This invention relates generally to bedding and seating products and, more particularly, to pocketed spring assemblies used in bedding and seating products.
Mattress spring core construction over the years has been a continuously improving art with advancements in materials and machine technology. A well known form of spring core construction is known as a Marshall spring construction wherein metal coil springs are encapsulated in individual pockets of fabric and formed as elongate or continuous strings of pocketed coil springs. In an earlier form, these strings of coil springs were manufactured by folding an elongate piece of fabric in half lengthwise to form two plies of fabric and stitching transverse and longitudinal seams to join the plies of fabric to define pockets within which the springs were enveloped.
More recently, improvements in spring core constructions have involved the use of fabrics which are thermally or ultrasonically weldable to themselves. By using such welding techniques, these fabrics have been advantageously used to create strings of individually pocketed coil springs wherein transverse and longitudinal welds, instead of stitching, are used to form the pockets encapsulating the springs.
Once strings of pocketed springs are constructed, they may be assembled to form a spring core construction for a mattress, cushion or the like by a variety of methods. For example, multiple or continuous strings may be arranged in a row pattern corresponding to the desired size and shape of a mattress or the like, and adjacent rows of strings may be interconnected by a variety of methods. The result is a unitary assembly of pocketed coil springs serving as a complete spring core assembly.
Conventional pocketed spring cores incorporating pocketed strings of springs typically use springs of uniform diameter and pitch. U.S. Pat. No. 5,868,383 discloses a pocketed spring assembly incorporating springs which have different diameters and different pitches. An end portion of the pocketed spring may substantially compress before a middle portion compresses. The end portion may compress without the middle portion compressing when subject to lighter loads. However, due to the seams separating individual pockets extending the full height of the string of springs, the advantages of the coil springs may not be fully realized. The capability of the individually pocketed springs to act independently from the adjacent pocketed springs in the string of springs may be compromised.
Therefore, there remains a need to combine multiple technologies to improve the feel and motion transfer in a bedding or seating product having a pocketed spring core.
In one aspect, a bedding or seating product is provided. The product comprises a pocketed spring assembly comprising a plurality of parallel strings of springs, each string joined to an adjacent string, each string comprising first and second opposed plies of fabric and a plurality of pockets formed along the length of the string by transverse or separating seams joining the first and second plies, and at least one spring positioned in each pocket. Each of the springs has upper and lower end turns and a plurality of central convolutions between the end turns, the convolutions decreasing in diameter and pitch from a middle portion of the spring towards the end turns. Each of the springs is preferably made of one piece of wire of a uniform diameter. An upper end of each transverse seam forming the adjacent pockets of the string is below an upper surface of the string of springs so as to partially separate the adjacent pockets when the springs are relaxed (not compressed). Cushioning materials may be placed on the pocketed spring assembly, and an upholstered covering may encase the pocketed spring assembly and cushioning materials.
The strings of springs can extend longitudinally or transversely. A bedding or seating product may be posturized into regions or zones of different firmness by incorporating different strings of springs into the product.
If the strings of springs extend transversely, the product can include a plurality of the strings having a “split top” feature in the seams between adjacent pockets and a plurality of the strings lacking the “split top” feature, the plurality of strings arranged in a plurality of zones longitudinally spaced apart. For example, the product can include three such zones. The three zones can comprise a central zone, a head end zone and a foot end zone. The end zones can have strings of springs having the “split top” feature, and the strings of springs comprising central zone can have strings of springs lacking the “split top” feature. Alternatively, the end zones can have strings of springs lacking the “split top” feature, and the strings of springs comprising central zone can have strings of springs with the “split top” feature.
If the strings of springs extend longitudinally, the product can include a plurality of the strings having the “split top” feature in the seams between adjacent pockets and a plurality of the strings lacking the “split top” feature, the plurality of strings arranged in a plurality of zones transversely spaced apart. For example, the product can include two such zones, a “his” side and a “hers” side. The “hers” side or zone can have strings of springs having the “split top” feature, and the “his” side or zone can comprise strings of springs lacking the “split top” feature.
