U.S. patent application number 14/572074 was filed with the patent office on 2016-06-16 for pocketed spring assembly comprising perimeter string of springs having rectangular convolutions.
The applicant listed for this patent is L&P Property Management Company. Invention is credited to Niels S. Mossbeck.
Application Number | 20160166076 14/572074 |
Document ID | / |
Family ID | 56109966 |
Filed Date | 2016-06-16 |
United States Patent
Application |
20160166076 |
Kind Code |
A1 |
Mossbeck; Niels S. |
June 16, 2016 |
Pocketed Spring Assembly Comprising Perimeter String of Springs
Having Rectangular Convolutions
Abstract
A bedding or seating product comprises a pocketed spring
assembly comprising a plurality of parallel interior strings of
individually pocketed coil springs. The interior strings of springs
may extend from head-to-foot or side-to-side of the product. The
pocketed spring assembly further comprises at least one perimeter
string of springs. Each of the springs of each perimeter string of
springs has rectangular convolutions to provide edge support to the
product.
Inventors: |
Mossbeck; Niels S.;
(Carthage, MO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
L&P Property Management Company |
South Gate |
CA |
US |
|
|
Family ID: |
56109966 |
Appl. No.: |
14/572074 |
Filed: |
December 16, 2014 |
Current U.S.
Class: |
5/720 ;
297/452.5 |
Current CPC
Class: |
A47C 27/065 20130101;
A47C 27/062 20130101; A47C 27/064 20130101; A47C 27/066 20130101;
A47C 23/0438 20130101; A47C 23/04 20130101 |
International
Class: |
A47C 27/06 20060101
A47C027/06; A47C 23/04 20060101 A47C023/04 |
Claims
1. A bedding or seating product comprising: a pocketed spring
assembly comprising an interior pocketed spring core comprising a
plurality of interior strings of springs joined to each other, each
of the interior strings of springs comprising a plurality of
interconnected pockets, each of the pockets containing at least one
coil spring encased in fabric, the fabric being joined to itself
along a longitudinal seam and adjacent individually pocketed coil
springs being separated from each other by at least one separating
seam joining opposed first and second plies; the pocketed spring
assembly further comprising at least one perimeter string of
springs, each perimeter string of springs being one continuous
string of pocketed springs surrounding four sides of the interior
pocketed spring core and comprising a plurality of interconnected
perimeter pockets, each of the perimeter pockets containing at
least one perimeter spring having rectangular convolutions, each
perimeter spring being encased in fabric and comprising four
substantially planar side surfaces, wherein one of the
substantially planar side surfaces is substantially parallel to and
contacts one of the substantially planar side surfaces of an
adjacent perimeter pocket; cushioning materials on at least one
side of the pocketed spring assembly; and a covering encasing the
pocketed spring assembly and cushioning materials.
2. A pocketed spring assembly for use in a bedding or seating
product, the pocketed spring assembly comprising: an interior
pocketed spring core comprising a plurality of interior strings of
springs joined to each other, each of the interior strings of
springs comprising a plurality of interconnected pockets, each of
the pockets containing at least one coil spring encased in fabric,
the fabric being joined to itself along a longitudinal seam and
adjacent individually pocketed coil springs being separated from
each other by at least one separating seam joining opposed first
and second plies; and the pocketed spring assembly further
comprising at least one perimeter string of springs, each perimeter
string of springs being one continuous string of pocketed springs
surrounding four sides of the interior pocketed spring core and
comprising a plurality of interconnected perimeter pockets, each of
the perimeter pockets containing at least one perimeter spring
having rectangular convolutions, each perimeter spring being
encased in fabric and comprising four substantially planar side
surfaces, wherein one of the substantially planar side surfaces is
substantially parallel to and contacts one of the substantially
planar side surfaces of an adjacent perimeter pocket.
3. The pocketed spring assembly of claim 2 wherein each of the
perimeter springs has square upper and lower end turns and a
plurality of square central convolutions between the end turns.
4. The pocketed spring assembly of claim 2 wherein the perimeter
springs have the same height as the coil springs.
5. The pocketed spring assembly of claim 3 wherein the perimeter
springs have a different height than the height of the coil
springs.
6. The pocketed spring assembly of claim 2 wherein the perimeter
springs have a greater height than the height of the coil
springs.
7. The pocketed spring assembly of claim 2 wherein the coil springs
have a greater height than the height of the perimeter springs.
8. The pocketed spring assembly of claim 2 wherein the interior
strings of springs extend transversely.
9. The pocketed spring assembly of claim 2 wherein the interior
strings of springs extend longitudinally.
10. The pocketed spring assembly of claim 2 wherein the
longitudinal seam is on one side of the interior string of
springs.
11. A pocketed spring assembly for use in a bedding or seating
product, the pocketed spring assembly comprising: an interior
pocketed spring core comprising a plurality of interior strings of
springs joined to each other, each of the interior strings of
springs comprising a plurality of interconnected pockets, each of
the pockets containing at least one coil spring encased in fabric;
and the pocketed spring assembly further comprising at least one
perimeter string of springs, each perimeter string of springs being
one continuous string of pocketed springs surrounding four sides of
the interior pocketed spring core and comprising a plurality of
interconnected pockets, each of the pockets of the perimeter string
of springs containing at least one perimeter spring having
rectangular convolutions, each perimeter spring being encased in
fabric and comprising four substantially planar side surfaces,
wherein one of the substantially planar side surfaces is
substantially parallel to and contacts one of the substantially
planar side surfaces of an adjacent perimeter pocket.
