U.S. patent application number 17/685664 was filed with the patent office on 2022-09-01 for independent suspension spring assembly.
This patent application is currently assigned to BEDGEAR LLC.. The applicant listed for this patent is BEDGEAR LLC.. Invention is credited to Eugene Alletto, JR..
Application Number | 20220273112 17/685664 |
Document ID | / |
Family ID | 1000006288725 |
Filed Date | 2022-09-01 |
United States Patent
Application |
20220273112 |
Kind Code |
A1 |
Alletto, JR.; Eugene |
September 1, 2022 |
INDEPENDENT SUSPENSION SPRING ASSEMBLY
Abstract
A spring assembly is provided that includes a plurality of first
strings of springs and a plurality of second strings of springs.
Each of the first strings are joined to at least another one of the
first strings or one of the second strings. Each of the first
strings includes first and second plies of fabric that define a
plurality of pockets formed along a length of the first string. The
pockets are formed by vertical seams that join the plies. The
vertical seams each include an upper slit that extends through a
top surface of the first string and a lower slit that extends
through a bottom surface of the first string. Each of the pockets
have at least one spring positioned therein.
Inventors: |
Alletto, JR.; Eugene; (Glen
Head, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BEDGEAR LLC. |
Farmingdale |
NY |
US |
|
|
Assignee: |
BEDGEAR LLC.
Farmingdale
NY
|
Family ID: |
1000006288725 |
Appl. No.: |
17/685664 |
Filed: |
March 3, 2022 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15616269 |
Jun 7, 2017 |
|
|
|
17685664 |
|
|
|
|
62347199 |
Jun 8, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 27/064 20130101;
A47C 27/07 20130101; A47C 27/062 20130101; F16F 3/04 20130101; A47C
27/0453 20130101 |
International
Class: |
A47C 27/06 20060101
A47C027/06; F16F 3/04 20060101 F16F003/04; A47C 27/045 20060101
A47C027/045; A47C 27/07 20060101 A47C027/07 |
Claims
1-20. (canceled)
21. A mattress comprising opposite head and foot ends, the head end
comprising a first spring assembly that defines a first zone, the
first spring assembly comprising first pockets and a first spring
disposed in each of the first pockets, each of the first pockets
being coupled to another one of the first pockets, the foot end
comprising a second spring assembly that defines a second zone, the
second spring assembly comprising second pockets and a second
spring disposed in each of the second pockets, each of the second
pockets being coupled to another one of the second pockets, the
second spring assembly being different than the first spring
assembly to provide the second zone with a firmness that is
different than a firmness of the first zone.
22. The mattress recited in claim 21, wherein the first pockets are
joined to one another by first vertical seams, the first spring
assembly comprising opposite upper and lower slits extending into
each of the first vertical seams.
23. The mattress recited in claim 22, wherein the slits of a
respective one of the first vertical seams have the same
length.
24. The mattress recited in claim 22, wherein there are no gaps or
openings between the slits of a respective one of the first
vertical seams.
25. The mattress recited in claim 22, wherein the second pockets
are joined to one another by second vertical seams, the second
spring assembly comprising opposite upper and lower slits extending
into each of the second vertical seams.
26. The mattress recited in claim 25, wherein the slits of a
respective one of the first vertical seams have the same length and
the slits of a respective one of the second vertical seams have the
same length.
27. The mattress recited in claim 25, wherein there are no gaps or
openings between the slits of a respective one of the first
vertical seams and no gaps or openings between the slits of a
respective one of the second vertical seams.
28. The mattress recited in claim 21, wherein an interior of one of
the first pockets is not in communication with an interior of
another one of the first pockets.
29. The mattress recited in claim 28, wherein an interior of one of
the second pockets is not in communication with an interior of
another one of the second pockets.
30. The mattress recited in claim 21, further comprising a third
spring assembly positioned between the first spring assembly and
the second spring assembly that defines a third zone, the third
zone having a firmness that is the same as the firmness of the
first zone.
