Note: Descriptions are shown in the official language in which they were submitted.
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POCKETED SPRING ASSEMBLY INCLUDING CUSHION PADS
Cross-Reference To Related Applications
[0001] This application is a Continuation-In-Part of U.S.
Patent Application
Serial No. 15/897,687 filed February 15, 2018 (pending), the disclosure of
which is
incorporated by reference herein.
Field of the Invention
[0002] This invention relates generally to bedding and seating
products and,
more particularly, to pocketed spring assemblies used in bedding and seating
products.
Background Of The Invention
[0003] Mattress spring core construction over the years has
been a
continuously improving art with advancements in materials and machine
technology.
A well known form of spring core construction is known as a Marshall spring
construction wherein metal coil springs are encapsulated in individual pockets
of
fabric and formed as elongate or continuous strings of pocketed coil springs.
In an
earlier form, these strings of coil springs were manufactured by folding an
elongate
piece of fabric in half lengthwise to form two plies of fabric and stitching
transverse
and longitudinal seams to join the plies of fabric to define pockets within
which the
springs were enveloped.
[0004] More recently, improvements in spring core
constructions have
involved the use of fabrics which are thermally or ultrasonically weldable to
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themselves. By using such welding techniques, these fabrics have been
advantageously used to create strings of individually pocketed coil springs
wherein
transverse and longitudinal welds, instead of stitching, are used to form the
pockets
encapsulating the springs.
[0005] Once strings of pocketed springs are constructed, they
may be
assembled to form a pocketed spring core or assembly for a mattress, cushion
or the
like by a variety of methods. For example, multiple or continuous strings may
be
arranged in a row pattern corresponding to the desired size and shape of a
mattress
or the like, and adjacent rows of strings may be interconnected by a variety
of
methods. The result is a unitary assembly of pocketed coil springs serving as
a
complete spring core assembly.
[0006] Conventional pocketed spring cores incorporating
pocketed strings of
springs have less motion transfer between sleeping partners when compared to
traditional helically-laced open coil spring assemblies. Each pocketed coil
spring is
able to move with greater independence and, therefore provide less influence
on
adjacent pocketed coil springs than if the coil springs were not inside
individual
pockets. However, with a traditional pocketed spring mattress, a sheet of foam
or
other cushioning layer is attached to an upper surface of the pocketed spring
assembly. The foam or cushioning sheet or sheets acts like a bridge, such that
a
load applied to one side of a mattress affects the other side of the mattress,
providing an undesirable bridging effect. The present invention eliminates the
undesirable bridging effect by encapsulating individual cushion members inside
outer
pockets of strings of springs.
[0007] U.S. Patent No. 6,490,744 discloses a pocketed spring
assembly
incorporating strings which have individually pocketed coil springs with
cushioning
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pads inside the pockets. However, due to the individual coil springs being un-
pocketed, the coil springs may damage the cushioning pads and/or affect the
feel of
the pocketed spring assembly due to the coil springs pressing against the
cushioning
pads. The capability of the individually pocketed springs to act independently
from
the adjacent pocketed springs in the string of springs may be compromised.
[0008] Therefore, there remains a need to combine multiple
technologies to
improve the feel and motion transfer in a bedding or seating product having a
pocketed spring core.
Summary Of The Invention
[0009] In one aspect, a bedding or seating product is
provided. The product
comprises a pocketed spring assembly and an edge support extending along each
of
two opposing sides of the pocketed spring assembly. Each edge support
comprises
a plurality of parallel edge strings of springs, each edge string being joined
to at least
one adjacent edge string. Each edge string comprises a piece of fabric
surrounding
a plurality of pocketed springs and a plurality of cushion pads, first and
second
opposed plies of fabric being on opposite sides of the pocketed springs and
cushion
pads. Outer pockets are formed along the length of the edge string by a
longitudinal
seam and transverse seams joining the first and second plies. At least one
pocketed
spring and at least one cushion pad are in each of the outer pockets. Each
cushion
pad may be individually pocketed and may be any desired size or shape.
[00010] Different coil springs may be located inside the inner
pockets of the
edge strings. In one embodiment, each of the coil springs of each edge string
has
upper and lower end turns and a plurality of central convolutions between the
end
turns, the central convolutions being the same diameter. Regardless of the
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configuration of coil spring, each coil spring is preferably made of one piece
of wire
of a uniform diameter, but not in all cases. In many embodiments, the coil
springs of
the edge strings are narrower than the coil springs of the interior strings
described
below. The pocketed springs of the edge strings are commonly coil springs but
may
be any springs or resilient members.
[00011] In at least one embodiment, the pocketed spring
assembly comprises a
plurality of parallel interior strings of springs, each interior string being
joined to at
least one adjacent interior string. Each interior string comprises a piece of
fabric
surrounding a plurality of pocketed springs and a plurality of cushion pads,
first and
second opposed plies of fabric being on opposite sides of the pocketed springs
and
cushion pads. Outer pockets are formed along the length of the interior string
by a
longitudinal seam and transverse seams joining the first and second plies. At
least
one pocketed spring and at least one cushion pad are in each of the outer
pockets.