12. The pocketed spring assembly of claim 11 wherein each of the
perimeter springs has square upper and lower end turns and a
plurality of square central convolutions between the end turns.
13. The pocketed spring assembly of claim 11 wherein the perimeter
springs have the same height as the coil springs.
14. The pocketed spring assembly of claim 11 wherein the perimeter
springs have a different height than the height of the coil
springs.
15. The pocketed spring assembly of claim 14 wherein the perimeter
springs have a greater height than the height of the coil
springs.
16. The pocketed spring assembly of claim 14 wherein the coil
springs have a greater height than the height of the perimeter
springs.
17. The pocketed spring assembly of claim 11 wherein each of the
coil springs are the same height.
18. A pocketed spring assembly for use in a bedding or seating
product, the pocketed spring assembly comprising: an interior
pocketed spring core comprising a plurality of interior strings of
springs joined to each other, each of the interior strings of
springs comprising a plurality of interconnected pockets, each of
the pockets containing at least one interior spring encased in
fabric, the fabric being joined to itself along a longitudinal seam
and adjacent individually pocketed interior springs being separated
from each other by at least one separating seam joining opposed
first and second plies; and the pocketed spring assembly further
comprising at least one perimeter string of springs, each perimeter
string of springs being one continuous string of pocketed springs
surrounding four sides of the interior pocketed spring core and
comprising a plurality of interconnected perimeter pockets, each of
the perimeter pockets containing at least one perimeter spring
encased in fabric, each perimeter spring having square convolutions
and each perimeter pocket comprising four substantially planar side
surfaces, wherein one of the substantially planar side surfaces is
substantially parallel to and contacts one of the substantially
planar side surfaces of an adjacent perimeter pocket.
19. The pocketed spring assembly of claim 18 wherein the fabric of
each perimeter string of springs is joined to itself along a
longitudinal seam and adjacent individually pocketed perimeter
springs being separated from each other by at least one separating
seam joining opposed first and second plies.
20. The pocketed spring assembly of claim 18 wherein the
longitudinal seam of each perimeter strings of springs is on one
side of the perimeter string of springs.
21. The pocketed spring assembly of claim 18 wherein the perimeter
springs have the same height as the interior springs.
22. The pocketed spring assembly of claim 18 wherein the interior
springs are coil springs.
23. The pocketed spring assembly of claim 18 wherein the perimeter
springs have a greater height than the height of the interior
springs.
24. The pocketed spring assembly of claim 18 wherein the interior
springs have a greater height than the height of the perimeter
springs.
25. The pocketed spring assembly of claim 18 wherein each of the
interior springs are the same height.
26. A pocketed spring assembly comprising: an interior pocketed
spring core comprising a plurality of interior strings of springs
joined to each other, each of the interior strings of springs
comprising a plurality of interconnected pockets, each of the
pockets containing at least one coil spring encased in fabric, the
fabric being joined to itself along a longitudinal seam and
adjacent individually pocketed springs being separated from each
other by at least one separating seam; and the pocketed spring
assembly further comprising at least one perimeter string of
springs, each perimeter string of springs being one continuous
string of pocketed springs surrounding at least one corner of the
interior pocketed spring core and comprising a plurality of
interconnected perimeter pockets, each of the perimeter pockets
containing at least one perimeter spring having rectangular
convolutions, each perimeter spring being encased in fabric and
comprising four substantially planar side surfaces, wherein one of
the substantially planar side surfaces is substantially parallel to
and contacts one of the substantially planar side surfaces of an
adjacent perimeter pocket.
27. The pocketed spring assembly of claim 26 wherein the perimeter
springs have the same height as the coil springs.
28. The pocketed spring assembly of claim 26 wherein the perimeter
springs have a different height than the height of the coil
springs.
29. The pocketed spring assembly of claim 26 wherein the perimeter
springs have a greater height than the height of the coil springs.
Description
TECHNICAL FIELD OF THE INVENTION
[0001] This invention relates to bedding and seating products and,
more particularly, to pocketed spring assemblies used in bedding
and seating products, including mattresses and the method of
manufacturing such pocketed spring assemblies.
BACKGROUND OF THE INVENTION
[0002] Pocketed spring cores or assemblies are commonly used in
seating or bedding products. Such pocketed spring assemblies are
commonly made of multiple strings or rows of individually pocketed
springs. Adjacent strings of individually pocketed springs are
joined together by gluing or otherwise attaching the fabric of the
strings of springs to each other.
[0003] Pocketed coil springs are often referred to as a Marshall
construction in which each coil spring is encased within its own
fabric sack or pocket. The sack or pocket is typically defined
between two plies of a fabric strip connected together at intervals
along transverse lines of attachment spaced along the strip. The
two-ply fabric strip is generally formed by folding a strip of
double width fabric upon itself along a longitudinal centerline,
leaving the overlapped plies along the unjoined opposite edges of
the strip to be connected to each other along a longitudinal seam.
After the springs are inserted between the plies, opposed plies are
joined along transverse lines of attachment to close the pockets
and separate adjacent springs.