31. The mattress recited in claim 30, further comprising a fourth
spring assembly positioned between the first spring assembly and
the third spring assembly that defines a fourth zone, the fourth
zone having a firmness that is the same as the firmness of the
second zone.
32. The mattress recited in claim 31, further comprising a fifth
spring assembly positioned between the first spring assembly and an
end surface of the foot end that defines a fifth zone, the fifth
zone having a firmness that is the same as the firmness of the
first zone.
33. The mattress recited in claim 21, further comprising a third
spring assembly positioned between the first spring assembly and
the second spring assembly that defines a third zone, the third
zone having a firmness that is different than the firmness of the
first zone.
34. The mattress recited in claim 33, further comprising a fourth
spring assembly positioned between the second spring assembly and
the third spring assembly that defines a fourth zone, the fourth
zone having a firmness that is the same as the firmness of the
first zone.
35. The mattress recited in claim 34, further comprising a fifth
spring assembly positioned between the second spring assembly and
an end surface of the foot end that defines a fifth zone, the fifth
zone having a firmness that is the same as the firmness of the
first zone.
36. The mattress recited in claim 21, further comprising a third
spring assembly positioned between the first spring assembly and
the second spring assembly that defines a third zone, the third
zone having a firmness that is the same as the firmness of the
second zone.
37. The mattress recited in claim 36, further comprising a fourth
spring assembly positioned between the second zone and the third
zone that defines a fourth zone, the fourth zone having a firmness
that is the same as the firmness of the first zone.
38. The mattress recited in claim 21, wherein the mattress
comprises opposite first and second side surfaces each extending
continuously from the head end to the foot end, the spring
assemblies each extending continuously from the first side surface
to the second side surface.
39. The mattress recited in claim 21, wherein at least one of the
first springs includes outer spring and an inner spring positioned
therein, the inner springs each being positioned within one of the
outer springs in a nested configuration.
40. The mattress recited in claim 39, wherein at least one of the
second springs includes outer spring and an inner spring positioned
therein, the inner springs of the second springs each being
positioned within one of the outer springs of the second springs in
a nested configuration.
41. The mattress recited in claim 39, wherein at least one of the
second springs includes only one spring.
42. The mattress recited in claim 21, wherein the first springs
each include outer spring and an inner spring positioned therein,
the inner springs each being positioned within one of the outer
springs in a nested configuration.
43. The mattress recited in claim 42, wherein each of the second
springs includes outer spring and an inner spring positioned
therein, the inner springs of the second springs each being
positioned within one of the outer springs of the second springs in
a nested configuration.
44. The mattress recited in claim 42, wherein each of the second
springs includes only one spring.
45. A mattress comprising opposite top and bottom ends, the top end
including a top end surface and the bottom end including an
opposite bottom end surface, the mattress comprising opposite first
and second side surfaces each extending from the top end surface to
the bottom end surface, the surfaces defining a perimeter of the
mattress, the top end comprising a first spring assembly that
defines a first zone, the first spring assembly comprising first
pockets and a first spring disposed in each of the first pockets,
each of the first pockets being coupled to another one of the first
pockets, the bottom end comprising a second spring assembly that
defines a second zone, the second spring assembly comprising second
pockets and a second spring disposed in each of the second pockets,
each of the second pockets being coupled to another one of the
second pockets, the first and second spring assemblies each
defining a portion of the perimeter, the second springs being
different than the first springs to provide the second zone with a
firmness that is different than a firmness of the first zone.
