Note: Descriptions are shown in the official language in which they were submitted.
POCKETED SPRING COMFORT LAYER AND METHOD OF MAKING SAME
[0001] Continue to [0002].
Technical Field of the Invention
[0002] 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.
Background of the Invention
[0003] 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. Patent 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 together or multiple coil
springs joined
together by helical lacing wires.
[0004] 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.
[0005] 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. Patent No. 7,636,972 discloses such a pocketed spring core.
[0006] 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
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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.
[0007] 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.
[0008] Still another objective of this invention has been to provide one or
more
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.
Summary of the Invention
[0009] 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.
[0010] 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.
[0011] When a load is applied to a comfort layer made with semi-impermeable
fabric, the rate of deflection of the comfort layer is retarded by the rate at
which air
escapes through the semi-impermeable fabric within which the pocketed springs
are
contained and by the rate at which air travels between segments of seams
separating
individual pockets.
[0012] When a load is applied to the comfort layer made with impermeable
fabric,
the rate of deflection of the comfort layer is retarded only by the rate at
which air
escapes or travels between segments of 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
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control airflow within the comfort layer. The length 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.
[0013] Any of the embodiments of comfort layer shown or described herein
may
be incorporated into a bedding product, such as a mattress, 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.
[0014] 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.
[0015] 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.
[0016] According to another aspect of the present invention, a method of
manufacturing a comfort layer for 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 method comprises forming a continuous blanket of individually
pocketed springs, each spring of which is contained within a pocket of fabric,
the pocket
of fabric being semi-impermeable to airflow through said fabric. The
continuous blanket
of individually pocketed springs is cut to a desired size after passing
through a machine,
which inserts multiple springs between two plies of fabric and joins the
fabric plies along
segmented seams around the perimeter of each of the springs in a row or group.
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[0017] The comfort layer is characterized, when a load is applied to the
comfort
layer, by the rate of deflection of the comfort layer being retarded by the
rate at which
air escapes through the semi-impermeable fabric within which the pocketed
springs are
contained and by the rate at which air travels between individual pockets. The
comfort
layer is further characterized by the rate of recovery of the comfort layer to
its original
height after removal of a load from the comfort layer being retarded by the
rate at which
air returns through the semi-impermeable fabric into the pockets within which
compressed springs are contained and by the rate at which air travels between
individual pockets. The rate at which air travels between individual pockets
is
determined by the size of gaps between the segments of seams separating
adjacent
pockets. Around the perimeter of the comfort layer, air enters and exits the
interior of
the comfort layer through gaps between the segments of the perimeter seams of
the
comfort layer. By constructing a comfort layer with gaps of a predetermined
size, the
airflow into and out of the comfort layer may be controlled. The airflow into
and out of
the comfort layer is further dependent upon the type of fabric used to
construct the
comfort layer.
[0018] The method of manufacturing a comfort layer for a bedding or seating
product may comprise the following steps. The first step comprises forming a
continuous blanket of individually pocketed springs, each of the springs being
surrounded by a segmented seam which allows airflow through the seam. The
continuous blanket of individually pocketed springs may be later cut to a
desired size.
Each spring is contained within a pocket having a seam comprising multiple
segments.
The pocket is semi-impermeable to airflow through the pocket due to gaps
between the
segments of the seams forming the pockets. The comfort layer is characterized
by slow
and gentle compression when a load is applied to the comfort layer. When a
load is
placed upon the comfort layer and then removed, the rate of return of the
comfort layer
to its original height is retarded by the rate at which air returns through
the semi-
impermeable pockets within which the springs are contained.
[0019] The fabric from which the pockets are made may be wholly or
partially
made of fabric non-permeable or impermeable to airflow. In such a situation,
the air
entering and exiting the pockets is limited by the air which flows through
gaps between
segments of seams surrounding the springs.
[0020] The fabric from which the pockets are made may be wholly or
partially
made of fabric semi-impermeable to airflow. In such a situation, the air
entering and
exiting the pockets is limited by the air, not only which flows through gaps
between
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segments of seams surrounding the springs, but also by air which flows through
the
fabric. Regardless of which fabric is used to make the plies, by controlling
the airflow
into and out of the individual pockets, the rate of recovery of the comfort
layer, when a
load is removed, may be different than the rate of entry of air into the
pockets when a
load is applied.
[0021] By restricting airflow through the seams of a pocketed spring
comfort
layer, a manufacturer of the comfort layer may create a comfort layer with a
luxury feel
without using any foam in a cost effective manner.