[0004] A variety of techniques have evolved for the manufacture of
pocketed springs, some contemplating the creation of the pockets
within the fabric plies prior to insertion of the wire spring and
others contemplating the insertion of compressed wire springs
between the plies of the strip and the subsequent creation of the
pockets by joining the two plies to each other along transverse
lines of attachment between adjacent springs. In recent times, heat
sensitive fabric and ultrasonic welding techniques have been
utilized to join the fabric plies together along the seams or lines
of attachment.
[0005] Pocketed spring assemblies are often inserted into a foam
partial encasement or "bucket" as the term is used in the art. One
or more upper layers of material may be located on top of the
"bucket" to complete the foam encasement. The foam encasement may
provide edge support and the appearance of a support border. If
such foam encased pocketed spring assemblies are roll packed, the
foam rails or any portion of the foam encasement may be damaged. If
the roll is stored, transported and stored at the location of a
bedding manufacturer for too long, the foam may not return to its
original intended form when unrolled at the bedding
manufacturer.
[0006] It is therefore an objective of this invention to provide a
seating or bedding product which has a pocketed spring assembly
interior and a perimeter of pocketed springs which may eliminate
the need for a foam encasement.
[0007] Still another objective of this invention is to provide a
seating or bedding product which has a pocketed spring assembly
having an edge support made of pocketed springs with the appearance
of a foam encasement.
SUMMARY OF THE INVENTION
[0008] The invention of this application which accomplishes these
objectives comprises a seating or bedding product made from an
assembly of pocketed springs, each spring of which is contained
within a fabric pocket. The pocketed spring assembly comprises a
plurality of interior strings of springs which may extend
longitudinally (end-to-end) or transversely (side-to-side) in the
product and at least one perimeter string of springs surrounding
the interior strings of springs.
[0009] One advantage of a pocketed spring assembly utilizing the
present invention is that multiple pocketed spring assemblies may
be roll packed, shipped to a desired destination for further
manufacture and unrolled without damage to the individual pocketed
spring assemblies.
[0010] According to one aspect of the invention, the bedding or
seating product comprises a pocketed spring assembly comprising a
plurality of parallel interior strings of springs joined to each
other. Each of the interior strings of springs comprises a
plurality of interconnected pockets, each of the pockets containing
at least one coil spring encased in fabric. The fabric is joined to
itself along a longitudinal seam which may be located along one
side of the string of springs. Adjacent individually pocketed
springs are separated from each other by at least one separating
seam joining opposed first and second plies. The pocketed spring
assembly further comprises at least one perimeter string of
springs. Each perimeter string of springs comprises a plurality of
interconnected perimeter pockets, each of the perimeter pockets
containing at least one perimeter spring having rectangular
convolutions. Each perimeter spring is encased in fabric.
Cushioning materials may be on at least one side of the product. A
covering may encase the pocketed spring assembly and cushioning
materials.
[0011] According to another aspect of the invention, a pocketed
spring assembly for use in a bedding or seating product comprises a
plurality of interior strings of springs joined together. Each of
the interior strings of springs comprises a piece of fabric joined
to itself along a longitudinal seam and multiple spaced separating
seams to define a plurality of pockets. Each pocket contains at
least one coil spring. Each of the springs has end turns and
central convolutions between the end turns. Opposed plies of the
fabric are joined together by the at least one separating seam. The
pocketed spring assembly further comprises at least one perimeter
string of springs. Each perimeter string of springs comprises a
plurality of interconnected perimeter pockets, each of the
perimeter pockets containing at least one perimeter spring having
rectangular convolutions. Each perimeter spring is encased in
fabric and comprises rectangular end turns and rectangular central
convolutions between the end turns. According to one embodiment,
the convolutions of each perimeter spring, including the end turns,
are square.
[0012] According to another aspect of the invention, a pocketed
spring assembly for use in a bedding or seating product comprises a
plurality of interior strings of springs joined together. Each of
the interior strings of springs comprises a piece of fabric joined
to itself along a longitudinal seam and multiple spaced separating
seams to define a plurality of pockets. Each pocket contains at
least one interior spring, each interior spring having circular
upper and lower end turns and central convolutions between the end
turns. Each of the separating seams joins opposed first and second
plies of an interior string of springs. The pocketed spring
assembly further comprises at least one perimeter string of
springs. Each perimeter string of springs comprises a plurality of
interconnected perimeter pockets, each of the perimeter pockets
containing at least one perimeter spring having square
convolutions. Each perimeter spring is encased in fabric and
comprises square end turns and square central convolutions between
the end turns which give the appearance of a conventional foam
encasement.
[0013] According to another aspect of the invention, a pocketed
spring assembly constructed in accordance with the present
invention may be posturized or have different regions of different
firmness. Some of the strings of springs may contain conventional
coil springs, while other strings of springs may contain springs
having rectangular convolutions, thus imparting different
firmnesses to the different strings of springs. Different regions
or sections of the pocketed spring assembly may be made of
different strings of springs to impart different firmnesses to the
regions.
[0014] According to another aspect of the invention, a pocketed
spring assembly for use in a bedding or seating product may
comprise an interior portion comprising strings of pocketed springs
joined together and at least one perimeter string of springs. The
perimeter pocketed springs of the perimeter string of springs may
have a height greater than the height of the pocketed coil springs
of the interior strings of springs. Alternatively, the height of
the perimeter pocketed springs of the perimeter string of springs
may be less than the height of the pocketed coil springs of the
interior strings of springs. In another embodiment, the height of
the perimeter pocketed springs of the perimeter string of springs
may be identical to the height of the pocketed coil springs of the
interior strings of springs.