46. A mattress comprising opposite top and bottom ends, the top end
including a top end surface and the bottom end including an
opposite bottom end surface, the mattress comprising opposite first
and second side surfaces each extending from the top end surface to
the bottom end surface, the surfaces defining a perimeter of the
mattress, the top end comprising a first spring assembly that
defines a first zone, the first spring assembly comprising first
pockets and a first spring disposed in each of the first pockets,
each of the first pockets being coupled to another one of the first
pockets, the bottom end comprising a second spring assembly that
defines a second zone, the second spring assembly comprising second
pockets and a second spring disposed in each of the second pockets,
each of the second pockets being coupled to another one of the
second pockets, the first and second spring assemblies each
defining a portion of the perimeter, the second springs being
different than the first springs to provide the second zone with a
firmness that is different than a firmness of the first zone,
wherein an interior of one of the first pockets is not in
communication with an interior of another one of the first pockets
and an interior of one of the second pockets is not in
communication with an interior of another one of the second
pockets, wherein the first pockets are joined to one another by
first vertical seams, the first spring assembly comprising opposite
upper and lower slits extending into each of the first vertical
seams, the second pockets being joined to one another by second
vertical seams, the second spring assembly comprising opposite
upper and lower slits extending into each of the second vertical
seams, the slits of a respective one of the first vertical seams
having the same length and the slits of a respective one of the
second vertical seams having the same length, and wherein there are
no gaps or openings between the slits of a respective one of the
first vertical seams and no gaps or openings between the slits of a
respective one of the second vertical seams.
Description
TECHNICAL FIELD
[0001] The present disclosure generally relates to systems that
include a temperature controlled bed system configured to draw
ambient air away from a sleeping surface of a mattress. Methods of
use are included.
BACKGROUND
[0002] Sleep is critical for people to feel and perform their best,
in every aspect of their lives. Sleep is an essential path to
better health and reaching personal goals. Indeed, sleep affects
everything from the ability to commit new information to memory to
weight gain. It is therefore essential for people to use bedding
that suit both their personal sleep preference and body type in
order to achieve comfortable, restful sleep.
[0003] Mattresses may include a plurality of springs that form a
spring assembly. One side of a mattress can wear out over time,
while the opposite side is maintained in a relatively new state.
Moreover, when one or more sleepers consistently sleep on one side
of a mattress, weight from the sleeper or sleepers' body(ies) can
cause permanent depressions in the mattress. As such, many mattress
manufactures of mattresses with spring assemblies suggest flipping
a mattress at least once a year to increase the life of the
mattress and/or prevent sagging or the creation of depressions in
the mattress.
[0004] Some conventional spring assemblies position at least some
of the springs in pockets to create strings of springs that are
arranged to form the spring assembly. However, these spring
assemblies do not allow for independent movement between adjacent
springs or allow for independent movement between adjacent springs
on both sides of the spring assembly. As such, there is no
independent movement between adjacent springs when the mattress is
flipped over. This disclosure describes an improvement over these
prior art technologies.
SUMMARY
[0005] In one embodiment, in accordance with the principles of the
present disclosure, a spring assembly is provided that includes a
plurality of first strings of springs and a plurality of second
strings of springs. Each of the first strings is joined to at least
another one of the first strings or one of the second strings. Each
of the first strings includes first and second plies of fabric that
define a plurality of pockets formed along a length of the first
string. The pockets are formed by vertical seams that join the
plies. The vertical seams each include an upper slit that extends
through a top surface of the first string and a lower slit that
extends through a bottom surface of the first string. Each of the
pockets includes at least one spring positioned therein.
[0006] In one embodiment, in accordance with the principles of the
present disclosure, a spring assembly is provided that includes a
first zone comprising a plurality of first strings of springs and a
second zone comprising a plurality of second strings of springs.