Each cushion pad may be individually pocketed and may be any desired size or
shape. The pocketed springs of the interior strings are commonly coil springs
but
may be any springs or resilient members.
[00012] The interior strings of the pocketed spring assembly
may extend
longitudinally (from end-to-end) or transversely (from side-to-side). The
pocketed
spring assembly may be posturized into regions or zones of different firmness
by
incorporating different interior strings into the pocketed spring assembly.
[00013] Cushioning materials may be placed on top and/or below
the pocketed
spring assembly. A covering, usually an upholstered covering, encases the
pocketed spring assembly, edge supports and cushioning materials.
[00014] In another aspect, a bedding or seating product
comprises a pocketed
spring assembly and an edge support extending around the perimeter of the
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pocketed spring assembly. The edge support comprises a plurality of perimeter
strings. Each perimeter string is joined to at least one adjacent perimeter
string.
Each of the perimeter strings comprises a plurality of interconnected outer
pockets
made from one piece of fabric. Each of the outer pockets contains at least one
inner
pocketed spring and at least one cushion pad. The piece of fabric is joined to
itself
along a longitudinal seam and has first and second opposed plies of fabric on
opposite sides of the inner pocketed springs. The first and second plies of
fabric are
joined by transverse seams between adjacent inner pocketed springs.
[00015] In at least some embodiments, the pocketed spring
assembly
comprises a plurality of parallel interior strings. Each interior string is
joined to at
least one adjacent interior string. Each of the interior strings comprises a
plurality of
interconnected outer pockets made from one piece of fabric. Each of the outer
pockets of the interior string contains at least one inner pocketed spring and
at least
one cushion pad. The piece of fabric of the interior string is joined to
itself along a
longitudinal seam and has first and second opposed plies of fabric on opposite
sides
of the inner pocketed springs. The first and second plies of fabric are joined
by
transverse seams between adjacent inner pocketed springs of the interior
string.
[00016] In double-sided bedding or seating products, two
cushion pads are in
each of the outer pockets of the perimeter strings and the interior strings.
At least
one inner pocketed spring is between the cushion pads. Each of the cushion
pads
may be individually pocketed. Each of the cushion pads may be made at least
partially of foam or any other resilient member including gel or a fiber pad.
[00017] In another aspect, a bedding or seating product
comprises a pocketed
spring assembly and an edge support extending around the perimeter of the
pocketed spring assembly. The edge support comprises at least one perimeter
string
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of springs. Each perimeter string comprises a plurality of interconnected
outer
pockets made from one piece of fabric. Each of the outer pockets contains at
least
one inner pocketed spring and at least one cushion pad. The piece of fabric is
joined
to itself along a longitudinal seam and has first and second opposed plies of
fabric
on opposite sides of the inner pocketed springs. The fabric of the first and
second
plies is joined by transverse seams. The transverse seams may be any desired
length.
[00018] The pocketed spring assembly may be any known pocketed
spring
assembly. In some embodiments, the pocketed spring assembly comprises a
plurality of parallel interior strings of springs. Each interior string is
joined to an
adjacent interior string. Each of the interior strings comprises a plurality
of
interconnected outer pockets made from one piece of fabric. Each of the outer
pockets contains at least one inner pocketed spring and at least one cushion
pad.
The piece of fabric is joined to itself along a longitudinal seam and has
first and
second opposed plies of fabric on opposite sides of the inner pocketed
springs. The
fabric of the first and second plies is joined by transverse seams which may
be any
desired length.
[00019] In most embodiments of the product, the inner pocketed
springs within
the one or more perimeter strings have a smaller diameter than the inner
pocketed
springs of the pocketed spring assembly. However, they may be different
diameters.
[00020] In most embodiments of the product, the perimeter
strings are
approximately the same height as the interior strings of the pocketed spring
assembly. However, they may be different heights.
[00021] One advantage of the invention is that when a bedding
or seating
product, such as a mattress, is manufactured, the manufacturer need not place
one
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or more sheets of cushioning material over the pocketed spring assembly prior
to the
unit being upholstered. The mattress manufacturer may simply place a cover
around
the pocketed spring assembly without using any sheets of cushioning material.
[00022] Another advantage of the invention is that the inner
pocketed coil
spring does not press into the cushion pad above/below it when subjected to a
load.
Because the inner pocketed spring is retained in its own inner pocket
independent of
the cushion pad or pads, the inner pocketed spring does not exert force on the
cushion pad or pads, thereby preserving the designed characteristics of the
cushion
pad or pads such as firmness, for example. The inner pockets of fabric
surrounding
the coil springs and/or the fabric surrounding each cushion pad preserves the
integrity of the cushion pads and increases the life of the pocketed spring
assembly.
The result is that the user "feels" more of the cushion pad or pads.
[00023] The accompanying drawings, which are incorporated in
and constitute
a part of this specification, illustrate embodiments of the invention and,
together with
the summary of the invention given above, and the detailed description of the
drawings given below, explain the principles of the present invention.