[0015] These and other objects and advantages of this invention
will be more readily apparent from the following description of the
drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view, partially broken away, of a
bedding product incorporating one embodiment of pocketed spring
assembly;
[0017] FIG. 2A is an enlarged perspective view of a portion of a
string of pocketed perimeter springs used in the pocketed spring
assembly of FIG. 1 before being folded;
[0018] FIG. 2B is an enlarged perspective view of a portion of a
string of pocketed perimeter springs used in the pocketed spring
assembly of FIG. 1 after being folded;
[0019] FIG. 3 is an enlarged perspective view, partially broken
away, of a portion of a string of pocketed perimeter springs used
in the pocketed spring assembly of FIG. 1;
[0020] FIG. 4 is a cross-sectional view, partially broken away, of
a portion of the perimeter strings of springs of the pocketed
spring assembly of FIG. 1;
[0021] FIG. 5 is a cross-sectional view, partially broken away,
taken along the line 5-5 of FIG. 1 without the covering;
[0022] FIG. 6 is a perspective view, partially broken away, of a
portion of an alternative pocketed spring assembly;
[0023] FIG. 6A is a cross-sectional view, partially broken away,
taken along the line 6A-6A of FIG. 6 without the covering;
[0024] FIG. 7 is a perspective view, partially broken away, of a
portion of an alternative pocketed spring assembly;
[0025] FIG. 7A is a cross-sectional view, partially broken away,
taken along the line 7A-7A of FIG. 7 without the covering;
[0026] FIG. 8 is a perspective view, partially broken away, of a
portion of an alternative pocketed spring assembly;
[0027] FIG. 8A is a cross-sectional view, partially broken away,
taken along the line 8A-8A of FIG. 8 without the covering;
[0028] FIG. 9 is a perspective view, partially broken away, of a
portion of an alternative pocketed spring assembly;
[0029] FIG. 9A is a cross-sectional view, partially broken away,
taken along the line 9A-9A of FIG. 9 without the covering;
[0030] FIG. 10A is a top view of another embodiment of pocketed
spring assembly;
[0031] FIG. 10B is a top view of another embodiment of pocketed
spring assembly;
[0032] FIG. 11A is a top view of another embodiment of pocketed
spring assembly; and
[0033] FIG. 11B is a top view of another embodiment of pocketed
spring assembly.
DETAILED DESCRIPTION OF THE DRAWINGS
[0034] With reference to FIG. 1, there is illustrated a bedding
product in the form of a single-sided mattress 10 incorporating
this 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 topper or any other suitable materials. Although
two padding or cushioning layers 14, 16 are illustrated on top of
the pocketed spring assembly 12, any number of padding or
cushioning layers may be used, including a single padding or
cushioning layer. The pocketed spring assembly 12 is mounted upon a
base 18 and is completely enclosed within a covering material
20.
[0035] 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 products shown and described herein, the length is
illustrated as being greater than the width. However, it is within
the contemplation of the present invention that the length and
width may be identical, as in a square product.
[0036] While the mattress 10 illustrated in FIG. 1 is a
single-sided mattress, the pocketed spring assembly 12, or 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.
[0037] FIGS. 9 and 9a illustrate a double-sided mattress 10d
comprising a pocketed spring assembly 12d different than the
pocketed spring assembly 12 shown in the mattress 10 of FIG. 1. For
example, the mattress 10d of FIGS. 9 and 9a has conventional
padding layers 14, 16 above and below the pocketed spring assembly
12d.
[0038] According to the practice of this invention, any of the
padding or cushioning layers may be omitted in any of the
embodiments shown or described herein. The novel features reside in
the pocketed spring assembly 12.
[0039] As shown in the embodiment illustrated in FIGS. 1-5,
pocketed spring assembly 12 is manufactured from multiple interior
strings of pocketed springs 26 joined together to form an interior
pocketed spring core 28. Each interior string of pocketed springs
26 extends from side-to-side or transversely across the full width
of the product 10. Although the interior strings of pocketed
springs 26 are illustrated as extending transversely or from
side-to-side in the pocketed spring assembly 12 of FIG. 1, they may
extend longitudinally or from end-to-end in this or any other
interior pocketed spring assembly shown or described herein.
[0040] These interior strings of pocketed springs 26 are connected
in side-by-side relationship as, for example, by gluing the sides
of the strings together in an assembly machine, so as to create an
assembly or matrix of springs having multiple rows and columns of
pocketed springs bound together as by gluing, welding or any other
conventional assembly process commonly used to create pocketed
spring cores or assemblies. As shown in FIG. 5, the interior
strings of pocketed springs 26 are joined so that individual
pockets 30 of coil springs 32 are aligned in transversely extending
rows 34 and longitudinally extending columns 36. Although not
shown, the interior strings of pocketed springs 26 may be offset
from one another in the interior pocketed spring core 28.