Each of the first strings is joined to another one of the first
strings or one of the second strings. The first strings have a
first configuration and the second strings have a second
configuration that is different than the first configuration. Each
of the first strings comprises first and second plies of fabric
that define a plurality of first pockets formed along a length of
the first string by first vertical seams that join the plies. The
first vertical seams each include an upper slit that extends
through a top surface of the first string and a lower slit that
extends through a bottom surface of the first string. Each of the
first pockets comprises at least one spring positioned therein. In
some embodiments, each of the second strings comprises third and
fourth plies of fabric that define a plurality of second pockets
formed along a length of the second string by second vertical seams
that join the third and fourth plies, the second vertical seams
being free of any slits that extend through a top surface of the
second string and free of any slits that extend through a bottom
surface of the second string, each of the second pockets comprising
at least one spring positioned therein. In some embodiments, each
of the first and second pockets comprises only one spring
positioned therein. In some embodiments, each of the first pockets
comprises only one spring positioned therein and each of the second
pockets comprises more than one spring positioned therein. In some
embodiments, each of the first pockets comprises more than one
spring positioned therein and each of the second pockets comprises
more than one spring positioned therein. In some embodiments, the
first zone comprises a plurality of first zones and the second zone
comprises a plurality of second zones, the first zones being spaced
apart by one of the second zones. In some embodiments, the first
zone comprises a plurality of first zones and the second zone
comprises first, second and third regions and the second zone
comprises fourth and fifth regions, the first and second regions
being spaced apart from one another by the fourth region and the
second and third regions being spaced apart from one another by the
fifth region. In some embodiments, the first region is configured
to support a sleeper's head while the second region supports the
sleeper's midsection and the third region supports the sleeper's
legs. In some embodiments, the first region is divided into
separate sections, the second zone extending between the separate
sections.
[0007] In one embodiment, in accordance with the principles of the
present disclosure, a mattress is provided that includes a spring
assembly comprising a first zone comprising a plurality of first
strings of springs and a second zone comprising a plurality of
second strings of springs, each of the first strings being joined
to another one of the first strings or one of the second strings.
Each of the first strings comprises first and second plies of
fabric that define a plurality of first pockets formed along a
length of the first string by first vertical seams that join the
plies. The first vertical seams each include an upper slit that
extends through a top surface of the first string and a lower slit
that extends through a bottom surface of the first string. Each of
the first pockets comprises at least one spring positioned therein.
Each of the second strings comprises third and fourth plies of
fabric that define a plurality of second pockets formed along a
length of the second string by second vertical seams that join the
third and fourth plies. The second vertical seams are free of any
slits that extend through a top surface of the second string and
free of any slits that extend through a bottom surface of the
second string. Each of the second pockets comprises at least one
spring positioned therein. The first zone comprises a plurality of
first zones and the second zone comprises a plurality of second
zones, the first zones being spaced apart by one of the second
zones. The mattress comprises a cushioning material positioned
above the top surfaces and a base material positioned below the
bottom surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present disclosure will become more readily apparent
from the specific description accompanied by the following
drawings, in which:
[0009] FIG. 1 is a side, perspective view, in part phantom, of a
spring assembly in accordance with the principles of the present
disclosure;
[0010] FIG. 1A is a side, close up view of a portion of the spring
assembly shown in FIG. 1 at Detail A in FIG. 1;
[0011] FIG. 2 is an end, perspective view, in part phantom, of the
spring assembly shown in FIG. 1;
[0012] FIG. 3 is a top, perspective view, in part phantom, of the
spring assembly shown in FIG. 1;
[0013] FIG. 4 is a bottom, perspective view, in part phantom, of
the spring assembly shown in FIG. 1;
[0014] FIG. 5 is a side view, in part phantom, of a portion of one
embodiment of a component of the spring assembly shown in FIG.
1;
[0015] FIG. 5A is a side, close up view of a portion of the spring
assembly shown in FIG. 5 at Detail B in FIG. 5;
[0016] FIG. 6 is a side view, in part phantom, of a portion of one
embodiment of a component of the spring assembly shown in FIG.
1;
[0017] FIG. 7 is a side view, in part phantom, of a portion of one
embodiment of a component of the spring assembly shown in FIG.
1;
[0018] FIG. 8 is a side view, in part phantom, of a portion of one
embodiment of a component of the spring assembly shown in FIG.
1;
[0019] FIG. 9 is a side view, in part phantom, of a portion of one
embodiment of a component of the spring assembly shown in FIG.
1;
[0020] FIG. 10 is a side view, in part phantom, of a portion of one
embodiment of a component of the spring assembly shown in FIG.
