Patent Application
20190000239
The present invention relates to pocketed coil spring assemblies and support cushions including the pocketed coil spring assemblies. In particular, the present invention relates to pocketed coil spring assemblies having seams that are positioned between each of the pocketed coil springs and that allow one or more ends of each pocketed coil spring to move independently of an adjacent pocketed coil spring.
Spring assemblies that make use of pocketed coil springs, which are also known as wrapped coils, encased coils, encased springs, or Marshall coils, are generally recognized as providing a unique feel to a mattress when used as a part of a spring assembly because each discrete coil is capable of moving independently to support the body of a user, or a portion thereof, resting on the mattress. In particular, in spring cores including a plurality of pocketed coil spring assemblies, each coil is wrapped in a fabric pocket and moves substantially independently of the other coils in the spring core to thereby provide individualized comfort and contouring to the body of a user. Moreover, as a result of moving substantially independently from one another, the pocketed coils also do not directly transfer motion from one pocketed coil to another, and, consequently, the movement of one user resting on a mattress assembly using pocketed coils will not disturb another user resting on the mattress assembly. In this regard, mattress assemblies constructed with a spring core using pocketed coil springs are generally recognized as providing a soft and luxurious feel, and are often more desirable than a traditional inner spring mattress. Accordingly, a spring core that makes use of pocketed coil springs and that further improves the unique feel and support provided by traditional pocketed coil springs would be both highly desirable and beneficial.
The present invention includes pocketed coil spring assemblies and support cushions including the pocketed coil spring assemblies. In particular, the present invention includes pocketed coil spring assemblies having seams that are positioned between each of the pocketed coil springs and that allow one or more ends of each pocketed coil spring to move independently of an adjacent pocketed coil spring.
In one exemplary embodiment of the present invention, a support cushion includes a plurality of rows of pocketed coil springs with each of the rows of pocketed coil springs being substantially identical to one another and arranged side-by-side to form a matrix. Each of the pocketed coil springs in each row are also substantially identical to one another with each of the pocketed coil springs including a coil spring surrounded by a flexible enclosure. A seam is also positioned between each one of the plurality of pocketed coil springs and an adjacent one of the plurality of pocketed coil springs such that the seam connects each of the flexible enclosures of the pocketed coil springs. Furthermore, an adhesive is also positioned between each row of pocketed coil springs and an adjacent row of pocketed coil springs to connect each of the rows of pocketed coils springs to one another.
With respect to the seams, each seam generally includes a top portion and a bottom portion and has a height substantially equal to the height of the each of the pocketed coil springs. In some embodiments, each seam defines a separation or further includes one or more welds that define a separation at the top portion of each seam to allow the upper ends of each of the pocketed coil springs to move independently of one another. For example, in some embodiments, each seam includes a first weld that extends from adjacent the lower ends of two adjacent pocketed coil springs to a node positioned on the seam at a height less than the height of the seam. A second weld then extends from the node to the upper end of one pocketed coil spring, and a third weld extends from the node to the upper end of the adjacent pocketed coil spring, such that the separation of the seam is defined by the second weld and the third weld and such that the seam and the welds have a Y-shaped configuration.
As another example of a seam defining a separation at the top portion of each seam and between two adjacent pocketed coil springs, in other embodiments, the seam includes a first weld that extends from adjacent the lower end to adjacent the upper end of one of the plurality of pocketed coil springs and a second weld that extends from adjacent the lower end to adjacent the upper end of an adjacent one of the plurality of pocketed coil springs. The separation that is defined by the seam is then defined by the seam itself between the first weld and the second weld. As yet another example of a seam defining a separation at a top portion of the seam, in further embodiments, each seam comprises a first weld that extends from adjacent the lower end to adjacent the upper end of each one of the plurality of pocketed coil springs, a second weld that extends from adjacent the lower end to adjacent the upper end of an adjacent one of the plurality of pocketed coil springs, and a third weld that is positioned between the first weld and the second weld and that extends to a height less than that of the first weld and the second weld. The separation defined by the seam in such an embodiment is then again defined by the seam itself between the first weld and the second weld and above the third weld.