Brief Description Of The Drawings
[00024] Fig. 1 is a perspective view, partially broken away, of
a bedding or
seating product incorporating a pocketed spring assembly according to the
principles
of the present invention.
[00025] Fig. lA is a perspective view, partially broken away,
of a bedding or
seating product incorporating another pocketed spring assembly.
[00026] Fig. 1 B is a perspective view, partially broken away,
of a double-sided
bedding product incorporating another pocketed spring assembly.
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[00027] Fig. 1C is a perspective view, partially broken away,
of another bedding
product incorporating the pocketed spring assembly of Fig. 1.
[00028] Fig. 2 is a perspective view, partially broken away, of
a portion of a
string of springs of Fig. 1 in an unloaded condition.
[00029] Fig. 2A is a perspective view, partially broken away,
of a portion of
another string of springs in an unloaded condition.
[00030] Fig. 3A is a cross-sectional view, partially broken
away, of the string of
springs of Fig. 2 in an unloaded condition.
[00031] Fig. 3B is a view similar to Fig. 3A, a portion of the
string of springs of
Fig. 3A being in a loaded condition.
[00032] Fig. 3C is a cross-sectional view, partially broken
away, of a string of
springs having a different spring in an unloaded condition.
[00033] Fig. 3D is a cross-sectional view, partially broken
away, of a string of
springs having a different spring in an unloaded condition.
[00034] Fig. 4 is a perspective view of a portion of the
pocketed spring
assembly of Fig. 1 in a relaxed condition.
[00035] Fig. 5 is a perspective view of a portion of another
pocketed spring
assembly in a relaxed condition, the strings of springs being offset from one
another.
[00036] Fig. 6 is a cross-sectional view, partially broken
away, of another string
of springs in an unloaded condition.
[00037] Fig. 7 is a cross-sectional view, partially broken
away, of double-sided
string of springs in an unloaded condition.
[00038] Fig. 8 is a top view of a posturized pocketed spring
assembly.
[00039] Fig. 9 is a top view of another posturized pocketed
spring assembly.
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[00040] Fig. 10 is a cross-sectional view, partially broken
away, of another
string of springs in an unloaded condition.
[00041] Fig. 11 is a cross-sectional view, partially broken
away, of another
string of springs in an unloaded condition.
[00042] Fig. 12 is a perspective view, partially broken away,
of a single-sided
bedding product incorporating the pocketed spring assembly of Fig. 1, but with
a
different edge support.
[00043] Fig. 13 is a top view of the pocketed spring assembly
and edge
support of Fig. 12.
[00044] Fig. 14 is a perspective view, partially broken away,
of a portion of an
edge string of Fig. 13 in an unloaded condition.
[00045] Fig. 15 is a cross-sectional view taken along the line
15-15 of Fig. 13.
[00046] Fig. 16 is a cross-sectional view, partially broken
away, like Fig. 15
showing a portion of a double-sided product.
[00047] Fig. 17 is a cross-sectional view, partially broken
away, like Fig. 16, of
another double-sided product.
[00048] Fig. 18 is a top view of another embodiment of edge
support
surrounding a pocketed spring assembly.
Detailed Description Of The Invention
[00049] Referring first to Fig. 1, there is illustrated a
bedding product in the form
of a single-sided mattress 10 incorporating the principles of the present
invention.
This product or mattress 10 comprises a pocketed spring assembly 12 over the
top
of which there lay conventional padding or cushioning layers 14, 16 which may
be
foam, fiber, gel, a pocketed spring blanket or any other suitable materials or
any
combination thereof. The pocketed spring assembly 12 is surrounded with a
border
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17 made of foam or any other suitable material (only a portion being shown in
Fig.
1). Although one type of border 17 is illustrated, the border may assume other
forms
or shapes of any desired size, such as pocketed coil springs. Alternatively,
the
border 17 may be omitted in this embodiment or any embodiment described or
shown herein. This complete assembly is mounted upon a base 18 and is
completely enclosed within an upholstered covering material 20. The base and
border, regardless of the type of border, are known in the industry as a
"bucket" into
which a pocketed spring assembly is inserted before the "bucket" is covered
with one
or more padding or cushioning layers.
[00050] As shown in Fig. 1, fully assembled, the product 10 has
a length "L"
defined as the linear distance between opposed end surfaces 22 (only one being
shown in Fig. 1). Similarly, the assembled product 10 has a width "W" defined
as the
linear distance between opposed side surfaces 24 (only one being shown in Fig.
1).
In the product shown in Fig. 1, the length is illustrated as being greater
than the
width. However, it is within the scope of the present invention that the
length and
width may be identical, as in a square product.
[00051] As shown in Fig. 1, pocketed spring assembly 12 is
manufactured from
multiple strings 26 of pocketed springs 28 joined together. Each string of
pocketed
springs 26 extends longitudinally or from head-to-foot along the full length
of the
product 10.
[00052] Although the strings of pocketed springs 26 are
illustrated as extending
longitudinally or from head-to-foot in the pocketed spring assembly 12 of Fig.