1;
[0021] FIG. 11 is a side view of a portion of one embodiment of a
component of the spring assembly shown in FIG. 1;
[0022] FIG. 12 is a side view of a portion of one embodiment of a
component of the spring assembly shown in FIG. 1;
[0023] FIG. 13 is a side view of a portion of one embodiment of a
component of the spring assembly shown in FIG. 1;
[0024] FIG. 14 is a side view of a portion of one embodiment of a
component of the spring assembly shown in FIG. 1;
[0025] FIG. 15 is a top view of one embodiment of a spring assembly
in accordance with the principles of the present disclosure;
[0026] FIG. 16 is a side view of a portion of one embodiment of a
component of the spring assembly shown in FIG. 15;
[0027] FIG. 17 is a top view of one embodiment of a spring assembly
in accordance with the principles of the present disclosure;
[0028] FIG. 18 is a top view of one embodiment of a spring assembly
in accordance with the principles of the present disclosure;
[0029] FIG. 19 is a top view of one embodiment of a spring assembly
in accordance with the principles of the present disclosure;
[0030] FIG. 20 is a top view of one embodiment of a spring assembly
in accordance with the principles of the present disclosure; a
[0031] FIG. 21 is a top view of one embodiment of components of a
mattress in accordance with the principles of the present
disclosure, with part separated; and
[0032] FIG. 22 is a side, cross section view of the mattress shown
in FIG. 21.
[0033] Like reference numerals indicate similar parts throughout
the figures.
DETAILED DESCRIPTION
[0034] The present disclosure may be understood more readily by
reference to the following detailed description of the disclosure
taken in connection with the accompanying drawing figures, which
form a part of this disclosure. It is to be understood that this
disclosure is not limited to the specific devices, methods,
conditions or parameters described and/or shown herein, and that
the terminology used herein is for the purpose of describing
particular embodiments by way of example only and is not intended
to be limiting of the claimed disclosure.
[0035] Also, as used in the specification and including the
appended claims, the singular forms "a," "an," and "the" include
the plural, and reference to a particular numerical value includes
at least that particular value, unless the context clearly dictates
otherwise. Ranges may be expressed herein as from "about" or
"approximately" one particular value and/or to "about" or
"approximately" another particular value. When such a range is
expressed, another embodiment includes from the one particular
value and/or to the other particular value. Similarly, when values
are expressed as approximations, by use of the antecedent "about,"
it will be understood that the particular value forms another
embodiment. It is also understood that all spatial references, such
as, for example, horizontal, vertical, top, upper, lower, bottom,
left and right, are for illustrative purposes only and can be
varied within the scope of the disclosure. For example, the
references "upper" and "lower" are relative and used only in the
context to the other, and are not necessarily "superior" and
"inferior."
[0036] The exemplary embodiments of the disclosed spring assemblies
are discussed in terms of strings of pocketed springs that are used
to form one or more spring assemblies that make up all or a portion
of a mattress. Reference will now be made in detail to the
exemplary embodiments of the present disclosure, which are
illustrated in the accompanying figures. Turning to FIGS. 1-22,
there are illustrated components of a spring assembly 30 and a
mattress 30a that includes spring assembly 30.
[0037] Spring assembly 30 includes one or a plurality of first
strings, such as, for example, strings 32. Strings 32 each include
a first ply of fabric 34 and a second ply of fabric 36, as best
shown in FIGS. 3 and 4. In some embodiments, plies 34, 36 are
formed by folding a single piece of material, such as for example,
material 38. That is, first ply 34 may be a first end of material
38 and second ply 36 may be a second end of material 38, wherein
material 38 is folded about a midsection 40 of material 38, as best
shown in FIG. 3. In some embodiments, material 38 is arranged such
that midsection 40 forms a top surface 42 of string 32 and plies
34, 36 are joined at an opposite bottom surface 44 of string 32, as
shown in FIGS. 3 and 4. It is envisioned that this configuration
may be reversed such that midsection 40 forms bottom surface 44 of
string 32 and plies 34, 36 are joined at top surface 42 of string
32. In some embodiment, material 38 can comprise acrylic, acetate,
cotton, linen, silk, polyester, wool, nylon, rayon, spandex, lycra,
hemp, manmade materials, natural materials (e.g., hemp) and blends
and/or combinations thereof.