In addition to the upper end of one pocketed coil spring moving independently of the upper end of the adjacent one of the pocketed coil springs in a particular row, in arranging the rows of pocketed coils springs in a matrix, the upper ends of each of the pocketed coils springs in one particular row are further configured to move independently of the upper ends of each of the pocketed coil springs in an adjacent row. In this regard, to connect a particular row of pocketed coil springs to an adjacent row of pocketed coil springs, an adhesive is applied to the flexible enclosures of each of the pocketed coils springs in a particular row and in an adjacent row. More specifically, the adhesive is generally positioned on the flexible enclosure of the pocketed coil springs below the upper end of each pocketed coil spring so as to allow the top ends of the pocketed coil springs in adjacent rows to move independent of one another. In this way, such an arrangement of the pocketed coils springs in the rows not only causes less interaction between the upper ends of the pocketed coil springs in a particular row and an adjacent row, but such an arrangement also provides a user resting on the mattress with an increased amount of conformance to his or her body and less motion transfer across the entirety of the mattress. Indeed, in some embodiments, an exemplary support cushion can also be provided where there is no separation formed in the seam at all, but yet, because of the configuration of the adhesive positioned between the rows of pocketed coil spring assemblies, the exemplary support cushion is still capable of providing increased amounts of conformance and less motion transfer.
With further respect to the flexible enclosures and the seams, the flexible enclosures and the seams are typically made of a non-woven fabric that can be joined or welded together by heat and pressure (e.g., via ultrasonic welding or similar thermal welding procedure) to form a generally cylindrical construction for each flexible enclosure and a generally planar construction for each seam. The coil spring of each of the pocketed coil springs, on the other hand, is generally made of a continuous wire having a length and forming a plurality of convolutions that are each made up of a portion of the continuous wire substantially equal to about one turn of the continuous wire (i.e., about 360° of the helical path of the continuous wire). In some embodiments, the continuous wire of each coil spring forms an upper end convolution, a lower end convolution opposite the upper end convolution, and a number of intermediate helical convolutions that helically spiral between the lower end convolution and the upper end convolution. In some embodiments, the upper end convolution of each coil spring forms a substantially closed circular loop at the topmost portion of the coil spring, while the lower end convolution similarly forms a substantially closed circular loop at the lowermost portion of the coil spring. In this way, such a coil spring thus terminates at either end in a generally planar form that serves as the supporting end structures of the exemplary pocketed coil springs.
The upper end convolution, the intermediate helical convolutions, and the lower end convolution of each coil spring are generally arranged such that the coil spring has a lower section and an upper section. Further, by forming the coil spring from a continuous wire, the upper end convolution, the intermediate helical convolutions, and the lower end convolution each have a respective diameter, and the continuous wire also defines various pitches between the lower end convolution, the intermediate helical convolutions, and the upper end convolution. By varying the diameters, the pitches, or both the diameters and the pitches included in the coil springs that are utilized in the pocketed coil spring assemblies of the present invention, however, a variable and non-linear loading response is provided in some embodiments where the upper section has a first spring constant that provides a softer feel as the spring is initially compressed, and where the lower section has a second spring constant that provides a firmer feel as the compression of the coil spring increases.
As described above, the seams of the exemplary pocketed coil spring assemblies are typically further configured such that the bottom portion of each seam is positioned adjacent to the lower end of the pocketed coil springs and, consequently, each seam is also positioned adjacent to the lower section of each coil spring. Similarly, the top portion of the seam (i.e., where the separation is defined, if present) is positioned adjacent to the upper end of each of the pocketed coils springs such that the separation defined by the seam is also positioned adjacent to the upper section of each coil spring. Moreover, and again as described above, the adhesive is also generally positioned adjacent to the lower end of the pocketed coil springs and, consequently, the adhesive is further positioned adjacent to the lower section of each coil spring. By virtue of this arrangement, the lower sections of each coil spring are thus generally secured in the lower end of the pocketed coil springs, while the upper sections of each coil spring are configured to move more independently. As such, not only is each coil spring able to partially compress without causing any compression in other coil springs, but because of the different spring constants between the upper section and the lower section of each coil spring, the lack of connection between each upper section of each coil spring provides for additional freedom of movement and thus a greater degree of comfort to a user during the initial compression.
Regardless of the particular configuration of the seams between each of the pocketed coil springs of the present invention, as noted above and because of the ability of the pocketed coil spring assemblies to provide a user with an increased amount of conformance to his or her body and less motion transfer, each of the pocketed coil spring assemblies described herein are particularly suited for use in a mattress and can be combined with one or more supporting or foundation layers. In some embodiments, an exemplary mattress is provided that further includes an upper body supporting layer positioned above the pocketed coil springs and a lower foundation layer positioned below the pocketed coil springs. In some embodiments, a sidewall then extends between the upper body supporting layer and the lower foundation layer and around the entire periphery of the two layers, such that the pocketed coil springs are completely surrounded. In some embodiments, the mattress can also include a cover that surrounds the upper body supporting layer, the sidewall, and the lower foundation layer to protect the underlying layers and the pocketed coil spring assemblies of the mattress.
Further features and advantages of the present invention will become evident to those of ordinary skill in the art after a study of the description, figures, and non-limiting examples in this document.
