Patent Grant
10813462
This invention relates to a comfort layer for bedding and seating products. More particularly, this invention relates to a pocketed spring comfort layer for use in seating or bedding products and the method of manufacturing such comfort layer.
Comfort layers are commonly used in seating or bedding products above/below a core, which may or may not include a spring assembly. Such comfort layers may include foam, fiber and gel products. U.S. Pat. No. 8,087,114 discloses a comfort layer made of pocketed springs. Such spring assemblies may be made of strings of individually pocketed coil springs joined or multiple coil springs joined by helical lacing wires.
Spring cores may be generally covered on the top and often on the bottom by pads of resilient foam as, for example, a pad of urethane or latex/urethane mix of foamed material. Within the last several years, more expensive cushions or mattresses have had the spring cores covered by a visco-elastic foam pad, which is slow acting or latex foam, which is faster acting than visco-elastic foam. That is, the visco-elastic foam pad is slow to compress under load and slow to recover to its original height when the load is removed from the visco-elastic foam pad. These visco-elastic pads, as well as the latex pads, impart a so-called luxury feel to the mattress or cushion. These pads also, because of their closed cell structure, retain heat and are slow to dissipate body heat when a person sits or lies atop such a foam pad-containing cushion or mattress.
Individually pocketed spring cores have been made with fabric material semi-impermeable to airflow through the fabric material, as more fully explained below. U.S. Pat. No. 7,636,972 discloses such a pocketed spring core.
European Patent No. EP 1707081 discloses a pocketed spring mattress in which each pocket has a ventilation hole in order to improve the airflow into and out of the pocket. However, one drawback to such a product, depending upon the fabric used in the product, is that the fabric of the pocket may create “noise”, as the sound is named in the industry. Such noise may be created by the fabric expanding upon removal of the load due to the coil spring's upwardly directed force on the fabric.
It is therefore an objective of this invention to provide a comfort layer for a seating or bedding product, which has the same luxury feel as a visco-elastic or latex pad-containing comfort layer, but without the heat retention characteristics of such a comfort layer.
Still another objective of this invention is to provide one or more comfort layers for a seating or bedding product having the same or a similar slow-to-compress and slow-to-recover to its original height luxury feel as memory foam.
Another objective of this invention is to provide a comfort layer for a seating or bedding product made, at least partially, with fabric impervious to airflow through the fabric, but which allows air to enter and exit the pockets at different flow rates in reaction to different loads being applied to one or more pockets.
Another objective of this invention is to provide a comfort layer for a seating or bedding product made, at least partially, with fabric impervious to airflow through the fabric, but which allows air to enter and exit the pockets via gaps in the seams of at least some of the pockets.
The invention, which accomplishes these objectives, comprises a comfort layer for a seating or bedding product. The comfort layer comprises an assembly or matrix of individually pocketed springs, each spring being contained within a fabric pocket. The fabric pocketing material within which the springs are contained may be semi-impermeable to airflow through the fabric material. As used herein, the term “semi-impermeable” means that the fabric material, while permitting some airflow through the material, does so at a rate which retards or slows the rate at which a spring maintained in a pocket of the fabric may compress under load or return to its original height when a load is removed from the pocketed spring. In other words, air may pass through such a semi-impermeable material, but at a reduced rate compared to the rate at which air usually flows through a non-woven polypropylene material commonly used in the bedding industry.
Alternatively, the fabric material within which the springs are contained may be non-permeable or impermeable to airflow through the fabric material. In other words, air may not flow through the fabric material.
When a load is applied to a comfort layer made with semi-impermeable fabric, the airflow through the comfort layer is at least partially controlled by the rate at which air escapes through the semi-impermeable fabric within which the pocketed springs are contained. If the weld seams of the comfort layer are segmented, the airflow through the comfort layer is at least partially controlled by the rate at which air travels between segments of weld seams separating individual pockets.
