Note: Descriptions are shown in the official language in which they were submitted.
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Title of the Invention
ENCASED ASYMMETRIC COIL INNERSPRINGS WITH ALTERNATING COIL SPRING
ORIENTATIONS
Related Applications
This application is related to U.S. provisional patent application number
61/784,085, filed
March 14, 2013.
Field of the Invention
[0001] The disclosure of this application is in the field of reflexive and
spring-containing support
structures, including furniture and mattresses.
Background of the Invention
[0002] Wire form springs individually encased in fabric, also known as
"pocketed" or Marshall
-
type coils and have been manufactured for many years for use as spring cores
for mattresses by
arranging the strings of pocketed coils in rows or columns within a perimeter.
With each coil
contained in its own pocket and attached to adjacent pockets, the axes of the
coils are held in
alignment and each coil is able to be compressed individually or in
combination in accordance
with the flexibility of the encasing fabric and the manner of attachment or
connection between
the coil pockets. In addition to conventional stitching, thermal welds have
been used at different
intervals to form and connect the pockets and thereby dictate to some extent
the support
characteristics of a pocketed spring core. Other variations on the basic
construct of pocketed coil
spring cores have focused on details of the fabric encasement ¨ such as
altering the length of the
pockets or pre-compressing coils within a pocket -- but with common coil
configurations
throughout, or different coil configurations with variations in wire gauge,
numbers and pitches of
turns, shapes and heights, in different strings of the core. These prior art
designs require
manufacturing strings of identical coils, encasing the coils in the particular
fabric configurations,
and then assembling the strings in an alternating pattern, about a perimeter
or in zones to form
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the finished spring core assembly. Although various pocketed spring core
characteristics and
performance can be achieved in these manners, the manufacture and assembly
thereof is tedious
and expensive.
Summary of the Present Disclosure
[0003] The present disclosure and related inventions provides a pocketed
spring core which in a
preferred embodiment utilizes a common coil configuration and a uniform
encasement or pocket
configuration, and wherein the coils have an asymmetrical configuration and
the vertical end-up
orientation of the coils is alternated or otherwise varied. Selected coils in
different areas or
patterns in the array of pocketed coils that form the spring core are
inverted, relative to a support
surface of the spring core, within the individual pockets. The inverted coils
have spring
characteristics including spring rate, stiffness and initial deflection force
which are different from
the spring characteristics of the non-inverted coils due to the asymmetry of
the coils along a
longitudinal axis. The coil configurations in various alternate embodiments
are generally helical
coil springs with spring bodies which are generally cylindrical (in profile),
conical, hour glass,
barrel shaped or coil-in-coil, Le. a smaller diameter helical coil body formed
continuously with
and inside of a larger diameter helical coil body. The ends of any of these
different types of coil
springs can be of any particular configuration, but in general include wire
form which lies in a
plane generally perpendicular to a longitudinal axis of the helical coil body.
The first and second
ends of the coil may be identically configured, or vary in size or
configuration.
[0004] These and other aspects of the present disclosure and related
inventions are further
described herein with reference to the drawing Figures.
Brief Description of the Figures
[0005] In the accompanying drawing Figures:
[0006] FIG. I is a perspective view of a portion of an embodiment of an
encased asymmetric
coil innerspring of the present disclosure;
[0007] FIG. 2 is a plan view of an embodiment of an encased asymmetric coil
innerspring of the
disclosure with columns of encased asymmetric coils with coil orientation
alternating between
columns;
[0008] FIG, 3 is a perspective view of an encased asymmetric coil of the
present disclosure;
[0009] FIG, 4 is an elevation of an encased asynunetric coil of the present
disclosure;
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[00010] FIG. 5 is an end view of the encased asymmetric coil of FIG, 4;
[00011] FIG. 6 is a plan view of an alternate embodiment of an encased
asymmetric coil
innerspring of the disclosure with zones or sides of an innerspring defined by
encased
asymmetric coils defined by coil orientation;
[00012] FIG. 7 is a plan view of an alternate embodiment of an encased
asymmetric coil
innerspring of the disclosure with zones of an innerspring defined by encased
asymmetric coils
defined by coil orientation;
[00013] FIG. 8 is a plan view of an alternate embodiment of an encased
asymmetric coil
innerspring of the disclosure with perimeter and non-perimeter zones of an
innerspring defined
by encased asymmetric coils defined by coil orientation;
[00014] FIG. 9 is a perspective view of an alternate embodiment of encased
asymmetric
coil of the present disclosure;
[00015] FIG. 10 is an elevation of an alternate embodiment of a portion of
an encased
asymmetric coil innerspring of the present disclosure;
[00016] FIG. 11 is a perspective view of an alternate embodiment of
encased asymmetric
coil of the present disclosure;
[00017] FIG. 12 is an elevation of an alternate embodiment of a portion of
an encased
asymmetric coil innerspring of the present disclosure;
[00018] FIG. 13 is a perspective view of an alternate embodiment of
encased asymmetric
coil of the present disclosure;
[00019] FIG. 14 is a perspective view of an alternate embodiment of
encased asymmetric
coil of the present disclosure;
[00020] FIG. 15 is a perspective view of an alternate embodiment of
encased asymmetric
coil of the present disclosure;
[00021] FIG. 16 is an elevation of an alternate embodiment of a portion of
an encased
asymmetric coil innerspring of the present disclosure.