The present invention includes pocketed coil spring assemblies and support cushions including the pocketed coil spring assemblies. In particular, the present invention includes pocketed coil spring assemblies having seams that are positioned between each of the pocketed coil springs and that allow one or more ends of each pocketed coil spring to move independently of an adjacent pocketed coil spring.
Referring first to
With further respect to the seams 60, and referring now to
In addition to the upper end 22 of one of the pocketed coil spring 20a, 20b, 20c moving independently of the upper end 22 of the adjacent one of pocketed coil springs 20a, 20b, 20c in a particular one of the rows 12a, 12b, 12c, by arranging the rows 12a, 12b, 12c of the pocketed coil springs 20a, 20b, 20c in a matrix, the upper ends 22 of each of the pocketed coil springs 20a, 20b, 20c in a particular one of the rows 12a, 12b, 12c are further capable of moving independently of the upper ends 22 of each of the pocketed coil springs in an adjacent one of the rows 12a, 12b, 12c. In this regard, and referring now to the initial two rows 12a, 12b shown in
With further respect to the flexible enclosures 50 and the seams 60, the flexible enclosures 50 and the seams 60 are typically made of a non-woven fabric that can be joined or welded together by heat and pressure (e.g., via ultrasonic welding or similar thermal welding procedure) to form a generally cylindrical construction for each flexible enclosure 50 and a generally planar construction for each seam 60. For example, suitable fabrics that can be used for the flexible enclosures 50 and the seams 60 can include one of various thermoplastic fibers known in the art, such as non-woven polymer-based fabric, non-woven polypropylene material, or non-woven polyester material. In embodiments where the flexible enclosures 50 and the seams 60 are made of such a non-woven fabric, the welds 72, 74, 76 of the seams 60 are typically formed via ultrasonic welding or other similar thermal welding procedures. Of course, both the flexible enclosures and the seams of the support cushions described herein can be made of other flexible fabrics as well including both woven and non-woven textiles, thin flexible elastomers, paper, or other materials that offer a flexible structure. Depending on the particular fabric or materials chosen, the exemplary welds can then be formed by making use of an adhesive, stitching, metal staples, snaps, buttons, hook and loop fasteners, or other such means. Accordingly, as used herein, the term “weld” is inclusive of any suitable means of securely joining together two overlapping fabric layers either permanently or temporarily.
Referring still to
As further discussed below, the upper end convolution 48, the six intermediate helical convolutions 42, 43, 44, 45, 46, 47, and the lower end convolution 41 of each coil spring 30 are generally arranged such that the coil spring 30 has a lower section 32 and an upper section 34. The lower section 32 of the coil spring 30 includes the lower end convolution 41, the first intermediate helical convolution 42, the second intermediate helical convolution 43, and the third intermediate helical convolution 44 (i.e., the three lower helical convolutions) and the upper section 34 of the coil spring 30 includes the fourth helical intermediate convolution 45, the fifth helical intermediate convolution 46, the sixth intermediate convolution 47 (i.e., the three upper helical convolutions), and the upper end convolution 48.
As also shown in
With respect to the pitch between the convolutions and the diameter of the convolutions in an exemplary coil spring of the present invention, in most coil springs formed using helically-spiraling continuous wire, the spring constant and resultant feel of the coil spring are typically determined by the gauge of the wire forming the coil spring, the total number of convolutions in the coil spring, the size of the convolutions (diameter), and the pitch or vertical spacing (or pitch angle) between the convolutions. In this regard, the pitch (or vertical spacing) between each convolution of a coil spring is typically controlled by the rate at which the continuous wire, which forms the coil spring, is drawn through a forming die in a coil-forming machine. Once formed, a larger pitch will typically produce a stiffer coil spring due to the increased vertical orientation of the wire, while a smaller pitch will typically produce a softer coil spring and allow for a larger number of total convolutions in the coil body. Similarly, larger diameter convolutions in a coil spring also contribute to a lower spring constant and consequentially softer feel than smaller diameter convolutions in coil springs. Of course, because the wire forming the coil spring is continuous, there is generally no defined beginning point or ending point of any single convolution. Furthermore, the diameter and pitch is typically adjusted gradually between one portion of the spring to another. As such, oftentimes a single convolution of a coil spring may not have just one single diameter or just one single pitch, but may include, for example, a beginning or end portion with a variable diameter and/or pitch that transitions to the adjacent convolution. Therefore, as used herein, the diameter and pitch of a convolution will typically refer to an average diameter and pitch, but can also be inclusive of a maximum diameter and pitch or a minimum diameter and pitch.