When a load is applied to the comfort layer made with impermeable fabric, the airflow through the comfort layer is controlled only by the rate at which air escapes or travels between segments of weld seams separating individual pockets. Regardless of the type of fabric used to make the comfort layer, the seam segments may be any desired shape, including curved or straight, and any desired length to control airflow within the comfort layer. The length, size and/or shape of the seam segments may be manufactured to achieve a desired airflow between the interior of the pocket and the space outside the pocket.
Any of the embodiments of comfort layer shown or described herein may be incorporated into a bedding product, such as a mattress, bedding foundation or pillow. Further, any of the embodiments of comfort layer shown or described herein may be incorporated into a seating product, such as a vehicle seat and/or office or residential furniture, such as a recliner.
Alternatively, any of the embodiments of comfort layer shown or described herein may be sold independently as a retail or wholesale item. In such an application, the comfort layer may be added to and/or removed from a bedding or seating product by a customer.
The comfort layer of the present invention, whether incorporated inside a bedding or seating product, or manufactured and sold as a separate product, provides an additional cooling effect to the product due to airflow through the comfort layer, including between adjacent pockets. The amount of airflow between pockets may be changed by changing the size of the teeth or slots on a welding tool, including an ultrasonic welding tool. This is an easy way to adjust airflow inside a comfort layer and out of the comfort layer without changing the fabric material of the comfort layer.
Another advantage of this invention is that the comfort layer allows air to flow between pockets inside a pocketed spring comfort layer and either exit or enter the comfort layer along the periphery or edge of the comfort layer, such airflow contributing to the luxurious “feel” of any bedding or seating product incorporating the comfort layer. The comfort layer of the present invention has the slow-acting compression and height recovery characteristics of heretofore expensive visco-elastic foam comfort layers, but without the undesirable heat retention characteristics of such foam comfort layers.
According to one aspect of the present invention, a comfort layer configured to overlay a core of a bedding or seating product is provided. The comfort layer is characterized by slow and gentle compression when a load is applied to the product. The comfort layer comprises a matrix of pocketed mini coil springs. Each mini coil spring is contained within a pocket of fabric between first and second plies of fabric. Each pocket has weld seams comprising linear weld segments joining the first and second plies of fabric of the pocket. Each weld seam has gaps between the linear weld segments through which air may flow between adjacent pockets. In some embodiments, the linear weld segments along outer sides of side pockets are longer than the remainder of the linear weld segments of the side pockets.
The comfort layer is characterized, when a load is applied to the comfort layer, by the rate of compression of at least some of mini coil springs inside some of the pockets of the comfort layer being retarded by the rate at which air escapes through the gaps of the weld seams, the rate of compression of the mini coil springs being controlled by the size of the gaps.
In some embodiments, at least one of the plies of fabric comprises multiple layers and is impermeable to airflow. In some of these embodiments, at least one of the plies of fabric comprises three layers. In some embodiments, each of the plies of fabric comprises multiple layers. In some embodiments, each of the plies of fabric is impermeable to airflow and comprises at least three layers.
According to another aspect of the present invention, a comfort layer configured to overlay a core of a bedding or seating product comprises a matrix of mini coil springs. A first ply of fabric is on one side of the matrix of mini coil springs. A second ply of fabric is on another side of the matrix of mini coil springs. The first and second plies of fabric are joined with weld seams around each of the mini coil springs. Each of the weld seams comprises linear weld segments with gaps between the linear weld segments through which air may flow between adjacent pockets. At least some of the individual pockets have linear weld segments of different lengths. In some embodiments, the comfort layer has side pockets and end pockets around the perimeter of the comfort layer. The linear weld segments surrounding the side pockets are different than the linear weld segments surrounding the end pockets.
The comfort layer is characterized, when at least some of the mini coil springs in at least some of the pockets are subjected to a load, air moves between the pockets through the gaps between the linear weld segments of the weld seams, the rate of compression of the mini coil springs being controlled by the size of the gaps between the linear weld segments of the weld seams.