[0022] These and other objects and advantages of this invention will be
more
readily apparent from the following drawings, in which:
Brief Description of the Drawings
[0023] Fig. 1 is a perspective view, partially broken away, of a bedding
product
incorporating one of the comfort layers of this invention;
[0024] Fig. 2 is a perspective view of the comfort layer of Fig. 1 being
manufactured;
[0025] Fig. 2A is a perspective view of a portion of the machine of Fig. 2,
the coil
springs being inserted into predetermined positions;
[0026] Fig. 3A is a cross-sectional view of a beginning portion of the
manufacturing process using the machine of Figs. 2 and 2A;
[0027] Fig. 3B is a cross-sectional view of the springs being compressed in
the
manufacturing process using the machine of Figs. 2 and 2A;
[0028] Fig. 3C is a cross-sectional view of the springs being laterally
moved in the
manufacturing process using the machine of Figs. 2 and 2A;
[0029] Fig. 3D is a cross-sectional view of the upper ply of fabric being
moved in
the manufacturing process using the machine of Figs. 2 and 2A;
[0030] Fig. 3E is a cross-sectional view of one of the springs being sealed
in the
manufacturing process using the machine of Figs. 2 and 2A;
[0031] Fig. 4 is an enlarged perspective view of a portion of the comfort
layer of
Fig. 1 partially disassembled and showing a portion of a welding tool;
[0032] Fig. 4A is an enlarged perspective view of a portion of the comfort
layer of
Fig. 1 partially disassembled and showing a portion of another welding tool;
[0033] Fig. 5 is a top plan view of a portion of the comfort layer of Fig.
1, the
arrows showing airflow inside the comfort layer;
[0034] Fig. 5A is a cross-sectional view taken along the line 5A-5A of Fig.
5;
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[0035] Fig. 5B is an enlarged cross-sectional view of an alternative
embodiment
having a different fabric;
[0036] Fig. 6 is a top plan view of a portion of another comfort layer, the
arrows
showing airflow inside the comfort layer;
[0037] Fig. 6A is a cross-sectional view taken along the line 6A-6A of Fig.
6;
[0038] Fig. 7 is a perspective view, partially broken away, of a bedding
product
incorporating another embodiment of comfort layer in accordance with the
present
invention;
[0039] Fig. 8 is a perspective view of the comfort layer of Fig. 7 being
manufactured;
[0040] Fig. 9 is an enlarged perspective view of a portion of the comfort
layer of
Fig. 7 partially disassembled and showing a portion of a welding tool;
[0041] Fig. 9A is an enlarged perspective view of a portion of the comfort
layer of
Fig. 7 partially disassembled and showing a portion of another welding tool;
[0042] Fig. 10 is a top plan view of a portion of the comfort layer of Fig.
7, the
arrows showing airflow inside the comfort layer;
[0043] Fig. 10A is a cross-sectional view taken along the line 10A-10A of
Fig. 10;
[0044] Fig. 10B is an enlarged cross-sectional view of an alternative
embodiment
having a different fabric;
[0045] Fig. 11 is a top plan view of a corner portion of the comfort layer
of Fig. 1,
the arrows showing airflow into and out of the comfort layer;
[0046] Fig. 11A is a top plan view of a corner portion of the comfort layer
of Fig.
7, the arrows showing airflow into and out of the comfort layer;
[0047] Fig. 12 is a top plan view of a corner portion of another embodiment
of
comfort layer;
[0048] Fig. 12A is a top plan view of a corner portion of another
embodiment of
comfort layer;
[0049] Fig. 13A is a perspective view of a posturized comfort layer; and
[0050] Fig. 13B is a perspective view of another posturized comfort layer.
Detailed Description of the Drawings
[0051] With reference to Fig. 1, there is illustrated a single-sided
mattress 10
incorporating one embodiment of comfort layer in accordance with this
invention. This
mattress 10 comprises a spring core 12 over the top of which there is a
conventional
cushioning pad 14 which may be partially or entirely made of foam or fiber or
gel, etc.
The cushioning pad 14 may be covered by a comfort layer 16 constructed in
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accordance with the present invention. A second conventional cushioning pad 14
may
be located above the comfort layer 16. In some applications, one or both of
the
cushioning pads 14 may be omitted. This complete assembly may be mounted upon
a
base 18 and is completely enclosed within an upholstered cover 20.