[0041] The pocketed spring assembly 12 of mattress 10 further
comprises a perimeter string of springs 38 surrounding interior
pocketed spring core 28. The perimeter string of springs 38 is
illustrated being one continuous string of pocketed springs 38
surrounding all four sides of interior pocketed spring core 28 and
joined to itself using any conventional joining mechanism,
including welding. However, the perimeter layer or layers of
pocketed spring assembly 12 may comprise any number of perimeter
strings of springs 38 joined together. For example, four perimeter
strings of springs 38 may be joined together to form the perimeter
layer, each perimeter strings of springs 38 being linear and joined
to an adjacent side of the interior pocketed spring core 28.
[0042] As best illustrated in FIG. 5, each interior string of
pocketed springs 26 comprises a row of interconnected fabric
pockets 30. Each of the fabric pockets 30 contains at least one
coil spring 32. As best shown in FIG. 5, each coil spring 32 has a
central or longitudinal axis A, an upper end turn 40, a lower end
turn 42 and a plurality of central convolutions 44 between the end
turns. FIG. 5 illustrates a coil spring 32 in which the diameter of
each end turn 40, 42 is identical to the diameter of the central
convolutions 44. However, a barrel-shaped or hourglass-shaped coil
spring may be located in some or all of the interior pockets 30 of
some or all of the interior strings of springs 26 in any of the
embodiments shown or described herein.
[0043] Preferably, one piece of fabric is used to create an
interior string of pocketed springs 26, the piece of fabric being
folded over onto itself around a plurality of aligned coil springs
32. As best shown in FIG. 5, opposite sides or plies of the fabric
are sewn, welded or otherwise secured together in order to create a
longitudinal seam (not shown) and a plurality of separating seams
46.
[0044] Although the seams in all of the embodiments shown herein
are shown as being spaced rectangles, any of the seams may be
spaced dots, triangles or solid line segments without spaces.
[0045] As shown in FIG. 5, the interior string of pocketed springs
26 has a generally planar top surface 48 in a top plane P1 and a
parallel generally planar bottom surface 50 in a bottom plane P2.
The linear distance between the top and bottom surfaces of the
interior string of pocketed springs 26 defines a height H of the
interior string of pocketed springs 26. This linear distance
further defines the height H of the pocketed spring assembly 12
because each of the interior strings of springs 26 has the same
height. However, it is within the scope of the present invention
that different interior strings of springs of the interior core of
a pocketed spring assembly have different heights.
[0046] FIGS. 2A and 4 illustrate a portion of the perimeter strings
of springs 38 in an open configuration before being folded into a
closed configuration. As shown in FIG. 2A, once the perimeter
strings of springs 38 is created in its open configuration, a
machine or operator may rotate adjacent pockets in the direction of
arrows 52, such that adjacent generally pocketed side surfaces
contact each other. One primary advantage of the present invention
is that the perimeter strings of springs 38, in its closed
configuration and attached to the interior pocketed spring core 28,
provides increased density and thus, edge support to the pocketed
spring assembly 12.
[0047] As best shown in FIG. 4, each perimeter string of pocketed
springs 38 comprises a row of interconnected fabric perimeter
pockets 56. Each of the fabric perimeter pockets 56 contains at
least one perimeter spring 54. As best shown in FIG. 2B, each
perimeter pocket 56 comprises four identical side surfaces 58 and
identical top and bottom surfaces 60, 61, respectively.
[0048] As best shown in FIG. 3, each perimeter spring 54 has a
central or longitudinal axis A, a rectangular upper end turn 62, a
rectangular lower end turn 64 and a plurality of rectangular
convolutions 64 between the end turns. Each of the rectangular
convolutions 64 comprises four linear portions 63 joined together
with rounded corner portions 65. In the perimeter spring 54 shown
in the drawings, the rectangle is a square; however, the rectangle
need not be a square. Any size rectangle may be used in any of the
embodiments shown or described herein in accordance with the
present invention.
[0049] Preferably, one piece of fabric is used to create each of
the perimeter string(s) of pocketed springs 38, the piece of fabric
being folded over onto itself around a plurality of aligned
perimeter springs 54. As best shown in FIGS. 3 and 4, opposite
sides or plies 68, 70 of the fabric are sewn, welded or otherwise
secured together in order to create a longitudinal seam 72 and a
plurality of separating seams 74. FIG. 2A illustrates ply 68 being
closest to the reader and ply 70 being behind the perimeter springs
54.
[0050] As best shown in FIGS. 2A, 2B and 3, opposed edges 76 of the
piece of fabric used to create the string of pocketed perimeter
springs 54 are aligned and spaced from the longitudinal seam 72 a
distance indicated by numeral 78. Although the drawings indicated
the longitudinal seam 72 being below the free edges 76 of the piece
of fabric, the longitudinal seam 72 may be above the free edges 76
of the piece of fabric.
[0051] As shown in FIGS. 4 and 5, the string of pocketed perimeter
springs 38 has a generally planar top surface 60 in top plane P1
and a parallel generally planar bottom surface 61 in a bottom plane
P2. The linear distance between the top and bottom surfaces of the
string of pocketed perimeter springs 38 defines a height H of the
string of pocketed perimeter springs 54. This linear distance
further defines the height H of the pocketed spring assembly 12
because each of the interior strings of springs 26 and perimeter
string of springs 38 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, as will be
described below.