According to another aspect of the present invention, a comfort layer configured to overlay a core of a bedding or seating product comprises mini coil springs. A first ply of fabric is on one side of the mini coil springs. A second ply of fabric is on another side of the mini coil springs. The first and second plies of fabric are joined with weld seams to create individual pockets which contain the mini coil springs. Each of the pockets has gaps between adjacent linear weld segments. The comfort layer is characterized, when at least some of the pockets are subjected to a load, air moves between the pockets through the gaps between the first and second plies of fabric, air flow through the comfort layer being controlled by the size of the gaps between the linear weld segments of the weld seams. The comfort layer has side pockets, the linear weld segments surround the side pockets being different lengths.
The comfort layer also has end pockets and interior pockets. The side and end pockets are around the perimeter of the comfort layer and surround the interior pocket. The linear weld segments surrounding at least one of the end pockets and interior pockets are the same length.
In some embodiments, the linear weld segments along outer sides of the side pockets are longer than the other linear weld segments surround the side pockets. In some embodiments, the linear weld segments surrounding the interior pockets are the same length. In some embodiments, the linear weld segments surrounding the end pockets are the same length.
These and other objects and advantages of this invention will be readily apparent from the following drawings, in which:
As shown in
While several embodiments of comfort layer are illustrated and described as being embodied in a single-sided mattress, any of the comfort layers shown or described herein may be used in a single-sided mattress, double-sided mattress or seating cushion. In the event that any such comfort layer is utilized in connection with a double-sided product, then the bottom side of the product's core may have a comfort layer applied over the bottom side of the core and either comfort layer may be covered by one or more cushioning pads made of any conventional material. According to the practice of this invention, though, either the cushioning pad or pads, on top and/or bottom of the core, may be omitted. The novel features of the present invention reside in the comfort layer.
Although core 12 is illustrated being made of unpocketed coil springs held together with helical lacing wires, the core of any of the products, such as mattresses shown or described herein, may be made wholly or partially of pocketed coil springs (see
During the welding process, the mini coil springs 28 may be at least partially compressed before pocket 44 is closed and thereafter. If desired, resilient members other than mini coil springs, such as foam or plastic or gel or a combination thereof, may be used. Each of the resilient members may return to its original configuration after a load is removed from the pockets in which the resilient members are located.
The size of the curved segments 26 of weld seams 30 is not intended to be limited by the illustrations; they may be any desired size depending upon the airflow desired inside the comfort layer. Similarly, the size, i.e., diameter of the illustrated weld seams 30, is not intended to be limiting. The placement of the weld seams 30 shown in the drawings is not intended to be limiting either. For example, the weld seams 30 may be organized into aligned rows and columns, as shown in
The weld segments may assume shapes other than the curved weld segments illustrated. For example, the weld seams may be circular around mini coil springs, but the weld segments may assume other shapes, such as triangles or circles or ovals of the desired size and pattern to obtain the desired airflow between adjacent pockets inside the comfort layer and into or out of the perimeter of the comfort layer.
In any of the embodiments shown or described herein, the mini coil springs 28 may be any desired size. One mini coil spring in a relaxed condition may be approximately two inches tall, have a diameter of approximately three inches and be made of seventeen and one-half gauge wire. While compressed inside one of the pockets 44, each of the mini coil springs 28 may be approximately one and one-half inches tall. However, the mini coil springs 28 in a relaxed condition may be any desired height, have any desired shape, such as an hourglass or barrel shape, have any desired diameter and/or be made of any desired wire thickness or gauge.
With reference to
As shown in
These curved weld segments 26 are created by the welding horn 32 of a machine (not shown) having multiple spaced protrusions 38 on the ultrasonic welding horn 32. As a result of these circular weld seams 30 joining plies 22, 24, the plies 22, 24 define a plurality of spring-containing pockets 44 of the comfort layer 16. One or more mini coil springs 28 may be contained within an individual pocket 44.