[0038] Strings 32 each extend along a longitudinal axis L between
opposite ends 35, 45 of strings 32. Plies 34, 36 are joined
together at spaced apart portions of material 38 by vertical seams
46 to define a plurality of pockets 48 along longitudinal axis L.
Vertical seams 46 define an end surface of end 35 and an end
surface of end 45, as shown in FIGS. 2-4. In some embodiment,
strings 32 each include the same number of pockets 48. In some
embodiment, strings 32 each include different numbers of pockets
48. It is envisioned that strings 32 may each include any number of
pockets 48. In some embodiments, strings 32 each include between
about 2 and about 40 pockets 48. In some embodiments, strings 32
each include about 3 pockets 48, about 4 pockets 48, about 5
pockets 48, about 6 pockets 48, about 7 pockets 48, about 8 pockets
48, about 9 pockets 48, about 10 pockets 48, about 11 pockets 48,
about 12 pockets 48, about 13 pockets 48, about 14 pockets 48,
about 15 pockets 48, about 16 pockets 48, about 17 pockets 48,
about 18 pockets 48, about 19 pockets 48, about 20 pockets 48,
about 21 pockets 48, about 22 pockets 48, about 23 pockets 48,
about 24 pockets 48, about 25 pockets 48, about 26 pockets 48,
about 27 pockets 48, about 28 pockets 48, about 29 pockets 48,
about 30 pockets 48, about 31 pockets 48, about 32 pockets 48,
about 33 pockets 48, about 34 pockets 48, about 35 pockets 48,
about 36 pockets 48, about 37 pockets 48, about 38 pockets 48, or
about 39 pockets 48.
[0039] In some embodiments, vertical seams 46 are evenly spaced
apart from one another along longitudinal axis L such that each of
pockets 48 has the same width, the width of each of pockets 48
being defined by the distance from one of vertical seams 46 to an
adjacent one of vertical seams 46. In some embodiments, vertical
seams 46 are not evenly spaced apart from one another along
longitudinal axis L such that at least one of pockets 48 have a
width that is different than a width another one of other pockets
48, the widths of pockets 48 being defined by the distance from one
of vertical seams 46 to an adjacent one of vertical seams 46.
Vertical seams 46 each have a length defined by the distance from
top surface 42 to bottom surface 44. In some embodiments, vertical
seams 46 each have the same length. In some embodiments, the length
of at least one of vertical seams 46 is different than the length
of at least another one of vertical seams 46.
[0040] In some embodiments, vertical seams 46 are formed by sewing,
adhering, or welding first ply 34 to second ply 36 along at least a
portion of the length of each vertical seam 46. In some
embodiments, vertical seams 46 are formed by a horizontal weld 50.
In some embodiments, horizontal weld 50 comprises a series of
horizontal welds 50 that each extend parallel to or substantially
parallel to longitudinal axis L and are spaced apart from one
another along the length of vertical seam 46, as shown in FIG. 1A.
In some embodiments, horizontal weld(s) 50 define a section or
section of each vertical seam 46 in which first ply 34 is joined
with second ply 36. In some embodiments, horizontal weld(s) 50 are
formed by thermal welding and/or ultrasonic welding. In some
embodiments, horizontal weld(s) 50 are spaced apart from one
another by portions 52 of vertical seam 46. In some embodiments,
first ply 34 is spaced apart from second ply 36 at portions 52.
That is, first ply 34 is not joined with second ply 36 at portions
52.
[0041] In some embodiments, horizontal welds 50 each have a width w
along longitudinal axis L that is greater than a height h of
horizontal welds 50 along a length of vertical seam 46, as shown in
FIG. 1A. In some embodiments, width w is about 1.25 to about 5
times greater than height h. In some embodiments, width w is about
1.5 times greater than height h, about 2 times greater than height
h, about 2.5 times greater than height h, about 3 times greater
than height h, about 3.5 times greater than height h, about 4 times
greater than height h, or about 4.5 times greater than height h.