[0052] As shown in Fig. 1, mattress 10 has a longitudinal dimension or
length L,
a transverse dimension or width W and a height H. Although the length L is
shown as
being greater than the width W, they may be identical. The length, width and
height
may be any desired distance and are not intended to be limited by the
drawings.
[0053] 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 and/or the product's pocketed core.
[0054] Although spring 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 Figs. 7 and 14), one or more foam pieces (not shown) or any
combination
thereof. Any of the comfort layers described or shown herein may be used in
any single
or double-sided bedding or seating product having any conventional core. The
core
may be any conventional core including, but not limited to, pocketed or
conventional
spring cores.
[0055] Fig. 4 illustrates the components of one embodiment of comfort layer
16
incorporated into the mattress 10 shown in Fig. 1. The comfort layer 16
comprises a
first or upper ply of fabric 22 and a second or lower ply of fabric 24 with a
plurality of
mini coil springs 28 therebetween. The fabric plies 22, 24 are joined together
with
circular containments or seams 30, each seam 30 surrounding a mini coil spring
28.
Each circular containment or seam 30 comprises multiple arced or curved weld
segments 26 with gaps 31 therebetween. The first and second plies of fabric
22, 24 are
joined together along each arced or curved weld segment 26 of each circular
containment or seam 30. The first and second plies of fabric 22, 24 are not
joined
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together along each gap 31 between adjacent weld segments 26 of each circular
containment or seam 30. The curved weld segments 26 are strategically placed
around
a mini coil spring 28 and create the circular containment or seam 30. The two
plies of
fabric 22, 24, in combination with one of the the circular weld seams 30,
define a
cylindrical-shaped pocket 44, inside of which is at least one resilient member
such as a
mini coil spring 28. See Figs. 5 and 5A.
[0056] 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.
[0057] The size of
the curved weld segments 26 of seams 30 are 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
seams 30, is not intended to be limiting. The placement of the seams 30 shown
in the
drawings is not intended to be limiting either. For example, the seams 30 may
be
organized into aligned rows and columns, as shown in Figs. 5 and 5A or
organized with
adjacent columns being offset from each other, as illustrated in Figs. 6 and
6A. Any
desired arrangement of seams may be incorporated into any embodiment shown or
described herein.
[0058] The weld
segments may assume shapes other than the curved weld
segments illustrated. For example, the welds or 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.
[0059] 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.
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[0060] With reference to Fig. 4, there is illustrated a portion of a mobile
ultrasonic
welding horn 32 and anvil 42. The movable ultrasonic welding horn 32 has a
plurality of
spaced cut-outs or slots 34 along its lower edge 36. The remaining portions 38
of the
ultrasonic welding horn's bottom 36 between the slots 34 are the portions
which weld
the two pieces of fabric 22, 24 together and create the curved weld segments
26. Along
the ultrasonic welding horn's bottom edge 36, the ultrasonic welding horn 32
can be
milled to make the slots a desired length to allow a desired airflow between
the curved
weld segments 26 as illustrated by the arrows 40 of Fig. 5. The airflows
affect the
feel/compression of the individually pocketed mini coil springs 28 when a user
lays on
the mattress 10.
[0061] As shown in Fig. 4, underneath the second ply 24 is an anvil 42
comprising a steel plate of 318th inch thickness. However, the anvil may be
any desired
thickness. During the manufacturing process, the ultrasonic welding horn 32
contacts
the anvil 42, the two plies of fabric 22, 24 therebetween, to create the
circular weld
seams 30 and hence, cylindrical-shaped pockets 44, at least one spring being
in each
pocket 44.
[0062] 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.
[0063] Fig. 4A illustrates another apparatus for forming the circular weld
seams
30 comprising multiple curved weld segments 26 having gaps 31 therebetween for
airflow. In this apparatus, the ultrasonic welding horn 32a has no protrusions
on its
bottom surface 39. Instead, the bottom surface 39 of ultrasonic welding horn
32a is
smooth. As shown in Fig. 4A, the anvil 42a has a plurality of curved
projections 41,
which together form a projection circle 43. A plurality of projection circles
43 extend
upwardly from the generally planar upper surface 45 of anvil 42a. When the
ultrasonic
welding horn 32a moves downwardly and sandwiches the plies 22, 24 of fabric
between
one of the projection circles 43 and the smooth bottom surface 39 of
ultrasonic welding
horn 32a, a circular weld seam 30 is created, as described above. Thus, a
plurality of
pockets 44 are created by the circular weld seams 30, each pocket 44
containing at
least one mini coil spring 28.