Detailed Description of Preferred and Alternate Embodiments
[00022] FIG. 1 illustrates a portion of a first embodiment of an encased
asymmetric coil
innerspring, indicated generally at 100 in which each of the coils 10 are
encased or pocketed
within an encasement or pocket 101, which may he formed from fabric or other
flexible material
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in sheet form and bonded together by stitching or adhesive. The encasements
101 are generally
cylindrical and aligned with planar ends 1001 and 1002 to form generally
planar support
surfaces. Continuous bands of encased coils are arranged in a rectangular
array of rows,
indicated at R, and columns, indicated at C, to form an innerspring for a
mattress or other
flexible support structure. in general, in a mattress innerspring, the columns
C of aligned
encased coils are oriented to run in a lengthwise direction between the head
and foot ends of the
mattress, and the rows R of aligned encased coils are oriented to run
transversely between the
longitudinal sides of the mattress. However, as described herein, the
references to columns C
and rows R are representative orientations only and the inventions as
disclosed and claimed are
not limited to any particular arrangement of the encased coils.
[00023] The term "coil" refers to a single coil spring, and is generally
synonymous with
the word "spring". As illustrated in FIGS. 1, 3, 4 and 5, coils 10A and 108
are in the
configuration of generally helical springs which include a helical coil body
11 formed by
multiple turns or helical windings of wire W. a first end 10131 and a second
end 1082. As
shown, the turns or helical windings of the coil body 11 are of varying
diameter, for example
gradually decreasing in diameter from first end 10131 to second end 1082, so
that the coil has a
generally tapered profile as shown in FIG. 4, and the second end /082 is
generally smaller than
first end 10131, As illustrated in this particular coil embodiment, the pitch
or angle of inclination
of the wire through the helical turns may be relatively constant, or may vary
as in later described
embodiments. The diameters of the helical turns and the variation thereof
whether constant or
otherwise is a significant factor in the overall spring rate or stiffness of
the coil, in addition to
other factors such as overall coil height and any pre-compression of the coil
by the encasement.
In this example of an asymmetrical coil body 11 and the differently sized coil
ends 10E31 and
10112, the support characteristics of the coils 10A and 10B as oriented in the
innerspring, for
example with coil ends 1082 and 10A1 being co-planar to form support surface
1001 of the
innerspring, are very different. For example, in the support surface plane
1001, coil end 1082
will have a higher apparent spring rate and stiffer feel than coil end 10A1.
The juxtaposition of
these coils and the respective coil ends in the alternating column
configuration shown in FIG. 2
to define the support plane 1001 creates a unique and novel support surface.
[00024] FIG. 6 illustrates an alternate embodiment of an encased
asymmetric coil
innerspring 200, also referred to as a "core", in which encased asymmetric
coils WA and 1013 as
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previously described (or alternatively other embodiments of encased asymmetric
coils as later
described) are arranged in their respective orientations in groups which
define right and left sides
of the innerspring 200, with coil end 10A1 of coils 10A forming one half of
the planar support
surface 2001, and coil end 10B1 of coils 1013 forming the other half of the
planar support surface
2001. In this embodiment, the two sides of the innerspring 200 will have
perceptibly different
support characteristics and feel when employed as the innerspring or core of a
mattress. This
also enables customization of a mattress by selection and orientation of coils
for each side of the
mattress. This embodiment also lends itself to expeditious or automated
manufacture, for
example by simply inverting the strings of encased coils on one side of the
innerspring, or by use
of two set-ups or lanes of encased coil manufacturing equipment in which the
coil orientation
differs and feeds directly to the designated half or zone of an innerspring.
[00025] FIG. 9 illustrates an alternate embodiment of an encased
asymmetric coil,
indicated generally at 20, which can be utilized in any of the described
encased asymmetric coil
innersprings. The coil 20 has an outer generally helical coil body 21 which
extends between a
first coil end 20131 and a second coil end 20B2. The coil body 21 may be
generally cylindrical
with a generally constant diameter of the helical turns, although the
diameters and number of
turns of the coil body may be varied according to configurations of the coil
forming machinery.