Portions 52 each have a width along longitudinal axis L that is
equal to width w. In some embodiments, portions 52 each have a
height h1 that is equal to height h. In some embodiments, height h1
is greater than height h. In some embodiments, height h1 is less
than height h.
[0042] In some embodiments, horizontal weld(s) 50 may be disposed
at alternate orientations, relative to longitudinal axis L, such
as, for example, transverse and/or other angular orientations such
as acute or obtuse, co-axial and/or may be offset or staggered. In
some embodiments, horizontal weld(s) 50 may have various shapes or
configurations, such as, for example, oval, oblong, triangular,
rectangular, square, polygonal, irregular, uniform, non-uniform,
variable, tubular and/or tapered.
[0043] In some embodiments, vertical seams 46 are formed by a
vertical weld 54. In some embodiments, vertical weld 54 comprises a
series of vertical welds 54 that each extend perpendicular or
substantially perpendicular to longitudinal axis L and are spaced
apart from one another along the length of vertical seam 46, as
shown in FIGS. 5-10. In some embodiments, vertical weld(s) 54
define a section or section of each vertical seam 46 in which first
ply 34 is joined with second ply 36. In some embodiments, vertical
weld(s) 54 are formed by thermal welding and/or ultrasonic welding.
In some embodiments, vertical weld(s) 54 are spaced apart from one
another by portions 56 of vertical seam 46. In some embodiments,
first ply 34 is spaced apart from second ply 36 at portions 56.
That is, first ply 34 is not joined with second ply 36 at portions
56.
[0044] In some embodiments, vertical welds 54 each have a width w1
along longitudinal axis L that is less than a height h2 of vertical
welds 54 along a length of vertical seam 46, as shown in FIG. 5A.
In some embodiments, height h2 is about 1.25 to about 5 times
greater than width w1. In some embodiments, height h2 is about 1.5
times greater than width w1, about 2 times greater than width w1,
about 2.5 times greater than width w1, about 3 times greater than
width w1, about 3.5 times greater than width w1, about 4 times
greater than width w1, or about 4.5 times greater than width w1.
Portions 56 each have a width along longitudinal axis L that is
equal to width w1. In some embodiments, portions 56 each have a
height h3 that is equal to height h2. In some embodiments, height
h3 is greater than height h2. In some embodiments, height h3 is
less than height h2.
[0045] In some embodiments, vertical weld(s) 54 may be disposed at
alternate orientations, relative to longitudinal axis L, such as,
for example, transverse and/or other angular orientations such as
acute or obtuse, co-axial and/or may be offset or staggered. In
some embodiments, vertical weld(s) 54 may have various shapes or
configurations, such as, for example, oval, oblong, triangular,
rectangular, square, polygonal, irregular, uniform, non-uniform,
variable, tubular and/or tapered.
[0046] In some embodiments, vertical seams 46 are each defined by a
column C1 of vertical welds 54 and a column C2 of vertical welds 54
that is spaced apart from column C1 by a section 58, as shown in
FIG. 5A. In some embodiments, first ply 34 is spaced apart from
second ply 36 at section 58. That is, first ply 34 is not joined
with second ply 36 at section 58. In some embodiments, column C1
and/or column C2 each include a single column of vertical welds
54.
[0047] In some embodiments, column C1 includes an outer column C3
of vertical welds 54 and an inner column C4 of vertical welds 54
and column C2 includes an outer column C5 of vertical welds 54 and
an inner column C6 of vertical welds 54, as shown in FIG. 5A.
Columns C4, C6 are spaced apart from one another by section 58. In
some embodiments, vertical welds 54 in column C3 engage vertical
welds 54 in column C4. In some embodiments, vertical welds 54 in
column C3 are spaced apart from vertical welds 54 in column C4
along longitudinal axis L. In some embodiments, vertical welds 54
in column C5 engage vertical welds 54 in column C6. In some
embodiments, vertical welds 54 in column C5 are spaced apart from
vertical welds 54 in column C6 along longitudinal axis L.