In the embodiments in which the fabric material of plies 22, 24 defining pockets 44 and enclosing the mini coil springs 28 therein is non-permeable or impermeable to airflow, upon being subjected to a load, a pocket 44 containing at least one mini coil spring 28 is compressed by compressing the mini coil spring(s) 28 and air contained within the pocket 44. Air exits the pocket 44 through gaps 31 between the curved segments 26 of the circular weld seams 30. Similarly, when a load is removed from the pocket 44, the mini coil spring 28 separates the fabric layers 22, 24, and air re-enters the pocket 44 through the gaps 31 between the curved segments 26 of the circular weld seams 30. As shown in
In the embodiments in which the fabric material is semi-impermeable to airflow, the rate at which the mini coil springs 28 compress when a load is applied to a pocketed spring core comfort layer 16 is slowed or retarded by the air entrapped within the individual pockets as the pocketed spring comfort layer 16 is compressed. Similarly, the rate of return of the compressed coil spring comfort layer to its original height after compression is retarded or slowed by the rate at which air may pass through the semi-impermeable fabric material into the interior of the individual pockets 44 of the pocketed spring comfort layer 16. In these embodiments, air passes through the gaps 31 between the curved segments 26 of the circular weld seams 30, as described above with respect to the embodiments having non-permeable fabric. However, in addition, some air passes through the fabric, both when the pocket 44 is compressed and when the pocket 44 is unloaded and enlarging or expanding due to the inherent characteristics of the mini springs 28.
As best illustrated in
In any of the embodiments shown or described herein, the sound attenuating layer may be a polyester circular stretch knit fabric. Such a sound attenuating layer may be secured to the middle airtight layer of thermoplastic polyurethane film prior to introduction into a machine such as machine 90. One combination of sound attenuating layer and airtight layer which has proven satisfactory is manufactured by Culp Home Fashions of Stokesdale, N.C. and has a fabric weight of 250 grams per square meter.
In any of the embodiments shown or described herein, the fabric material of at least one of the plies may be impermeable to airflow through the fabric. Each ply may comprise three layers, including from the inside moving outwardly: 1) a polypropylene non-woven fabric layer 27 having a density of approximately one ounce per square yard commercially available from Atex, Incorporated of Gainesville, Ga.; 2) a polyether thermoplastic polyurethane film layer 29 having a thickness of approximately 1.0 mil (0.001 inches) commercially available from American Polyfilm, Incorporated of Branford, Conn.; and 3) a lofted needle punch polyester fiber batting layer 33 having a density of 0.5 ounces per square foot commercially available from Milliken & Company of Spartanburg, S.C. The middle thermoplastic polyurethane film layer 29 is impermeable to airflow and may be any desired thickness. One thickness which has proven to function satisfactorily is 2.0 millimeters. The lofted needle punch polyester fiber batting layer 33 acts as a sound dampening layer which quiets and muffles the film layer 29 as the springs are released from a load (pressure in the pocket goes from positive to negative) or loaded (pressure in the pocket goes from neutral to positive). The polypropylene non-woven fabric layer 27 keeps the segmented air passages open such that the pocket 44 may “breathe”. Without the polypropylene non-woven fabric layer 27 closest to the springs, the middle thermoplastic polyurethane film 29 would cling to itself and not allow enough air to pass through the segmented air passages. The polypropylene non-woven fabric layer 27 closest to the springs also makes the product more durable by protecting the middle thermoplastic polyurethane film layer 29 from contacting the spring 28 and deteriorating from abrasion against the spring 28.
Heat-activated glue may be placed between the airtight layer 29 and the sound attenuating layer 33. The airtight layer 29 and the sound attenuating layer 33 may then be laminated together by passing them through a heat-activated laminator (not shown). The protective layer 27 may or may not be glue laminated to the other two layers. After passing through the heat-activated laminator, at least two of the three layers may be combined.