1, they
may extend transversely or from side-to-side as shown in the pocketed spring
assembly 12a shown in the product 10a shown in Fig. 1A. The pocketed spring
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assembly 12a comprises multiple strings 26a of pocketed springs, identical to
the
strings of springs 26, but shorter in length.
[00053] Fig. 1B illustrates a double-sided mattress 10b
comprising a pocketed
spring assembly 12b and border 17 identical to those shown in the mattress 10
of
Fig. 1. However, the mattress 10b of Fig. 1B has conventional padding layers
14, 16
above and below a double-sided pocketed spring assembly 12b. The double-sided
pocketed spring assembly 12b comprises a plurality of strings 26b of pocketed
springs, one being partially shown in cross-section in Fig. 7.
[00054] Fig. 1C illustrates a single-sided mattress 10c
comprising a pocketed
spring assembly 12 and border 17 identical to those shown in the mattress 10
of Fig.
1. However, the mattress 10c of Fig. 1C has a pocketed topper 19 comprising
miniature pocketed coil springs in addition to padding layers 14, 16 above the
pocketed topper 19. A scrim layer 21 separates the pocketed topper 19 from the
pocketed spring assembly 12. Although one configuration of pocketed topper 19
is
illustrated, any pocketed topper known in the art may be used.
[00055] According to this invention, any of the padding or
cushioning layers,
including the pocketed topper 19, may be omitted in any of the embodiments
shown
or described herein. The novel features reside in the pocketed spring
assembly.
[00056] These strings of pocketed springs 26, 26a and 26b, and
any other
strings of springs described or shown herein, may be connected in side-by-side
relationship as, for example, by gluing the sides of the strings together in
an
assembly machine, to create an assembly or matrix of springs having multiple
rows
and columns of pocketed springs bound together as by gluing, welding or any
other
conventional assembly process commonly used to create pocketed spring cores or
assemblies.
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[00057] Referring to Figs. 4 and 5, the strings 26 of pocketed
springs may be
joined so that the individually pocketed springs 28 are aligned in
transversely
extending rows 30 and longitudinally extending columns 32. Alternatively, the
strings
26 of pocketed springs may be offset from one another in a pocketed spring
assembly. In such an arrangement, shown in Fig. 5, the individually pocketed
springs 28 are not aligned in rows and columns; instead the individually
pocketed
springs 28 fill gaps or voids 70 of the adjacent strings 26. Fig. 5 shows a
portion of a
pocketed spring assembly 12' with multiple strings 26 arranged in this manner.
Either alignment of strings may be incorporated into any of the pocketed
spring
assemblies or cores illustrated or described herein. Although Figs. 4 and 5
illustrate
strings 26, the same alignments may be used in any pocketed spring assembly
having strings 26a or 26b.
[00058] As best illustrated in Figs. 2, 3A and 3B, each string
26 of pocketed
springs 28 comprises a row of interconnected fabric outer pockets 34. Each of
the
fabric outer pockets 34 contains at least one inner pocketed coil spring 82
and at
least one cushion pad 54. Each inner pocketed coil spring 82 comprises a coil
spring 36 encased in an inner pocket 35 having two side seams 37. The inner
pocket 35 may be made of a single piece of fabric or any number of pieces of
fabric.
[00059] Figs. 2, 3A and 3B illustrate a one-sided string 26 for
use in a single-
sided pocketed spring assembly, such as pocketed spring assembly 12. In string
26,
one cushion pad 54 rests on the fabric of the inner pocket 35 above the
individually
pocketed coil spring 36. In this orientation, the coil spring 36 is prevented
from
contacting and damaging the material of the cushion pad 54.
[00060] For ease of understanding, Fig. 2 illustrates the
leftmost outer pocket
34 shown in dashed lines and the inner pocket 35 shown in solid lines. In Fig.
2, the
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other outer pockets 34 of string 26 are shown in solid lines and the inner
pockets 35
shown in dashed lines.
[00061] As best shown in Fig. 2, the cushion pad 54 is shown as
being shaped
like a hockey puck or puck-shaped. Cushion pad 54 is illustrated in Fig. 2
having a
circular upper surface 76, a circular lower surface 78 and a sidewall 80.
[00062] Fig. 2A illustrates a string 27 identical to string 26,
but having a
different cushion pad 54a. Cushion pad 54a has a different shape than cushion
pads 54 inside the inner pockets 35 of the string 27. Fig. 2A illustrates a
cushion
pad 54a having a rectangular upper surface 76a, a rectangular lower surface
78a
and four rectangular sidewalls 80a. Although Fig. 2A illustrates square upper
and
lower surfaces and sidewalls, one or more surfaces or sidewalls may be other
rectangular shapes. Although Figs. 2 and 2A illustrate cushion pads 54, 54a,
respectively, of a certain size and shape, the drawings are not intended to
limit the
size or shape of the cushion pads.
[00063] Each cushion pad 54, 54a is illustrated being a single
piece of material,
such as foam, but may be any number of pieces of any desired material joined
together. Alternatively, the cushion pad 54, 54a may be made of fiber, cotton,
gel or
any combination thereof.