In another aspect, a pocketed spring assembly for a bedding or seating product is provided. The pocketed spring assembly comprises a plurality of parallel strings of springs. Each string is joined to an adjacent string of springs. Each of the strings comprises a plurality of interconnected pockets. Each of the pockets contains at least one spring encased in fabric. The fabric is joined to itself along a longitudinal seam and has first and second opposed plies of fabric on opposite sides of the springs. The fabric of the first and second plies is joined by transverse seams. Each of the springs has upper and lower end turns and a plurality of central convolutions between the end turns. The spring has two end portions and a middle portion between the end portions, the convolutions of the middle portion being greater in diameter and pitch than the convolutions of the end portions of the spring. Each of the springs is preferably made of one piece of wire of a uniform diameter. Each of the transverse seams forming the adjacent pockets of the string has one end located below an upper surface of the string of springs so as to partially separate the adjacent pockets.
In another aspect, a string of springs for a pocketed spring assembly for a bedding or seating product is provided. The pocketed spring assembly comprises a plurality of parallel strings of springs. Each string is joined to an adjacent string of springs. Each of the strings comprises a plurality of interconnected pockets. Each of the pockets contains at least one spring encased in fabric. The fabric is joined to itself along a longitudinal seam and has first and second opposed plies of fabric on opposite sides of the springs. The fabric of the first and second plies is joined by transverse seams. Each of the springs has two end portions and a middle portion between the end portions, the convolutions of the middle portion being greater in diameter and pitch than the convolutions of the end portions of the spring. Each of the springs is preferably made of one piece of wire of a uniform diameter. Each of the transverse seams forming the adjacent pockets of the string has an upper end located below an upper surface of the string of springs so as to partially separate the adjacent pockets and enable an upper end portion of the spring to compress without substantially compressing the middle portion of the spring.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the summary of the invention given above, and the detailed description of the drawings given below, serve to explain the principles of the present invention.
Referring first to
As shown in
As shown in
Although the strings of pocketed springs 26 are illustrated as extending longitudinally or from head-to-foot in the pocketed spring assembly 12 of
According to the practice of this invention, any of the padding or cushioning layers, including the pocketed topper 19, may be omitted in any of the embodiments shown or described herein. The novel features reside in the pocketed spring assembly.
These strings of pocketed springs 26, 26a and 26b, and any other strings of springs described or shown herein, may be connected in side-by-side relationship as, for example, by gluing the sides of the strings together in an assembly machine, so as to create an assembly or matrix of springs having multiple rows and columns of pocketed springs bound together as by gluing, welding or any other conventional assembly process commonly used to create pocketed spring cores or assemblies.
Referring to
As best illustrated in
Preferably, one piece of fabric is used to create the string of pocketed springs 26, the piece of fabric being folded over onto itself around the coil springs 36. As best shown in
Although the seams or welds in all of the embodiments shown herein are shown as being heat welded spaced rectangles, any of the seams may be spaced dots, triangles or solid line segments without spaces.
As best shown in
As shown in
In accordance with an embodiment of the present invention, in strings 26 of pocketed springs 28, the transverse seams 52 forming the adjacent pockets 34 are divided as at 64 to thereby form a cut, slit, or notch by, for example, cutting, slitting, severing, melting, or the like, from the upper surface 60 of the string of pocketed springs 26 inwardly (downwardly as illustrated), so as to partially separate the adjacent pockets 34. Preferably, the divide 64 extends to beyond or below the upper end turn 38 of the spring 36. As best shown in
The significance of divide 64 may be appreciated with reference to
Referring now to
Referring now to
Referring now to
The various embodiments of the invention shown and described are merely for illustrative purposes only, as the drawings and the description are not intended to restrict or limit in any way the scope of the claims. Those skilled in the art will appreciate various changes, modifications, and improvements which can be made to the invention without departing from the spirit or scope thereof. The invention in its broader aspects is therefore not limited to the specific details and representative apparatus and methods shown and described. Departures may therefore be made from such details without departing from the spirit or scope of the general inventive concept. The invention resides in each individual feature described herein, alone, and in all combinations of any and all of those features. Accordingly, the scope of the invention shall be limited only by the following claims and their equivalents.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/013,290 filed Jun. 17, 2014, which is fully incorporated by reference herein.
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5868383 | Codos | Feb 1999 | A |
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D681980 | DeFranks | May 2013 | S |
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Number | Date | Country |
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20030061737 | Jul 2003 | KR |
Number | Date | Country | |
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20150359349 A1 | Dec 2015 | US |
Number | Date | Country | |
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62013290 | Jun 2014 | US |