An alternative method for laminating all three layers without the use of glue may be using an ultrasonic lamination procedure. This process creates ultrasonic welds in a set pattern across the fabric, thereby making the fabric a unitary three-layered ply of material.
As shown in
Similarly, the shape, as well as the size, of any of the weld seams shown or described herein is not intended to be limiting. Shapes other than linear weld segments 68 may be used to create weld seams 70, as well as any weld seams shown or described herein. For purposes of this document, “weld segment” is not intended to be limited to linear segments. A “weld segment” of a weld seam is intended to include such shapes as triangles or circles or ovals of any desired size and pattern to obtain the desired airflow between adjacent pockets and into or out of the perimeter of the comfort layer.
With reference to
As shown in
These linear weld segments 68 may be created by the welding horn 72 of a machine (shown in
In some embodiments, the fabric material defining pockets 84 and enclosing the mini coil springs 28 therein is non-permeable to airflow. When subjected to a load, these pockets 84 (with mini coil springs 28 therein) are compressed, causing the air contained within the pockets 84 to move between pockets 84, as shown by arrows 82 of
In other embodiments, the fabric material is semi-impermeable to airflow, and some air passes through the fabric. The rate at which the mini springs 28 compress when a load is applied to a pocketed spring core comfort layer 56 is slowed or retarded by the air entrapped within the individual pockets 84 as the pocketed spring comfort layer 56 is compressed and, similarly, the rate of return of the compressed coil spring comfort layer 56 to its original height after compression is retarded or slowed by the rate at which air may pass through the semi-impermeable fabric material into the interior of the individual pockets 84 of the pocketed spring comfort layer 56. In these embodiments, air passes through the gaps 77 between the weld segments 68 of the weld seams 70, as described above with respect to the embodiments having non-permeable fabric. However, in addition, some air passes through the fabric, both when the pocket 84 is compressed and when the pocket 84 is expanded due to the spring(s) therein.
In accordance with the practice of this invention, one fabric material semi-impermeable to airflow, which may be used in either of the two plies of the pocketed spring comfort layers disclosed or shown herein, may be a multi-layered material, including one layer of woven fabric as, for example, a material available from Hanes Industries of Conover, N.C. under product names Eclipse 540. In testing, using a 13.5 inch disc platen loaded with a 25 pound weight, six locations on a queen size mattress were tested to determine the time required for the pocketed mini coil springs of a comfort layer having rectangular-shaped weld seams made with the multi-layered fabric material described above to compress to half the distance of its starting height. Once the weight of the platen was removed, the time for the pocketed mini coil springs of the comfort layer to return to their starting height was measured. Using such a testing method, the average rate of compression was 0.569 inches per second, and the average rate of recovery was 0.706 inches per second. These averages are not intended to be limiting. These averages may be dependent upon the type(s) of material of the plies and/or size and shape of the weld segments comprising the weld seams which, in turn, may vary the rate of compression and rate of recovery due to airflow. Such variables may be adjusted/changed to achieve variations in feel and comfort of the end product.
In an air permeability test known in the industry as the ASTM Standard D737, 2004 (2012), “Standard Test Method for Air Permeability of Textile Fabrics,” ASTM International, West Conshohocken, Pa. 2010, airflow through the multi-layered, semi-impermeable material available from Hanes Industries of Conover, N.C. described above was measured. The results ranged between 0.029-0.144 cubic feet per minute.
Alternatively, the fabric material of the first and second plies of any of the embodiments shown or disclosed herein may be material disclosed in U.S. Pat. Nos. 7,636,972; 8,136,187; 8,474,078; 8,484,487 and 8,464,381, each one of which is fully incorporated herein. In accordance with the practice of this invention, this material may have one or more coatings of acrylic or other suitable material sprayed onto or roller coated onto one side of the fabric to make the fabric semi-impermeable to airflow as described hereinabove.