[0052] As shown in FIG. 5, the perimeter string of springs 38 is
glued or otherwise secured to the periphery of the interior
pocketed spring core 28. As shown in FIG. 1, the perimeter string
of springs 38 has a generally rectangular shape comprising two
linear end portions 80 (only one being shown) and two linear side
portions 82. The end portions 80 are glued or otherwise secured to
the outermost transversely extending interior strings of springs
26, and the side portions 82 are glued or otherwise secured to the
outermost pockets 30 of the transversely extending interior strings
of springs 26 along seams 84. In the event, the interior strings of
springs 26 were longitudinally, rather than transversely extending,
the end portions 80 would be glued or otherwise secured to the
outermost pockets 30 of the longitudinally extending interior
strings of springs 26, and the side portions 82 would be glued or
otherwise secured to the outermost longitudinally extending
interior strings of springs 26.
[0053] FIGS. 6 and 6A illustrate an alternative embodiment of
one-sided bedding or seating product 10a having a pocketed spring
assembly 12a. Pocketed spring assembly 12a is slightly different
than pocketed spring assembly 12 of product 10. The interior
pocketed spring core 28 comprising multiple interior strings of
springs 26 of a height H of pocketed spring assembly 12a is
identical to the interior pocketed spring core 28 of pocketed
spring assembly 12 of bedding product 10.
[0054] However, the perimeter string of springs 38a of pocketed
spring assembly 12a is taller than perimeter string of springs 38
described above and illustrated in FIGS. 1-5. As best shown in FIG.
6A, the string of pocketed perimeter springs 38a has a generally
planar top surface 60a in top plane P3, and a parallel generally
planar bottom surface 61a in a bottom plane P2. The linear distance
between the top and bottom surfaces 60a, 61 a of the string of
pocketed perimeter springs 38a defines a height H1 of the perimeter
string of pocketed springs 38a. This linear distance is greater
than the height H of the interior pocketed spring core 28 of
pocketed spring assembly 12a of bedding product 10a. Therefore,
this embodiment of product has additional edge support.
[0055] The perimeter string of springs 38a of pocketed spring
assembly 12a has a generally rectangular shape comprising two
linear end portions 80a (only one being shown) and two linear side
portions 82a. The end portions 80a are glued or otherwise secured
to the outermost transversely extending interior strings of springs
26, and the side portions 82a are glued or otherwise secured to the
outermost pockets 30 of the transversely extending interior strings
of springs 26 along seams 84a. In the event, the interior strings
of springs 26 extend longitudinally, rather than transversely
extending, the end portions 80a would be glued or otherwise secured
to the outermost pockets 30 of the longitudinally extending
interior strings of springs 26, and the side portions 82a would be
glued or otherwise secured to the outermost longitudinally
extending interior strings of springs 26.
[0056] The difference in height between the height H1 of the
perimeter string of pocketed springs 38a and the lesser height H of
the interior strings of springs 26 creates a trough 86 inside which
resides a generally rectangular shaped cushion 15, as shown in FIG.
6A. The cushion 15 may be made of foam, fiber, gel, a pocketed
spring topper or any combination thereof or any other suitable
material. Although the cushion 15 is shown as a single piece, it
may comprise multiple pieces joined together or separated.
[0057] FIGS. 7 and 7A illustrate an alternative embodiment of
one-sided bedding or seating product 10b having a pocketed spring
assembly 12b. Pocketed spring assembly 12b is slightly different
than pocketed spring assembly 12 of product 10. The interior
pocketed spring core 28 comprising multiple interior strings of
springs 26 of a height H of pocketed spring assembly 12b is
identical to the interior pocketed spring core 28 of pocketed
spring assembly 12 of bedding product 10.
[0058] However, the perimeter string of springs 38b of pocketed
spring assembly 12b is shorter than perimeter string of springs 38
described above and illustrated in FIGS. 1-5. As best shown in FIG.
7A, the string of pocketed perimeter springs 38b has a generally
planar top surface 60b in top plane P4 and a parallel generally
planar bottom surface 61b in a bottom plane P2. The linear distance
between the top and bottom surfaces 60b, 61 b of the string of
pocketed perimeter springs 38b defines a height H2 of the string of
pocketed perimeter springs 38b. This linear distance is less than
the height H of the interior pocketed spring core 28 of pocketed
spring assembly 12b of bedding product 10b. Therefore, this
embodiment of product needs additional edge support.
[0059] The perimeter string of springs 38b of pocketed spring
assembly 12b has a generally rectangular shape comprising two
linear end portions 80b (only one being shown) and two linear side
portions 82b. The end portions 80b are glued or otherwise secured
to the outermost transversely extending interior strings of springs
26, and the side portions 82b are glued or otherwise secured to the
outermost pockets 30 of the transversely extending interior strings
of springs 26 along seams 84b. In the event the interior strings of
springs 26 extend longitudinally, rather than transversely
extending, the end portions 80b would be glued or otherwise secured
to the outermost pockets 30 of the longitudinally extending
interior strings of springs 26, and the side portions 82b would be
glued or otherwise secured to the outermost longitudinally
extending interior strings of springs 26.
[0060] The difference in height between the height H2 of the
perimeter string of pocketed springs 38b and the greater height H
of the interior strings of springs 26 creates a generally
rectangular trough 88 inside which resides a generally
rectangular-shaped cushion 90, as shown in FIG. 7A. The cushion 90
may be made of foam, fiber, gel, a pocketed spring topper or any
combination thereof, including any other suitable material.