In the exemplary coil springs of the present invention described herein, the wire gauge of the coil springs generally has a range of about 10 awg to about 20 awg, which includes, in some embodiments, a range of about 11 awg to about 17 awg, and, in other embodiments, a range of about 12 awg to about 16 awg. By varying the diameters, the pitches, or both the diameters and the pitches included in the coil springs utilized in the pocketed coil spring assemblies of the present invention, however, a variable and non-linear loading response is provided in some embodiments where a first spring constant provides a softer feel as the spring is initially compressed and a second spring constant provides a firmer feel as the compression of the coil spring increases. In other words, by forming the continuous wire of a coil spring in an exemplary pocketed coil spring assembly of the present invention in a manner where at least one of the pitches is different than another one of the pitches, where at least one of the diameters of the convolutions is different from another one of the diameters of the convolutions, or a combination thereof, an exemplary pocketed coil spring can be configured to provide a non-linear response to loading (i.e., where increased support is observed after the spring has been compressed an initial predetermined distance).
Referring still to
With further respect to the exemplary coil spring 30 shown in
Referring still to
To provide an additional amount of independent movement in the pocketed coil spring assemblies of the present invention, in some embodiments, rather than an exemplary seam defining a separation at only the top portion of the seam, it is contemplated that a separation can also be defined by the bottom portion of the seam or at both the top portion of the seam and the bottom portion of the seam. For example, in some embodiments, a support cushion assembly can be provided similar to the embodiments described in
As an even further refinement, in additional embodiments of the support cushions of the present invention, the separation defined by a seam of an exemplary pocketed coil spring assembly of the present invention is not directly defined by one or more welds, but rather is positioned between various welds in a particular row of a pocketed coil spring assembly. For instance, and referring now to
As another refinement, in yet another exemplary embodiment of the present invention and referring now to
As yet another refinement, in some embodiments of the present invention, an exemplary support cushion can also be provided where there is no separation formed in the seam at all, but yet, because of the configuration of the adhesive positioned between the rows of pocketed coil spring assemblies, the exemplary support cushion is still capable of providing increased amounts of conformance and less motion transfer across the entirety of the support cushion. For example, and referring now to
With further respect to the seams 360, each seam 360 includes a top portion 362 and a bottom portion 364 and has a height substantially equal to the height of each of the pocketed coil springs 320a, 320b, 320c. Each seam 360 further includes a weld 372 that extends from the bottom portion 364 of each seam 360 to a height substantially less than the height of the seam 360 (e.g., to a height that is 50 to 75% the height of the seam 360) and, more specifically, to a height substantially equal to or less than a height of the lower section 332 of each coil spring 330. However, neither the weld 372 nor the seam 360 itself defines a separation that allows each of the upper end 322 of each pocketed coil spring 320a, 320b, 320c to move independently from an adjacent one of the pocketed coil springs 320a, 320b, 320c in one of the rows 312a, 312b, 312c. In this regard, to provide increased amounts of conformance and less motion transfer across the mattress 310, an adhesive 80 is still applied to the flexible enclosures 50 of each of the pocketed coils springs 20a, 20b, 20c in one of the particular rows 312a, 312b, 312c (e.g., the row 312a) and an adjacent one of the rows 312a, 312b, 312c (e.g., the row 312b), and is generally positioned on the flexible enclosure 50 of the pocketed coil spring 20a substantially below the upper end 322 of each of the pocketed coil springs 320a, 320b, 320c to allow the upper ends 22 of the pocketed coil springs 320a, 320b, 320c in one of the rows 312a, 312b, 312c to move independently of the upper ends 22 of the pocketed coil springs 320a, 320b, 320c in an adjacent one of the rows 312a, 312b, 312c.
Regardless of the particular configuration of the seams between each of the pocketed coil springs of the present invention, as noted above and by virtue of the ability of the pocketed coil spring assemblies to provide a user with an increased amount of conformance to his or her body and less motion transfer, each of the pocketed coil spring assemblies described herein are particularly suited for use in a mattress and can be combined with one or more supporting or foundation layers. For instance, and referring once again to the mattress 10 shown in
In the mattress 10 shown in
In addition to the various supporting and foundation layers, in some embodiments, the exemplary support cushions described herein can further include a cover that surrounds and protects the various layers and spring assemblies of the support cushions. For example, in the mattress 10 shown in
Finally, although the support cushions shown in
One of ordinary skill in the art will recognize that additional embodiments are also possible without departing from the teachings of the present invention or the scope of the claims which follow. This detailed description, and particularly the specific details of the exemplary embodiments disclosed herein, is given primarily for clarity of understanding, and no unnecessary limitations are to be understood therefrom, for modifications will become apparent to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the claimed invention.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2015/067775 | 12/29/2015 | WO | 00 |
