of the foam dampening inserts 50 of the disclosure is the lateral extension of the segments 50a-50e from the central core 50i which resides principally between the adjacent coils. This lateral extension allows the segments 50a-50e to act as leaf spring members in concert with the compression and recoil of the helical turns of the coil bodies. As the coils are compressed under a normal load, the foam dampening insert 50 is correspondingly compressed in at least two principle modes, one by compression of the insert 50 in its substantial entirety, i.e., along an axis generally parallel to the coils axes A and compression of the central core 50i, and by vertical deflection of the laterally extending segments 50a-50e induced by contact with a corresponding turn or segment of the engaged coil. Because the foam dampening insert has a spring rate which may be different than that of the coils, such as a spring rate which is less than that of the coils or less than an aggregate spring rate of the innerspring 10, the foam dampening insert 50 thus acts as a dampener to reduce the overall spring rate of the innerspring and mattress, in the region or zone where the insert 50 is installed in the innerspring 10. In this regard the zone or overall or average spring rate of the innerspring or mattress can be designed or tuned by combinations of the known spring rates of the coils and of the inserts 50. As known in the wire-forming arts, the spring rate of the wire form helical coils is determined by the coil design, including such design factors as height, diameter, number of turns in the helix and angles or pitch between the turns. The spring rate of the innerspring is also affected by the number or density of coils, their relative arrangement and manner of interconnection, such as lacing wires.
The spring rate and/or dampening effect of the foam dampening inserts 50 is determined and can be adjusted by such factors as the type of foam material and additives used, density, method of formation (e.g., injection molded or extruded), and design configuration such as the cross-section including size and shape of the central core 50i and the number, size and shape and orientation of the segments 50a-50e. For example, openings or voids may be formed in the central core 50i in order to reduce material and accordingly alter the spring rate and dampening effect. The shape or shapes of the segments 50a-50e may be made to fit tightly or loosely with the corresponding regions 40a-40e, and may be tapered or contoured in accordance with the coil helix. In one design aspect, the cross-sectional thickness of one or more of the segments 50a-50e is less tan or substantially less than a cross-sectional thickness of the central core 50i. Also, the cross-sectional configurations may differ among the various segments 50a-50e, such as for example some being thicker than others, some having a different shape or profile, and some being tapered to a lesser or greater extent than others at points distant from the central core 50i. One or more openings or voids 50o may be formed in the foam dampening inserts 50, such as for example in the central core 50i or in any of the segments or regions. The size, shape and location of openings or voids 50o are further design parameters which can be set to establish the spring rate or dampening effect of the insert 50 in combination with an innerspring. These and other shapes, configurations and structures can be made as foam structures which are molded or extruded of suitable types of polyurethane foams and alloys thereof. A preferred method of manufacture is by extrusion through a die which defines the described cross-sectional configuration, in any lengths for widthwise or lengthwise installation dimensioned with innersprings. When made as extrusions, the foam dampening inserts 50 are formed with an exterior skin.
As shown in the Figures and mentioned, the foam dampening inserts 50 may be arranged in any number, any length and any orientation, or combinations thereof, with an innerspring 10. In a longitudinal orientation shown in