[0064] 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
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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 weld 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 weld
segments
26 of the circular weld seams 30. As shown in Fig. 5, the size of the gaps 31
between
the segments 26 of circular seams 30 of perimeter pockets 44 defines how
quickly air
may enter or exit the comfort layer 16.
[0065] 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 weld 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.
[0066] As best illustrated in Fig. 5, the individual pockets 44 of comfort
layer 16
may be arranged in longitudinally extending columns 46 extending from head-to-
foot of
the bedding product and transversely extending rows 48 extending from side-to-
side of
the bedding product. As shown in Figs. 5 and 5A, the individual pockets 44 of
one
column 46 are aligned with the pockets 44 of adjacent columns 46.
[0067] Fig. 5B illustrates a portion of an alternative embodiment of
comfort layer
16b. In this embodiment, the fabric material of each of the first and second
plies 23,2
may be a three-layered fabric impermeable to airflow. Each ply of fabric 23,
25
comprises three layers, including from the inside moving outwardly: 1) a
protective
layer of fabric 27; 2) an airtight layer 29; and 3) a sound attenuating or
quieting layer 33.
More specifically, the protective layer of fabric 27 may be a polypropylene
non-woven
fabric having a density of one ounce per square yard. The airtight layer 29
may be a
thermoplastic polyurethane film layer having a thickness of approximately 1.0
mil (0.001
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inches). The sound attenuating layer 33 may be a lofted polyester fiber
batting having a
density of 0.5 ounces per square foot. These materials and material
specifications,
such as the densities provided for the outer layers, have proven to be
effective, but are
not intended to be limiting. For example, the thickness of the impermeable
middle layer
of thermoplastic polyurethane film may vary depending upon the desired
characteristics
of the multi-layered fabric. The fiber batting layer need not be made of
polyester; it may
be made of other materials. Similarly, the fiber batting layer need not be
lofted.
[0068] 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,
Georgia;
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, Connecticut; 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, South Carolina. 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 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.
[0069] 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 together.
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[0070] 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 piece of material.
[0071] Figs. 6 and 6A illustrate another comfort layer 50 having the same
pockets
44 and same springs 28 as does the embodiment of comfort layer 16 of Figs. 1-
5A. As
best illustrated in Fig. 6, the individual pockets 44 of comfort layer 50 are
arranged in
longitudinally extending columns 52 extending from head-to-foot of the bedding
product
and transversely extending rows 54 extending from side-to-side of the bedding
product.
As shown in Figs. 6 and 6A, the individual pockets 44 of one column 52 are
offset from,
rather than aligned with, the pockets 44 of the adjacent columns 52.
[0072] Fig. 7 illustrates an alternative embodiment of comfort layer 56
incorporated into a single-sided mattress 60. Single-sided mattress 60
comprises a
pocketed spring core 62, a cushioning pad 14 on top of the pocketed spring
core 62, a
base 18, another cushioning pad 14 above comfort layer 56, and an upholstered
covering material 20. Pocketed spring core 62 may be incorporated into any
bedding or
seating product, including a double-sided mattress, and is not intended to be
limited to
single-sided mattresses. As described above, comfort layer 56 may be used in
any
conventional core, including a spring core made with non-pocketed conventional
springs, such as coil springs.
[0073] As shown in Fig. 7, mattress 60 has a longitudinal dimension or
length L,
a transverse dimension or width W and a height H. Although the length L is
shown as
being greater than the width W, they may be identical. The length, width and
height
may be any desired distance and are not intended to be limited by the
drawings.
[0074] Fig. 9 illustrates the components of the comfort layer 56
incorporated into
the mattress 60 shown in Fig. 7. The comfort layer 56 comprises a first ply of
fabric 64
and a second ply of fabric 66 joined together with multiple linear weld
segments 68.
These weld segments 68 are strategically placed around a mini coil spring 28
and
create a rectangular containment or seam 70. During the welding process, the
mini coil
springs 28 may be compressed. The length and/or width of the linear weld
segments
68 of seams 70 is not intended to be limited to those illustrated; they may be
any
desired size depending upon the airflow desired through the comfort layer.
Similarly,
the size of the illustrated seams 70 is not intended to be limiting. Shapes
other than
linear weld segments may be used to create rectangular seams. Such shapes may
include, but are not limited to, triangles or circles or ovals of any desired
size and
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pattern to obtain the desired airflow between adjacent pockets and into or out
of the
perimeter of the comfort layer.