In any of the embodiments shown or described herein, the fabric material of at least one of the plies may be impermeable to airflow through the fabric. Each ply may comprise three layers, including from the inside moving outwardly: 1) a polypropylene non-woven fabric layer 27 having a density of approximately one ounce per square yard commercially available from Atex, Incorporated of Gainesville, Ga.; 2) a polyether thermoplastic polyurethane film layer 29 having a thickness of approximately 1.0 mil (0.001 inches) commercially available from American Polyfilm, Incorporated of Branford, Conn.; and 3) a lofted needle punch polyester fiber batting layer 33 having a density of 0.5 ounces per square foot commercially available from Milliken & Company of Spartanburg, S.C. The middle thermoplastic polyurethane film layer 29 is impermeable to airflow. The lofted needle punch polyester fiber batting layer 33 acts as a sound-dampening layer which quiets and muffles the film layer 29 as the springs are released from a load (pressure in the pocket goes from positive to negative) or loaded (pressure in the pocket goes from neutral to positive). The polypropylene non-woven fabric layer 27 keeps the segmented air passages open, such that the pocket 84 may “breathe”. Without the polypropylene non-woven fabric layer 27 closest to the springs 28, the middle thermoplastic polyurethane film 29 would cling to itself and not allow enough air to pass through the segmented air passages. The polypropylene non-woven fabric layer 27 closest to the springs 28 also makes the product more durable by protecting the middle thermoplastic polyurethane film layer 29 from contacting the spring 28 and deteriorating from abrasion against the spring 28.
Heat-activated glue may be placed between the airtight layer 29 and the sound attenuating layer 33. In some applications, additional heat active glue may be placed between the airtight layer 29 and the protective layer 27. At least two layers may then be laminated together by passing them through a heat-activated laminator (not shown). The protective layer 27 may remain unattached to the other two layers after passing through the laminator. However, in some processes after passing through the heat-activated laminator, all three layers may be combined and form one of the fabric plies. An alternative method for laminating all three layers may be using an ultrasonic lamination procedure. This process creates ultrasonic welds in a set pattern across the fabric, thereby making it one piece or ply of material.
As best illustrated in
Machine 90 discloses a conveyor 92 on which are loaded multiple mini coil springs 28. The conveyor 92 moves the mini coil springs 28 in the direction of arrow 94 (to the right as shown in
The machine 90 further comprises a compression plate 108, which is movable between raised and lowered positions by lifters 110. Although two lifters 110 are illustrated in
As best shown in
As best shown in
As best illustrated in
Air flows between pockets 84c and into and out of the comfort layer 56c through gaps 83 between linear segments 81 of weld seams 70c. The segments 81 of weld seams 70c are longer than other segments of other weld seams shown herein. One purpose of the longer segments 81 of weld seams 70c is so that air flows between pockets 84c at the corners of the pockets 84c, as depicted by arrows 85. The segments 81 of weld seams 70c join the first and second plies 65, 67 of fabric so air does not flow therebetween. Thus, air flows between pockets 84c only at the corners of the pockets 84c, as depicted by arrows 85. The desired amount of air flow between pockets 84c may be achieved by designing the gaps 83 between segments 81 of weld seams 70c to a desired size.
This aspect of the invention is illustrated with regards to a comfort layer 56d, a portion of which is shown in
As best illustrated in
As shown in
In this embodiment, the fabric of each of the first and second plies 89, 91 may be the same three-layered fabric impermeable to airflow shown in
For purposes of this document, the gaps 77 of weld seams 70 of comfort layer 56d may be considered valves which change in size depending on the load placed upon the pockets 84d of comfort layer 56d or removed from the pockets 84d of comfort layer 56d to control air flow as described below. Gaps 77 of the weld seams 70 function as valves in controlling the air flow into and out of the pockets 84d of the comfort layer 56d without any material or apparatus other than the multi-layered fabric of the plies 89, 91 of comfort layer 56d. The construction of the comfort layer 56d has inherent valves therein between seam segments, the valves controlling air flow into and out of the pockets 84d of the comfort layer 56d depending upon the size of the gaps and seam segments, the load(s) placed on the comfort layer 56d and the composition of the fabric material of the plies 89, 91 of comfort layer 56d, among other factors.