[0061] FIGS. 8 and 8A illustrate an alternative embodiment of
one-sided bedding or seating product 10c having a pocketed spring
assembly 12c. Pocketed spring assembly 12c is slightly different
than pocketed spring assembly 12 of product 10. The interior
pocketed spring core 28 comprising multiple interior strings of
springs 26 of a height H of pocketed spring assembly 12b is
identical to the interior pocketed spring core 28 of pocketed
spring assembly 12 of bedding product 10.
[0062] However, the pocketed spring core 12c has two perimeter
strings of springs 38c, 38cc of the same height, as opposed to one.
Each of the perimeter strings of springs 38c, 38cc of pocketed
spring assembly 12c is the same height as perimeter string of
springs 38 described above and illustrated in FIGS. 1-5 and the
same height as the interior strings of springs 26 of the interior
pocketed spring core 28. As best shown in FIG. 8A, each of the
perimeter strings of pocketed springs 38c, 38cc has a generally
planar top surface 60c in top plane P1 and a parallel generally
planar bottom surface 61c in a bottom plane P2. The linear distance
between the top and bottom surfaces 60c, 61 c of each perimeter
string of pocketed springs 38c, 38cc defines a height H of the
string of pocketed perimeter springs. This linear distance is
identical to the height H of the interior pocketed spring core 28
of pocketed spring assembly 12c of bedding product 10c.
[0063] The inner perimeter string of springs 38c of pocketed spring
assembly 12c has a generally rectangular shape comprising two
linear end portions 80c (only one being shown) and two linear side
portions 82c. The end portions 80c are glued or otherwise secured
to the outermost transversely extending interior strings of springs
26, and the side portions 82c are glued or otherwise secured to the
outermost pockets 30 of the transversely extending interior strings
of springs 26 along seams 84c. The outer perimeter string of
springs 38cc of pocketed spring assembly 12c has a generally
rectangular shape comprising two linear end portions 80cc (only one
being shown) and two linear side portions 82cc. The end portions
80cc are glued or otherwise secured to the linear end portions 80c
of the inner perimeter string of springs 38c (only one being
shown), and the side portions 82cc are glued or otherwise secured
to the linear end portions 80c of the inner perimeter string of
springs 38c along seams 84cc.
[0064] FIGS. 9 and 9A illustrate an alternative embodiment of
two-sided bedding or seating product 10d having a pocketed spring
assembly 12d. Pocketed spring assembly 12d is slightly different
than pocketed spring assembly 12 of product 10. The interior
pocketed spring core 28 comprising multiple interior strings of
springs 26 of a height H of pocketed spring assembly 12d is
identical to the interior pocketed spring core 28 of pocketed
spring assembly 12 of bedding product 10.
[0065] However, the perimeter string of springs 38d of pocketed
spring assembly 12d is taller than perimeter string of springs 38
described above and illustrated in FIGS. 1-5. As best shown in FIG.
6A, the string of pocketed perimeter springs 38d has a generally
planar top surface 60d in top plane P5 and a parallel generally
planar bottom surface 61d in a bottom plane P6. The linear distance
between the top and bottom surfaces 60d, 61 d of the string of
pocketed perimeter springs 38d defines a height H3 of the perimeter
string of pocketed springs 38d. This linear distance is greater
than the height H of the interior pocketed spring core 28 of
pocketed spring assembly 12d of bedding product 10d. Therefore,
this embodiment of product has additional edge support.
[0066] The perimeter string of springs 38d of pocketed spring
assembly 12d has a generally rectangular shape comprising two
linear end portions 80d (only one being shown) and two linear side
portions 82d. The end portions 80d are glued or otherwise secured
to the outermost transversely extending interior strings of springs
26, and the side portions 82d are glued or otherwise secured to the
outermost pockets 30 of the transversely extending interior strings
of springs 26 along seams 84d. In the event the interior strings of
springs 26 extend longitudinally, rather than transversely
extending, the end portions 80d would be glued or otherwise secured
to the outermost pockets 30 of the longitudinally extending
interior strings of springs 26, and the side portions 82d would be
glued or otherwise secured to the outermost longitudinally
extending interior strings of springs 26.
[0067] The difference in height between the height H3 of the
perimeter string of pocketed springs 38d and the lesser height H of
the interior strings of springs 26 creates a trough 92 on each side
of the mattress 10 inside which resides a generally
rectangular-shaped cushion 94, as shown in FIG. 9A. The cushion 94
may be made of foam, fiber, gel, a pocketed spring topper or any
combination thereof or any other suitable material. Although the
cushion 94 is shown as a single piece, it may comprise multiple
pieces joined together or separated.
[0068] FIG. 10A illustrates an alternative embodiment of bedding
product 10e. This product 10e may be a single-sided or double-sided
product having a pocketed spring assembly 12e. The product 10e has
a perimeter string of springs 96, which may be identical to any
perimeter string of springs shown or described herein. However, the
interior pocketed spring core 28e of pocketed spring assembly 12e
is different than any of the interior pocketed spring cores shown
or described herein. The interior pocketed spring core 28e of
pocketed spring assembly 12e of this embodiment is posturized or
has different regions of different firmness due to the
constructions of the strings of springs used in the interior
pocketed spring core 28e of pocketed spring assembly 12e. Although
illustrated as having two regions or areas of different firmness F1
and F2, such a posturized pocketed spring assembly may have any
number of such regions across the width of the product.