[0075] With reference to Fig. 9, there is illustrated a portion of an
ultrasonic
welding horn 72 and anvil 74. The mobile or movable ultrasonic welding horn 72
has a
plurality of spaced cut-outs or slots 76 between projections 80. The
projections 80 of
the ultrasonic welding horn 72 are the portions which weld the two pieces of
fabric 64,
66 together and create the linear weld segments 68 in rectangular weld seams
70.
Along the ultrasonic welding horn's lower portion 78, the ultrasonic welding
horn 72 can
be milled to allow a desired airflow between the linear weld segments 68 as
illustrated
by the arrows 82 of Fig. 7. The airflows affect the feel/compression of the
individually
pocketed mini coil springs 28 when a user lays on the mattress 60.
[0076] As shown in Fig. 9, underneath the second ply 66 is an anvil 74
comprising a steel plate of 318th inch thickness. However, the anvil may be
any desired
thickness. During the manufacturing process, the ultrasonic welding horn 72
contacts
the anvil 74, the two plies of fabric 64, 66 being therebetween, to create the
rectangular
weld seams 70 and, hence, pockets 84, at least one spring 28 being in each
pocket 84.
See Figs. 10 and 10A.
[0077] These linear weld segments 68 may be created by the welding horn 72
of
a machine (shown in Fig. 8 and described below) having multiple spaced
protrusions 80
on the ultrasonic welding horn 72. As a result of these rectangular weld seams
70
defining the spring-containing pockets 84 of the comfort layer 56, each mini
coil spring
28 is contained within its own individual pocket 84. Air exits the pocket 84
through gaps
77 between the weld segments 68 of the rectangular weld seams 30. Similarly,
when a
load is removed from the pocket 84, the mini coil spring 28 separates the
fabric layers
64, 66, and air re-enters the pocket 84 though the gaps 77 between the weld
segments
68 of the rectangular weld seams 70. As shown in Fig. 10, the size of the gaps
77
between the segments 68 of rectangular weld seams 70 of the pockets 84 defines
how
quickly air may enter or exit the comfort layer 56.
[0078] Fig. 9A illustrates another apparatus for forming the rectangular
weld
seams 70 comprising multiple linear weld segments 68 having gaps 77
therebetween
for airflow. In this apparatus, the ultrasonic welding horn 72a has no
protrusions on its
bottom surface 79. Instead, the bottom surface 79 of ultrasonic welding horn
72a is
smooth. The anvil 74a has a plurality of linear projections 71, which together
form a
projection pattern 73, shown in Fig. 9A. A plurality of spaced projections 71
in pattern
73 extend upwardly from the generally planar upper surface 75 of anvil 74a.
When the
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ultrasonic welding horn 72a moves downwardly and sandwiches the plies 64, 66
of
fabric between the projections 71 and the smooth bottom surface 79 of
ultrasonic
welding horn 72a, rectangular weld seams 70 are created. Thus, a plurality of
pockets
84 are created by the rectangle weld seams 70, each pocket 84 containing at
least one
mini coil spring 28.
[0079] 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 Figs. 10 and 11A, until the air exits the perimeter pockets 84
into the
atmosphere, as shown in Fig. 11A. Due to such fabric material being
impermeable to
air, the rate at which the mini springs 28 compress when a load is applied to
a pocketed
spring core comfort layer 56 containing the mini coil springs 28 is slowed or
retarded by
the size of the gaps 77 between the linear weld segments 68 of rectangular
weld seams
70. Upon removal of the load, the rate of return of the spring comfort layer
56 to its
original height depends upon the mini coil springs 28 in the pockets 84
returning to their
original height, causing separation of the layers of fabric, drawing air into
the pockets 84
through the gaps 77 between the linear weld segments 68 of rectangular weld
seams
70.
[0080] 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.
[0081] 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,
14
including one layer of woven fabric as, for example, a material available from
Hanes Industries
of Conover, North Carolina 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.
[0082] 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, North
Carolina described
above was measured. The results ranged between 0.029-0.144 cubic feet per
minute.
[0083] 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. Patent
Nos.
7,636,972; 8,136,187; 8,474,078; 8,484,487 and 8,464,381. 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 so as to make the
fabric semi-
impermeable to airflow as described hereinabove.
[0084] Fig. 10B illustrates a portion of an alternative embodiment of
comfort layer 56b.