If a load is applied to the pocket 84d that is significantly greater than the load needed to open the valves 77 of the weld seams 70, the fabric material of the pocket 84d will elastically stretch and open further to allow more air to pass through the valves or gaps in the weld seams. Thereby, the valves react to the specific load applied. Such reaction contributes to the unique luxurious feel of a comfort layer made in accordance with the present invention.
In the event the plies are made of the multi-layered fabric disclosed herein, the ability of the valves to stretch and react to the air pressure is largely due to the middle thermoplastic polyurethane film layer. The middle thermoplastic polyurethane film layer is a relatively elastic material which returns to its original shape after a load is removed. When the load is released, the valves return to their original condition which is a relatively restrictive state in which the air pressure inside the pockets is at atmospheric pressure at ambient temperature.
As best shown in
As best illustrated in
As best shown in
However, as best shown in
Air flows between interior pockets 101, side pockets 95 and end pockets 105 into and out of the comfort layer 56e through gaps 83e between linear segments 68e of intersecting linear weld seams 70c. Air also flows into and out of the side pockets 95 through gaps 111 between the long weld segments 81e. The long weld segments 81 are longer than weld segments 68e of linear weld seams 70e of comfort layer 56e. One purpose of the long weld segments 81 of side pockets 95 is so that air flows into and out of side pockets 95 at a slower rate than air flows into and out of the interior pockets 101 and end pockets 105 when a load is placed on or removed from any portion of the comfort layer 56e. The long weld segments 81e of side pockets 95 join the first and second plies 65e, 67e of fabric so air does not flow therebetween. The desired amount of air flow between side pockets 95 may be achieved by designing the gaps 101 between long weld segments 81e to a desired size.
The difference in length between long weld segments 81e and weld segments 68e of linear weld seams 70e constrains airflow into and out of the side pockets 95 and gives the comfort layer 56e a unique feel. The rate of recovery of the interior pockets 101 and end pockets 105 is greater than the rate of recovery of the side pockets 95. The restricted airflow into and out of the side pockets 95 relative to the airflow into and out of the interior and end pockets 101, 105 provides the comfort layer 56e a more consistent rate of recovery across the width of the comfort layer 56e when the comfort layer 56e is loaded and unloaded in any location. Making the rate of recovery more consistent across the width of the comfort layer 56e provides the same feel at every location when a person lays on a product having a comfort layer like comfort layer 56e. Although
While I have described several preferred embodiments of this invention, persons skilled in this art will appreciate that other semi-impermeable and non-permeable fabric materials may be utilized in the practice of this invention. Similarly, such persons will appreciate that each pocket may contain any number of coil springs or other type of spring, made of any desired material. Persons skilled in the art may further appreciate that the segments of the weld seams may be stitched, glued or otherwise adhered or bonded. Therefore, I do not intend to be limited except by the scope of the following appended claims.
This application is a continuation-in-part of U.S. patent application Ser. No. 16/520,403 filed Jul. 24, 2019, a continuation of U.S. patent application Ser. No. 15/628,128 filed Jun. 20, 2017, now U.S. Pat. No. 10,405,665, a continuation-in-part of U.S. patent application Ser. No. 15/062,318 filed Mar. 7, 2016, now U.S. Pat. No. 9,968,202, a continuation-in-part of U.S. patent application Ser. No. 14/879,672 filed Oct. 9, 2015, now U.S. Pat. No. 9,943,173, which claims the benefit of U.S. Provisional Patent Application Ser. No. 62/115,785 filed Feb. 13, 2015, each application of which is fully incorporated by reference herein.
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