[0069] As illustrated in FIG. 10A, the interior pocketed spring
core 28e of pocketed spring assembly 12e has a plurality of
longitudinally extending interior strings of springs 26e, 26ee
joined together. The interior pocketed spring core 28e of pocketed
spring assembly 12e of the mattress 10e has a "firm" side or region
98 and a "soft" side or region 99. The "firm" portion F1 is firmer
than the "soft" portion F2 due to the construction of the interior
strings of springs making up each side, portion or region. For
example, the "firm" side 98 of interior pocketed spring core 28e of
pocketed spring assembly 12e may comprise interior strings of
springs 26e, while the "soft" side 99 of pocketed spring assembly
12e may comprise interior strings of springs 26ee. Because the
convolutions of the pocketed springs of interior strings of springs
26ee are circular, rather than rectangular like the convolutions of
the springs of interior strings of springs 26ee, the firmness of
the group of connected interior strings of springs 26e in section
99 of pocketed spring assembly 12e is less firm or "softer" than
the firmness of the group of connected interior strings of springs
26ee in section 98 of pocketed spring assembly 12e.
[0070] FIG. 10B illustrates another alternative embodiment of
bedding product 10f. This product 10f may be a single-sided or
double-sided product having a pocketed spring assembly 12f. The
product 10f has a perimeter string of springs 100 which may be
identical to any perimeter string of springs shown or described
herein. However, the interior pocketed spring core 28f of pocketed
spring assembly 12f is different than any of the interior pocketed
spring cores shown or described herein. The pocketed spring
assembly 12f of this embodiment is posturized or has different
regions of different firmness due to the constructions of the
interior strings of springs 26f, 26ff used in the interior pocketed
spring core 28e of pocketed spring assembly 12e. Although
illustrated as having three regions or areas of two different
firmnesses 102, 104, such a posturized pocketed spring assembly may
have any number of such regions across the length of the
product.
[0071] As illustrated in FIG. 10B, the interior pocketed spring
assembly 28f has a plurality of transversely extending strings of
springs 26f, 26ff joined together. The interior pocketed spring
assembly 28f of the mattress 10f has a "firm" area or region 104
and two "soft" areas or regions 102 on opposite sides of the firm
region 104, the "firm" portion 104 being firmer than the "soft"
portions 102, due to the construction of the interior strings of
springs making up each portion or region. For example, the "firm"
region 104 of interior pocketed spring assembly 28f may comprise
strings of springs 26f containing springs having rectangular
convolutions, as shown in FIG. 3, while the "soft" regions 102 of
interior pocketed spring assembly 28f may comprise strings of
springs 26ff having conventional coil springs. Because the
convolutions of the pocketed springs of interior strings of springs
26ff are circular, rather than rectangular like the convolutions of
the springs of interior strings of springs 26f, the firmness of the
group of connected interior strings of springs 26f in sections 102
of pocketed spring assembly 12f is less firm or "softer" than the
firmness of the group of connected interior strings of springs 26ff
in section 104 of pocketed spring assembly 12f.
[0072] FIG. 11A illustrates an alternative embodiment of bedding
product 10g. This product 10g comprises a pocketed spring assembly
12g, which may have a uniform, non-posturized "feel" or firmness.
The pocketed spring assembly 12g comprises an interior pocketed
spring assembly 28g and a perimeter string of springs 106 glued or
otherwise secured together around the perimeter of the interior
pocketed spring assembly 28g. The interior pocketed spring assembly
28g comprises a plurality of joined transversely extending strings
of springs 26g extending in the direction shown by the dashed line
108. Each of the transversely extending strings of springs 26g of
the interior pocketed spring assembly 28g has springs with
rectangular convolutions, like the string of springs shown in FIG.
4. The height of the perimeter string of springs 106 may be
identical to, less than or greater than the height of all or some
of the transversely extending strings of springs 26g of the
interior pocketed spring assembly 28g. The height of the
transversely extending strings of springs 26g of the interior
pocketed spring assembly 28g is commonly uniform; however, some of
the transversely extending strings of springs 26g of the interior
pocketed spring assembly 28g may be a different height than
others.
[0073] FIG. 11B illustrates an alternative embodiment of bedding
product 10h. This product 10h comprises a pocketed spring assembly
12h, which may have a uniform, non-posturized "feel" or firmness.
The pocketed spring assembly 12h comprises an interior pocketed
spring assembly 28h and a perimeter string of springs 110 glued or
otherwise secured together around the perimeter of the interior
pocketed spring assembly 28h. The interior pocketed spring assembly
28h comprises a plurality of joined longitudinally extending
strings of springs 26h extending in the direction shown by the
dashed line 112. Each of the longitudinally extending strings of
springs 26h of the interior pocketed spring assembly 28h has
springs with rectangular convolutions, like the string of springs
shown in FIG. 4. The height of the perimeter string of springs 110
may be identical to, less than or greater than the height of all or
some of the longitudinally extending strings of springs 26h of the
interior pocketed spring assembly 28h. The height of the
longitudinally extending strings of springs 26h of the interior
pocketed spring assembly 28h is commonly uniform; however, some of
the longitudinally extending strings of springs 26h of the interior
pocketed spring assembly 28h may be a different height than
others.
[0074] While I have described several preferred embodiments of this
invention, persons skilled in this art will appreciate that other
strings of springs 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. Therefore, I do not intend to be
limited except by the scope of the following appended claims.
* * * * *