The coil ends 20131 and 20132 may be generally the same diameter or of
different diameters as
illustrated, also by configuration of the coil forming machinery. The coil 20
also includes an
inner helical coil body indicated generally at 22 which is generally co-axial
with the outer coil
body 21 and extends into the interior of the outer coil body 21 from the coil
end 20131. Alternate
embodiments and other aspects and features of this type of coil-in-coil spring
which can be used
in any of the encased asymmetric coil innersprings described herein are
disclosed in commonly
owned U.S. Patent No. 7,908,693, the entire disclosure of which is
incorporated by reference.
[00026] FIG. 10 illustrates a strand of encased coils 20 with alternating
orientation of the
coil ends 20131 and 20132 between the opposed innerspring surfaces 2001 and
2002. In this
embodiment also, due to the different spring characteristics of the coil ends
20131 and 20132, the
alternating orientation of the coils creates a support surface with a novel
hybrid combination of
spring characteristics which act together to define the overall support and
feel of the innerspring
and mattress.
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[00027] FIG. 11 illustrates an alternate embodiment of an encased
asymmetric coil,
indicated generally at 30, which can be utilized in any of the described
encased asymmetric coil
innersprings. The coil 30 has a generally helical coil body 31 which extends
between coil ends
30131 and 30B2. The diameter and pitch of each of the helical turns of the
coil body 31 may be
constant or varied according to the configuration of the coil forming
machinery. The coil ends
30131 and 30132 can be of any particular formation and as illustrated are of
the type with one or
more generally linear segments or offsets which are not aligned or continuous
with the helical
coil body 31, and which may extend beyond a diameter of the coil body 31. The
coil 30 also
includes a non-helical segment indicated at 301 which extends from coil end
30131. The non-
helical segment 301 alters the overall spring rate and characteristics of the
coil 30 and the initial
spring rate and feel of coil end 30B1. Other embodiments of coils with non-
helical segments
proximate either or both ends of the coil, which can be used in any of the
encased asymmetric
innersprings of the present disclosure, are described below with reference to
FIGS. 1345, and
further disclosed in commonly owned US. Patent No. 7,404,223, the entire
disclosure of which
is hereby incorporated by reference.
[000281 FIG. 12 illustrates a strand of encased coils 30 with alternating
orientation of the
coil ends 30131 and 30B2 between the opposed innerspring surfaces 2001 and
2002. In this
embodiment also, due to the different spring characteristics of the coil ends
30131 and 30132, the
alternating orientation of the coils creates a support surface with a novel
hybrid combination of
spring characteristics which act together to define the overall support and
feel of the innerspring
and mattress. Also contributing to the hybrid spring characteristics of the
innerspring is the fact
that the encasement 101 of the strands of coils of both orientations may be
fused or otherwise
attached.
[00029] FIG. 13 illustrates an alternate embodiment of an encased
asymmetric coil,
indicated generally at 40, which can be utilized in any of the described
encased asymmetric coil
innersprings. The coil 40 has a generally helical coil body 41 which extends
between coil ends
40B1 and 40132. The diameter and pitch of each of the helical turns of the
coil body 41 may be
constant or varied according to the configuration of the coil forming
machinery. The coil ends
40131 and 40132 can be of any particular formation and as illustrated are
generally circular and
with a radius greater than that of the coil body 41. The coil 40 also includes
a non-helical
segment indicated at 401 which extends from coil end 40131. The non-helical
segment 401 alters
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the overall spring rate and characteristics of the coil 40 and the initial
spring rate and feel of coil
end 40B1. Either coil end 40131 or 4082 can be oriented within the encasement
101 to lie in the
support plane 2001 or 2002, in any arrangement or alternating arrangement, for
example in the
manner as described with reference to FIG. 12.
[00030] FIG. 14 illustrates an alternate embodiment of an encased
asymmetric coil,
indicated generally at 50, which can be utilized in any of the described
encased asymmetric coil
innersprings. The coil 50 has a generally helical coil body 51 which extends
between coil ends
50131 and 50132. The diameter and pitch of each of the helical turns of the
coil body 51 may be
constant or varied according to the configuration of the coil forming
machinery. The coil ends
50131 and 50132 can be of any particular formation and as illustrated are of
the type with one or
more generally linear segments or offsets which are not aligned or continuous
with the helical
coil body 51, and which may extend beyond a diameter of the coil body 51. The
coil 50 also
includes a non-helical segment indicated at 501 which extends from coil end
50B1. The non-
helical segment 501 alters the overall spring rate and characteristics of the
coil 50 and the initial
spring rate and feel of coil end 50131. Either coil end 508I or 50132 can be
oriented within the
encasement 101 to lie in the support plane 2001 or 2002, in any arrangement or
alternating
arrangement, for example in the manner as described with reference to FIG. 12.