In this embodiment, the fabric material of each of the first and second plies
65, 67 may be the
same three-layered fabric impermeable to airflow shown in Fig. 5B and
described above. This
three-layered fabric impermeable to airflow may be used in any embodiment
shown or
described herein, including for any pocketed spring core. Each ply of fabric
65, 67 comprises
three layers, including from the inside moving outwardly: 1) a protective
layer of fabric 27; 2)
an airtight layer 29; and 3) a sound attenuating or
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quieting layer 33. If desired, the protective layer of fabric 27 may be
omitted. More
specifically, the protective layer of fabric 27 may be a polypropylene non-
woven fabric
having a density of one ounce per square yard. The airtight layer 29 may be a
thermoplastic polyurethane film layer having a thickness of approximately 1.0
mil (0.001
inches). The sound attenuating layer 33 may be a lofted polyester fiber
batting having a
density of 0.5 ounces per square foot. These materials and material
specifications, such
as the densities provided for the outer layers, have proven to be effective,
but are not
intended to be limiting. For example, the thickness of the middle layer 29
impermeable
to airflow may vary depending upon the desired characteristics of the multi-
layered
fabric. The fiber batting layer need not be made of polyester; it may be made
of other
materials. Similarly, the fiber batting layer need not be lofted.
[0085] 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,
Georgia;
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, Connecticut; 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, South Carolina. 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.
[0086] 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
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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 together 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.
[0087] As best illustrated in Fig. 10, the individual pockets 84 of comfort
layer 56
may be arranged in longitudinally extending columns 86 extending from head-to-
foot of
the bedding product and transversely extending rows 88 extending from side-to-
side of
the bedding product. As shown in Figs. 10 and 10A, the individual pockets 84
of one
column 86 are aligned with the pockets 84 of the adjacent columns 86. Air may
flow
between pockets 84 and into and out of the comfort layer 56 between the linear
segments 68 of seams 70.
[0088] Fig. 11 illustrates one corner of comfort layer 16 of mattress 10
showing
airflow between the curved weld segments 26 of the peripheral pockets 44, as
illustrated by the arrows 40. Although Fig. 11 illustrates the arrows 40 only
on one
corner pocket 44, each of the pockets 44 around the periphery of the comfort
layer 16
allows airflow through the gaps 31 between the weld segments 26 of circular
seams 30.
This airflow controls the amount of air entering the comfort layer 16 when a
user
changes position or gets off the bedding or seating product, thus allowing the
springs 28
in the pockets 44 to expand and air to flow into the comfort layer 16.
Similarly, when a
user gets onto a bedding or seating product, the springs 28 compress and cause
air to
exit the pockets 44 around the periphery of the comfort layer 16 and exit the
comfort
layer. The amount of air exiting the comfort layer 16 affects the
feel/compression of the
individually pocketed mini coil springs 28 when a user lays on the mattress
10.
[0089] Fig. 11A illustrates one corner of comfort layer 56 of mattress 60
of Fig. 7
showing airflow between the weld segments 68 of the peripheral pockets 84, as
illustrated by the arrows 82. Although Fig. 11A illustrates the arrows 82 only
on one
corner pocket 84, each of the pockets 84 around the periphery of the comfort
layer 56
allows airflow through the gaps 77 between the weld segments 68 of rectangular
seams
70. This airflow controls the amount of air entering the comfort layer 56 when
a user
changes position or gets off the bedding or seating product, thus allowing the
springs 28
in the pockets 84 to expand and air to flow into the comfort layer 56.
Similarly, when a
user changes position or gets onto a bedding or seating product, the springs
28
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compress and cause air to exit the pockets 84 around the periphery of the
comfort layer
16 and exit the comfort layer. The amount of air exiting the comfort layer 56
affects the
feel/compression of the individually pocketed mini coil springs 28 when a load
is applied
to the mattress 10.
[0090] Fig. 12 illustrates one corner of an alternative embodiment of
comfort
layer 16a, which may be used in any bedding or seating product. The comfort
layer 16a
comprises aligned rows 48 and columns 46 of pockets 44a, each pocket 44a
comprising a circular seam 30a joining upper and lower plies of fabric, as
described
above. However, each of the circular seams 30a is a continuous seam, as
opposed to
a seam having curved weld segments with gaps therebetween to allow airflow
through
the circular seam. These circular seams 30a of pockets 44a allow no airflow
through
the seams 30a. Therefore, the fabric material of the first and second plies of
pockets
44a of comfort layer 16a must be made of semi-impermeable material to manage
or
control airflow into and out of the pockets 44a of comfort layer 16a. The type
of
material used for comfort layer 16a solely controls the amount of air entering
the
comfort layer 16a when a user gets off the bedding or seating product, thus
allowing the
springs 28 in the pockets 44a to expand and air to flow into the comfort layer
16a.