[00064] The coil spring 36 is preferably made of one piece of
wire of a uniform
diameter, but may be made of other materials, multiple strands of twisted wire
and/or
may be a non-uniform diameter. As best shown in Fig. 2, each coil spring 36
has a
central or longitudinal axis A, an upper end turn 38, a lower end turn 40 and
a
plurality of central convolutions 42 between the end turns. Figs. 2 and 3A
illustrate a
barrel-shaped coil spring 36 in which the diameter of the end turns 38, 40 is
less
than the diameter of the central convolutions 42, the central convolutions 42
tapering
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or decreasing in diameter and pitch as one moves from a center or middle
portion 44
of the coil spring towards the end turns. As best shown in Fig. 2, each barrel-
shaped
coil spring 36 has two end portions which are not identical, an upper end
portion 46
and a lower end portion 48. The upper end portion 46 has more convolutions
than
the lower end portion 48, as best shown in Figs. 3A and 3B.
[00065] Preferably, one piece of fabric is used to create the
outer pockets 34 of
the string 26 of pocketed springs 36, the piece of fabric being folded over
onto itself
around the inner pocketed coil springs 82 and the cushion pads 54. As best
shown
in Fig. 2, opposite sides or plies 47, 49 of the fabric are sewn, welded or
otherwise
secured together to create a longitudinal seam 50 and a plurality of
separating or
transverse seams 52. Fig. 2 illustrates ply 47 being closest to the reader and
ply 49
being behind the springs 36.
[00066] Although the seams or welds in the embodiments shown
herein are
shown as being welded spaced rectangles, any of the seams may be spaced dots,
triangles or solid line segments without spaces.
[00067] As best shown in Fig. 2, opposed edges 56 of the piece
of fabric used
to create the string of pocketed springs 26 are aligned and spaced from the
longitudinal seam 50 a distance indicated by numeral 58. Although the drawings
indicated the longitudinal seam 50 being below the free edges 56 of the piece
of
fabric, the longitudinal seam 50 may be above the free edges 56 of the piece
of
fabric.
[00068] As shown in Figs. 2 and 3A, the string of pocketed
springs 26 has a
generally planar top surface 60 in a top plane P1 and a parallel generally
planar
bottom surface 62 in a bottom plane P2. The linear distance between the top
and
bottom surfaces 60, 62 of the string 26 defines a height H of the string 26.
This
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linear distance further defines the height H of the pocketed spring assembly
12
because each of the strings 26 has the same height. However, it is within the
scope
of the present invention that different strings of springs of a pocketed
spring
assembly have different heights.
[00069] In accordance with one embodiment, in strings 26, the
transverse
seams 52 forming the adjacent outer pockets 34 are divided as at 64 to thereby
form
a cut, slit, or notch by, for example, cutting, slitting, severing, melting,
or the like,
from the upper surface 60 of the string 26 inwardly (downwardly as
illustrated), to
partially separate the adjacent outer pockets 34. Preferably, the divide 64
extends to
beyond or below the cushion pad 54, but may be any desired length including
less
than the height of the cushion pad 54. As best shown in Figs. 2 and 3A, the
transverse seams 52 of the strings 26 each have an upper end 66 located at the
bottom of each divide 64 and a lower end 68. As shown in Fig. 3A, the upper
end 66
of each transverse seam 52 is located below adjacent cushion pads 54 when the
coil
springs 36 are in a relaxed condition and not loaded.
[00070] The significance of divide 64 may be appreciated with
reference to Fig.
3B. Divide 64 essentially decouples each cushion pad 54 from its adjacent
cushion
pad 54 during initial deflection of cushion pad 54. This creates more of an
individual
coil performance and allows the inner pocketed coil spring 82 to engage a
person
sleeping on the mattress 10 sooner while giving the person a softer feel at
the
beginning of the coil deflections. It is believed that this arrangement
provides a more
comfortable pocketed spring assembly 12.
[00071] Fig. 6 illustrates another embodiment of string 26c
which may be used
in any of the pocketed spring assemblies or products shown or described
herein.
The string 26c comprises the same seams, same inner pocketed springs 82 and
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outer fabric pockets 34 as incorporated into strings 26. However, each cushion
pad
54' comprises a cushion pad 54 encased in a fabric cover 84. Each cushion pad
54'
has its own fabric cover 84 which prevents the coil spring 36 of the inner
pocketed
coil spring 82 from contacting and damaging the cushion pad or pads over time,
in
addition to the inner pocket 35 of fabric of the inner pocketed coil spring
82.
[00072] Referring now to Figs. 1B and 7, while the mattresses
10 illustrated in
Figs. 1, lA and 1C are single-sided mattresses, any other pocketed spring
assembly
shown or described herein, may be incorporated into any bedding or seating
product,
including a double-sided mattress or seating cushion.
[00073] Fig. 7 illustrates a portion of a string of springs 26b
used in a double-
sided pocketed spring assembly, like pocketed spring assembly 12b shown in
Fig.