[00031] FIG. 15 illustrates an alternate embodiment of an encased
asymmetric coil,
indicated generally at 60, which can be utilized in any of the described
encased asymmetric coil
innersprings. The coil 60 has a generally helical coil body 61 which extends
between coil ends
60131 and 60B2. The diameter and pitch of each of the helical turns of the
coil body 61 may be
constant or varied according to the configuration of the coil forming
machinery, to produce a coil
body which generally cylindrical (equal diameter turns), hourglass (smaller
diameter
intermediate turns) or barrel-shaped (larger diameter intermediate turns). The
coil ends 60131
and 60132 can be of any particular formation and as illustrated are generally
circular and with a
radius equal to or less than that of the coil body 61. The coil 60 also
optionally includes a non-
helical segment indicated at 601 which extends from coil end 60B1. The non-
helical segment
601 alters the overall spring rate and characteristics of the coil 60 and the
initial spring rate and
feel of coil end 60/31. Either coil end 60131 or 60132 can be oriented within
the encasement 101
to lie in the support plane 2001 or 2002, in any arrangement or alternating
arrangement, for
example in the manner as described with reference to FIG. 12.
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[00032] Any of the described asymmetric coil configurations can be
modified in order to
achieve any desired form of asymmetry. For example, FIG. 16 illustrates
asymmetric coils 70 in
which a generally helical coil body 71 is formed by multiple helical turns or
wire in which the
pitch or angle of the helix is varied among the turns, as illustrated. In
general, the smaller the
pitch turns, such as those proximate to coil end 70B1, produce a lower spring
rate and softer
support characteristic, and the larger pitch turns such as those proximate to
coil end 70B2
produce a higher spring rate and firmer support characteristic. The coils 70
are illustrated in an
alternating orientation arrangement in an encased strand as the innerspring or
core of a mattress
with at least one layer of overlying foam F and upholstery U. for example over
support surface
2001.
[00033] FIG. 7 illustrates an alternate embodiment of an encased
asymmetric coil
innerspring 300 in which encased asymmetric coils, including any of the coils
10, 20, 30, 40, 50,
60 or 70 and variants thereof, are in an alternating arrangement with coils in
a first orientation A
in selected rows and coils in a second orientation, e.g. 180 degree or upside-
down orientation,
across a width dimension of an innerspring as illustrated. This width-wise
zoning of the
innerspring 300 is beneficial for optimizing support of a mattress in higher
pressure zones such
as the head, shoulder and lumbar areas. The width-wise row patterns of
alternating coil
orientations may be equally spaced from head to foot, or not.
[00034] FIG. 8 illustrates an alternate embodiment of an encased
asymmetric coil
innerspring 400 in which encased asymmetric coils, including any of the coils
10, 20, 30, 40, 50,
60 or 70 and variants thereof, are in an alternating arrangement with coils in
a first orientation A
at the longitudinal perimeters of the innerspring and coils in a second
orientation, e.g. 180 degree
or upside-down orientation, in the central region of the innerspring.
Preferably, the coils of
orientation A have a higher spring rate in order to create a firmer support
surface alone the
longitudinal edges of a mattress support surface.
[00035] The production of any of the described coils and coil arrangements
can be manual
or automated by appropriate configuration of coil forming and pocketed coil
manufacturing
machinery. The coil orientation within its encasement 101 can be determined by
coil handling
machinery between a coil former and transition to automated equipment which
handles the
encasement material to receive coils and forms the individual encasements
between coils. A
single coil forming machine can be used and the coils then oriented
accordingly prior to closure
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of the encasement material. Alternatively, when two coil forming machines are
employed, one
can be configured to deliver coils for encapsulation in the opposite
orientation. In a continuous
coil production operation, coils can be fed from one or two coil forming
machines to a coil
encapsulation mechanism and the orientation of the coil changed in a
continuous feed operation
so that a single strand of coils may include coils with first and second or
inverted orientations.
The single strand containing coils with first and second orientations can then
be assembled or
arranged as desired to form the core. For simple manual assembly, uniformly
completed strands
of coils can be simply cut to length and placed in the desired orientation in
a desired row or
column of an innerspring array. Also as noted a single innerspring may contain
two or more
types of encased asymmetric coils in either orientation and in any pattern..
[00036] The foregoing descriptions of various embodiments of the
disclosure and related
inventions are representative of ways in which the inventions may be realized
and are not
otherwise limiting to the scope of the following claims.
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