Similarly, when a user gets onto a bedding or seating product, the springs 28
compress
and cause air to exit the pockets 44a of the comfort layer 16a and exit the
comfort layer.
The amount of air exiting the comfort layer 16a affects the feel/compression
of the
individually pocketed mini coil springs 28 when a user lays on the product
incorporating
the comfort layer 16a.
[0091] Fig. 12A illustrates one corner of an alternative embodiment of
comfort
layer 56a, which may be used in any bedding or seating product. The comfort
layer 56a
comprises aligned rows 88 and columns 86 of pockets 84a, each pocket 84a
comprising a rectangular seam 70a joining upper and lower plies of fabric as
described
above. However, each of the rectangular seams 70a is a continuous seam, as
opposed
to a seam having weld segments with gaps therebetween to allow airflow through
the
seam. These rectangular seams 70a of pockets 84a allow no airflow through the
seams 70a. Therefore, the fabric material of the first and second plies of
pockets 84a
of comfort layer 56a must be made of semi-impermeable material to allow some
airflow
into and out of the pockets 84a of comfort layer 56a. The type of material
used for
comfort layer 56a solely controls the amount of air entering the comfort layer
56a when
a user gets off the bedding or seating product, thus allowing the springs 28
in the
pockets 84a to expand and air to flow into the comfort layer 56a. Similarly,
when a user
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gets onto a bedding or seating product, the springs 28 compress and cause air
to exit
the pockets 84a of the comfort layer 56a and exit the comfort layer. The
amount of air
exiting the comfort layer 56a affects the feel/compression of the individually
pocketed
mini coil springs 28 when a user lays on the product incorporating the comfort
layer
56a.
[0092] Fig. 2 illustrates a machine 90 used to make several of the comfort
layers
shown and disclosed herein, including comfort layer 16 shown in Fig. 1. Some
parts of
the machine 90 may be changed to make other comfort layers shown or described
herein, such as comfort layer 56 shown in Fig. 7. Machine 90 comprises a pair
of
ultrasonic welding horns 32, and at least one stationary anvil 42, as shown in
Fig. 4.
Alternatively, ultrasonic welding horns 32a and anvil 42a of Fig. 4A may be
used in the
machine.
[0093] 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 Fig. 2) until the mini coil springs 28 are located
in
predetermined locations, at which time the conveyor 92 stops moving. Machine
90
further discloses several actuators 96, which move a pusher assembly 97,
including a
pusher plate 98 in the direction of arrow 100. Although two actuators 96 are
illustrated
in Figs. 2 and 2A, any number of actuators 96 of any desired configuration may
be used
to move the pusher assembly 97. The pusher plate 98 has a plurality of spaced
spring
pushers 102 secured to the pusher plate 98 underneath the pusher plate 98. The
spring pushers 102 push the mini coil springs 28 between stationary guides 104
from a
first position shown in Fig. 2 to a second position shown in Fig. 4 in which
the mini coil
springs 28 are located above the stationary anvil 42 (or above the alternative
anvil 42a
shown in Fig. 4A). Fig. 2A illustrates the mini coil springs 28 being
transported from the
first position to the second position, each mini coil spring 28 being
transported between
adjacent stationary guides 104. The stationary guides 104 are secured to a
stationary
mounting plate 106.
[0094] 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 Figs. 2 and 2A, any number of lifters 110 of any desired
configuration
may be used to move the compression plate 108.
[0095] As best shown in Fig. 2, machine 90 further comprises three pressers
112
movable between raised and lowered positions via actuators 116. Figs. 3B and
3C
show one of the pressers 112 in a raised position, while Figs. 3A, 3D and 3E
show the
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presser in a lowered position. Each presser has a blade 114 at the bottom
thereof for
bringing the plies 22, 24 of fabric together when the presser is lowered, as
shown in
Figs. 3A, 3D and 3E.
[0096] As best shown in Fig. 3A, machine 90 further comprises rollers 120,
122
around which the plies, 22, 24, respectively, pass before they come together.