1B. The fabric outer pockets 34b of such strings 26b are slightly different
than the
fabric outer pockets 34 of string of springs 26. There are divides 64 along
the tops
and bottoms of the strings 26b.
[00074] Fig. 7 illustrates a two-sided string 26b for use in a
double-sided
pocketed spring assembly 12b, as shown in Fig. 1B. Two cushion pads 54 are
located inside each outer pocket 34b along with an inner pocketed spring 82
located
between the cushion pads 54. One of the cushion pads 54 is located above the
inner pocketed coil spring 82b and the other cushion pad 54 is located below
the
inner pocketed coil spring 82b. Although Fig. 7 illustrates cushion pads 54
lacking
covers, encased cushion pads 54' or cushion pads of different shapes, such as
shown in Fig. 2A, may be used in the double-sided string 26b or any string
shown or
described herein.
[00075] Additionally, the coil springs 36b of inner pocketed
springs 82b are
different than the coil springs 36 of inner pocketed springs 82 shown in Figs.
3A and
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3B. Each coil spring 36b comprises a central or longitudinal axis Al, an upper
end
turn 38b, a lower end turn 40b and a plurality of central convolutions 42b
between
the end turns. Figs. 1B and 7 illustrate a barrel-shaped coil spring 36b in
which the
diameter of the end turns 38b, 40b is less than the diameter of the central
convolutions 42b, the central convolutions 42b tapering or decreasing in
diameter
and pitch as one moves from a center or middle portion 44b of the coil spring
towards the end turns. As best shown in Fig. 7, each barrel-shaped coil spring
36b
has two identical end portions 46b.
[00076] Referring now to Fig. 8, longitudinally extending
strings are shown in
one preferable arrangement for a spring core for a bedding or seating product,
such
as a mattress. As can be seen, the longitudinally extending strings are
arranged in a
plurality of zones on the pocketed spring assembly 12d. By way of example, two
zones 72, 74 are illustrated, with the zones corresponding roughly to a "firm"
side
and a "soft" side. By way of further example, the longitudinally extending
strings of
the "soft" zone 72 each have the split top feature shown and described herein.
The
longitudinally extending strings of the "firm" zone 74 are strings lacking any
split top
feature. Of course, other arrangements are within the scope of the invention.
For
example, the pocketed spring assembly 12d shown in Fig. 8 may comprise
transversely extending strings rather than longitudinally extending strings.
In such
an arrangement, each transversely extending string would have to be half firm
and
half soft. Therefore, each string would have only half the string having the
split top
feature, the other half lacking such feature.
[00077] Referring now to Fig. 9, the transversely extending
strings are shown in
one preferable arrangement for a pocketed spring assembly 12e for a bedding or
seating product, such as a mattress. As can be seen, the transversely
extending
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strings are arranged in a plurality of zones on the pocketed spring assembly
12e. By
way of example, three zones are illustrated, with the zones corresponding
roughly to
the location of a sleeper's head and shoulders, mid-section, knees and feet.
By way
of further example, the two end "soft" zones 86 each comprise strings of
springs
having the split top feature shown and described herein. The transversely
extending
strings of the middle or "firm" zone 88 are strings lacking any split top
feature. Of
course, other arrangements are within the scope of the invention. For example,
the
mattress shown in Fig. 9 may comprise longitudinally extending strings rather
than
transversely extending strings. In such an arrangement, each longitudinally
extending string would have to be divided into three sections; a middle "firm"
section
and two end or "soft" sections. Therefore, each string would have only the end
thirds
of the string having the split top feature, the middle third lacking such
feature.
[00078] Figs. 30 and 3D illustrate portions of other
embodiments of strings 26d,
26e, respectively, which may be incorporated into any of the products shown or
described herein. The strings 26d, 26e each comprise the same seams and outer
pockets 34 as incorporated into strings 26. However, the springs 36d, 36e
within the
strings 26d, 26e, respectively are different than the springs 36 of strings
26.
Although springs 36d, 36e are only shown in Figs. 30 and 30, they may be used
in
any string shown or described herein, including two-sided strings having
cushion
pads above and below each coil spring.
[00079] As shown in Fig. 30, coil springs 36d (only one being
shown) each
have identical end turns 38d of a smaller diameter than the central
convolutions 42d
therebetween in a central portion 44d thereof. The central convolutions 42d of
coil
springs 36d are identical having the same diameter greater than the diameter
of end
turns 38d.
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[00080] As shown in Fig. 3D, coil springs 36e (only one being
shown) each
have two identical end portions 46e and a central portion 44e therebetween.
The
central portion 44e has more convolutions than each end portion 46e, as shown
in
Fig. 3D. Each coil spring 36e has identical end turns 38e of a larger diameter
than
the central convolutions 42e therebetween of the central portion 44e. The
central
convolutions 42e of coil springs 36e have the same diameter, which is greater
than
the diameter of end turns 38e.
[00081] Fig. 10 illustrates another embodiment of string 26d
which may be
used in any of the pocketed spring assemblies or products shown or described
herein. The double-sided string 26d comprises the same seams, same coil
springs
36h and outer fabric pockets 34b as incorporated into strings 26b shown in
Fig. 7.
However, each coil spring 36 lacks an inner pocket but is surrounded by the
fabric of
the outer pocket, along with one or more individually pocketed cushion pads
54'.
[00082] Like the cushion pads 54' shown in Fig. 6, each cushion
pad 54'
comprises a cushion pad 54' encased in a fabric cover 84. Each cushion pad 54'
has its own fabric cover 84 which prevents the coil spring 36b from contacting
and
damaging the cushion pad or pads over time.
[00083] Although the string 26d is shown as a double-sided
string, the concept
illustrated therein of combining an un-pocketed coil spring with pocketed
cushion
pads may be incorporated into any of the strings or pocketed spring assemblies
shown or described herein, including single sided strings and single-sided
pocketed
spring assemblies. Any of the coil springs shown or described herein may be
used in
a version in which only the cushion pad or pads is pocketed, and the coil
spring has
no inner pocket, just an outer pocket.
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[00084] Fig. 11 illustrates another embodiment of string 26e
which may be
used in any of the pocketed spring assemblies or products shown or described
herein. The double-sided string 26e comprises the same seams, same inner
pocketed springs 82b including same coil springs 36b, same cushion pads 54 and
same outer fabric pockets 34b as incorporated into strings 26b shown in Fig.
7.
However, each string 26e lacks divides 64 or "split top" feature. Any of the
embodiments of strings or pocketed spring assemblies shown or described herein
may lack the divides or "split top" feature regardless of the whether one-
sided or
double-sided.
[00085] Referring to Figs. 12-15, there is illustrated a
bedding product in the
form of a single-sided mattress 10d incorporating additional principles of the
present
invention. This product or mattress 10d comprises a pocketed spring assembly
12
as shown and described above. However, any pocketed spring assembly described
or shown herein may be used in this mattress 10d. The mattress 10d uses
pocketed
springs for two sides 11 of edge support. Each side 11 of the mattress 10d has
an
edge support 13 comprising at least one longitudinally extending edge string
90.
[00086] In the embodiment illustrated in Figs. 12-15, each side
11 of the
mattress 10d has two edge strings 90 secured to each other with adhesive or
any
other known method. On each side 11, the innermost edge string 90 of edge
support
13 is secured to the outermost interior string 26 of the pocketed spring
assembly 12
with adhesive or any other known method. Although the drawings illustrate two
edge
strings 90 per side 11, any number of edge strings 90 may be used per side.
[00087] As best illustrated in Figs. 14 and 15, each edge
string 90 of pocketed
springs 92 comprises a row of interconnected fabric outer pockets 98. Each of
the
fabric outer pockets 98 contains at least one inner pocketed coil spring 101
and at
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least one cushion pad 94. The embodiment of Figs. 12-15 has one inner pocketed
coil spring 101 and one cushion pad 94 within each of the fabric outer pockets
98.
Each inner pocketed coil spring 101 comprises a coil spring 96 encased in an
inner
pocket 95 having two side seams 97. The inner pocket 101 may be made of a
single
piece of fabric or any number of pieces of fabric.
[00088] Fig. 14 illustrates a one-sided edge string 90 for use
with a single-sided
pocketed spring assembly, such as pocketed spring assembly 12. In edge string
90,
one cushion pad 94 rests on the fabric of the inner pocket 95 above the inner
pocket
101 containing coil spring 96. In this orientation, the coil spring 96 is
prevented from
contacting and damaging the material of the cushion pad 94.
[00089] For ease of understanding, Fig. 14 illustrates the
leftmost outer pocket
98 shown in dashed lines and the inner pocket 101 shown in solid lines. In
Fig. 14,
the other outer pockets 98 of edge string 90 are shown in solid lines and the
inner
pockets 95 shown in dashed lines.
[00090] As best shown in Fig. 14, the cushion pad 94 is shown
as being
shaped like a hockey puck or puck-shaped. Cushion pad 94 is illustrated in
Fig. 14
having a circular upper surface 100, a circular lower surface 102 and a
sidewall 104.
However, any configuration of cushion pad may be used in the edge strings 90.
[00091] Fig. 15 illustrates one edge support 13 (two edge
strings 90) secured to
one side of a pocketed spring assembly 12. One skilled in the art will
appreciate than
the other side of mattress 10d is a mirror image thereof.
[00092] The coil spring 96 is preferably made of one piece of
wire of a uniform
diameter, but may be made of other materials, multiple strands of twisted wire
and/or
may be a non-uniform diameter. As best shown in Fig. 14, each coil spring 96
has a
central or longitudinal axis AA, an upper end turn 106, a lower end turn 108
and a
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plurality of central convolutions 110 between the end turns. Figs. 14 and 15
illustrate
a coil spring 96 in which the diameter of the end turns 106, 108 is less than
the
diameter of the central convolutions 110, the central convolutions 110 being
approximately the same diameter. Although one configuration of coil spring 96
is
illustrated, the drawings are not intended to be limiting; the coil springs 96
may be
other known configurations.