After the
circular seams 30 are created by the ultrasonic welding horn 32 and anvil 42,
thereby
creating the pockets 44, a main roller 116 and secondary roller 118 pull the
continuous
spring blanket 124 downwardly. Once a desired amount of continuous spring
blanket
124 is made, a blade 126 cuts the continuous spring blanket 120 to create
comfort layer
16 of the desired size. Of course, the machine 90 may be programmed to create
the
desired length and width of comfort layer. This machine 90 is adapted to make
any of
the comfort layers shown or disclosed herein having circular weld seams.
[0097] Fig. 3A illustrates the ultrasonic welding horn 32 in a lowered
position
contacting the stationary anvil 42 with at least one of the pressers 112 in a
lowered
position pressing the upper ply 22 into contact with the lower ply 24. A new
row of mini
coil springs 28 has been moved into a loading position with the compression
plate 108
in its raised position.
[0098] Fig. 3B illustrates the ultrasonic welding horn 32 in a raised
position
spaced from the anvil 42 with at least one of the pressers 112 in a raised
position. The
compression plate 108 is moved to its lowered position by lifters 110, thereby
compressing the row of mini coil springs 28 located on the conveyor 92.
[0099] Fig. 30 illustrates the row of compressed mini coil springs 28
located on
the conveyor 92 being pushed downstream towards the ultrasonic welding horn 32
and
stationary anvil 42 by the pusher assembly 97. More particularly, the pushers
102
secured to the pusher plate 98 contact the compressed mini coil springs 28 and
move
them downstream between the stationary guides 104 and past the raised pressers
112.
[00100] Fig. 3D illustrates the pusher assembly 97 being withdrawn in the
direction
of arrow 128. Additionally, the pressers 112 are moved to a lowered position,
pressing
the upper ply 22 into contact with the lower ply 24. Also, the compression
plate 108 is
moved to its raised position by lifters 110.
[00101] Fig. 3E illustrates the ultrasonic welding horn 32 in a lowered
position
contacting the stationary anvil 42 with at least one of the pressers 112 in a
lowered
position pressing the upper ply 22 into contact with the lower ply 24. A new
row of mini
coil springs 28 has been moved by the conveyor 92 into a position in which
they may be
compressed with the compression plate 108 during the next cycle.
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[00102] Fig. 8 illustrates a machine 130, like the machine 90 shown in
Figs. 2 and
2A. However, instead of having two ultrasonic welding horns 32, machine 130
has four
ultrasonic welding horns 72 along with anvil 74. Alternatively, ultrasonic
welding horns
72a and anvil 74a of Fig. 9A may be used in machine 130. This machine 124 is
adapted to make any of the comfort layers shown or disclosed herein having
rectangular weld seams, as opposed to circular weld seams.
[00103] Fig. 13A illustrates a posturized comfort layer 132 having three
different
areas or regions of firmness depending upon the airflow within each of the
areas or
regions. The comfort layer 132 has a head section 134, a foot section 136 and
a
lumbar or middle section 138 therebetween. The size and number of segments in
the
seams, along with the type of material used to construct the posturized
comfort layer
132, may be selected so at least two of the sections may have a different
firmness due
to different airflows within different sections. Although three sections are
illustrated in
Fig. 13A, any number of sections may be incorporated into a posturized comfort
layer.
Although each of the sections is illustrated being a certain size, they may be
other
sizes. The drawings are not intended to be limiting. Although Fig. 13A shows
each of
the segmented seams of comfort layer 132 being circular, a posturized comfort
layer,
such as the one shown in Fig. 13A, may have rectangular or square segmented
seams.
[00104] Fig. 13B illustrates a posturized comfort layer 140 having two
different
areas or regions of firmness depending upon the airflow within each of the
areas or
regions. The comfort layer 140 has a first section 142 and a second section
144. The
size and number of segments in the seams, along with the type of material used
to
construct the posturized comfort layer 140, may be selected so at least two of
the
sections may have a different firmness due to different airflows within
different sections.
Although two sections are illustrated in Fig. 13B, any number of sections may
be
incorporated into a posturized comfort layer. Although each of the sections is
illustrated
being a certain size, they may be other sizes. The drawings are not intended
to be
limiting. Although Fig. 13B shows each of the segmented seams of comfort layer
140
being circular, a posturized comfort layer, such as the one shown in Fig. 13B,
may have
rectangular or square segmented seams.
[00105] While we 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
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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.
22