[00093] Preferably, one piece of fabric is used to create the
outer pockets 98 of
the edge string 90 of pocketed springs 92, the piece of fabric being folded
over onto
itself around the inner pocketed coil springs 101 and the cushion pads 94. As
best
shown in Fig. 14, opposite sides or plies 107, 109 of the fabric are sewn,
welded or
otherwise secured together to create a longitudinal seam 112 and a plurality
of
separating or transverse seams 114. Fig. 14 illustrates ply 107 being closest
to the
reader and ply 109 being behind the inner pocketed coil springs 101 and the
cushion
pads 94.
[00094] Although the seams or welds in the embodiments shown
herein are
shown as being welded spaced rectangles, any of the seams may be spaced dots,
triangles or solid line segments without spaces.
[00095] As best shown in Fig. 14, opposed edges 116 of the
piece of fabric
used to create the edge string 90 are aligned and spaced from the longitudinal
seam
112 a distance indicated by numeral 118. Although the drawings indicated the
longitudinal seam 112 being below the free edges 116 of the piece of fabric,
the
longitudinal seam 112 may be above the free edges 116 of the piece of fabric.
[00096] As shown in Figs. 14 and 15, the edge string 90 has a
generally planar
top surface 120 in a top plane P1 and a parallel generally planar bottom
surface 122
in a bottom plane P2. The linear distance between the top and bottom surfaces
120,
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122 of the edge string 90 defines a height H of the edge string 90. This
linear
distance further defines the height H of the pocketed spring assembly 12
because
each of the edge strings 90 has the same height H as the interior strings 26
of the
pocketed spring assembly 12. However, it is within the scope of the present
invention that different strings of springs of a pocketed spring assembly have
different heights.
[00097] Fig. 16 illustrates a view like Fig. 15 showing a
cross-sectional view of
a double-sided pocketed spring assembly 12b and opposed side edge supports 13'
(only one being shown in Fig. 16). Each edge support 13' comprises two edge
strings 90'. Fig. 16 illustrates a portion of a pocketed spring assembly 12b
having
two-sided strings 26b in a double-sided pocketed spring assembly 12b, the same
pocketed spring assembly 12b shown in Fig. 7.
[00098] In each edge string 90', two cushion pads 94 are
located inside each
outer pocket 98' along with an inner pocketed spring 101' located between the
cushion pads 94. Each inner pocketed coil spring 101' comprises a coil spring
96'
encased in an inner pocket 95'. One of the cushion pads 94 is located above
the
inner pocketed coil spring 101' and the other cushion pad 94 is located below
the
inner pocketed coil spring 101'. Although Fig. 16 illustrates cushion pads 94
lacking
covers, encased cushion pads 94" or cushion pads of different shapes, such as
shown in Fig. 2A, may be used in the double-sided edge string 90' or any
string
shown or described herein.
[00099] Fig. 17 illustrates another embodiment of double-sided
edge string 90"
which may be used with any of the double-sided pocketed spring assemblies or
products shown or described herein. The double-sided edge string 90" comprises
the same seams, same coil springs 96' and outer fabric pockets 98' as
incorporated
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into double-sided edge strings 90' shown in Fig. 17. However, each coil spring
96'
lacks an inner pocket but is surrounded by the fabric of the outer pocket 98',
along
with one or more individually pocketed cushion pads 94".
[000100] Fig. 18 is a top view of another embodiment of bedding
or seating
product 10e. This product or mattress 10e comprises a pocketed spring assembly
12 as shown and described above. However, any pocketed spring assembly
described or shown herein may be used in this mattress 10e. The mattress 10e
uses pocketed springs for four sides of edge support. Each side 111 and each
end of
the mattress 113 has an edge support 124 comprising at least one continuous
perimeter string 190. In the embodiment illustrated in Fig. 18, two continuous
perimeter strings 190 are secured around the perimeter of the pocketed spring
assembly 12. The innermost perimeter string 190 is glued with adhesive to the
pocketed spring assembly 12 and the outermost perimeter string 190 is glued
with
adhesive to the innermost perimeter string 190. Each perimeter string 190 may
be a
single-sided string as described herein for use with a single-sided pocketed
spring
assembly. Alternatively, each perimeter string 190 may be a double-sided
string as
described herein for use with a double-sided pocketed spring assembly.
[000101] The various embodiments of the invention shown and
described are
merely for illustrative purposes only, as the drawings and the description are
not
intended to restrict or limit in any way the scope of the claims. Those
skilled in the
art will appreciate various changes, modifications, and improvements which can
be
made to the invention without departing from the spirit or scope thereof. The
invention in its broader aspects is therefore not limited to the specific
details and
representative apparatus and methods shown and described. Departures may
therefore be made from such details without departing from the spirit or scope
of the
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general inventive concept. For example, more than two cushion pads or more
than
one inner pocketed spring may be inside an outer pocket. The invention resides
in
each individual feature described herein, alone, and in all combinations of
any and
all of those features. Accordingly, the scope of the invention shall be
limited only by
the following claims and their equivalents.
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