[0048] In some embodiments, vertical welds 54 in column C3 that
engage vertical welds 54 in column C4 are staggered such that a top
surface 54a of a vertical weld 54 in column C3 is offset along
column C1 from a top surface 54a of the vertical weld 54 in column
C4 that the vertical weld 54 in column C3 engages; and a bottom
surface 54b of the vertical weld 54 in column C3 is offset along
column C1 from a bottom surface 54b of the vertical weld 54 in
column C4 that the vertical weld 54 in column C3 engages, as shown
in FIG. 5A. Likewise, vertical welds 54 in column C5 that engage
vertical welds 54 in column C6 are staggered such that a top
surface 54a of a vertical weld 54 in column C5 is offset along
column C2 from a top surface 54a of the vertical weld 54 in column
C6 that the vertical weld 54 in column C5 engages; and a bottom
surface 54b of the vertical weld 54 in column C5 is offset along
column C2 from a bottom surface 54b of the vertical weld 54 in
column C6 that the vertical weld 54 in column C5 engages, as also
shown in FIG. 5A.
[0049] In some embodiments, a top surface 54a of one of vertical
welds 54 in column C3 is coaxial with a top surface 54a of one of
vertical welds 54 in column C6, as shown in FIG. 5A. Likewise, a
bottom surface 54b of one of vertical welds 54 in column C3 is
coaxial with a bottom surface 54b of one of vertical welds 54 in
column C6. In some embodiments, a top surface 54a of one of
vertical welds 54 in column C4 is coaxial with a top surface 54a of
one of vertical welds 54 in column C5, as shown in FIG. 5A.
Likewise, a bottom surface 54b of one of vertical welds 54 in
column C4 is coaxial with a bottom surface 54b of one of vertical
welds 54 in column C5.
[0050] In some embodiments, heights h2 of vertical welds 54 in
column C3 are the same as heights h2 of vertical welds 54 in column
C4. In some embodiments, heights h2 of vertical welds 54 in column
C3 are less than heights h2 of vertical welds 54 in column C4. In
some embodiments, heights h2 of vertical welds 54 in column C3 are
greater than heights h2 of vertical welds 54 in column C4. In some
embodiments, heights h2 of vertical welds 54 in column C5 are the
same as heights h2 of vertical welds 54 in column C6. In some
embodiments, heights h2 of vertical welds 54 in column C5 are less
than heights h2 of vertical welds 54 in column C6. In some
embodiments, heights h2 of vertical welds 54 in column C5 are
greater than heights h2 of vertical welds 54 in column C6.
[0051] In some embodiments, one or more of vertical seams 46
include an upper slit, such as, for example, a slit 60 that extends
through top surface 42 of string 32 and/or a bottom slit, such as,
for example, a slit 62 that extends through bottom surface 44 of
string 32, as shown in FIGS. 5-14. In some embodiments, slits 60
extend parallel to slits 62. In some embodiments, slits 60 extend
transverse to slits 62. In some embodiments, slits 60, 62 are each
positioned between columns C1, C2 of one vertical seam 46. In some
embodiments, slits 60, 62 are each equidistant between columns C1,
C2 of one vertical seam 46. In some embodiments, at least one of
slits 60, 62 is closer to one of columns C1, C2 of one vertical
seam 46 than another one of columns C1, C2 of the same vertical
seam 46.
[0052] In some embodiments, slits 60, 62 have the same length, as
shown in FIGS. 5-7. This allows mattress 30a to be flipped such
that spring assembly 30 will provide the same amount of movement
between pockets 48 whether top surface 42 is positioned adjacent a
sleep surface (e.g., a surface of mattress 30a that is furthest
from the floor) or bottom surface 44 is positioned adjacent the
sleep surface, as discussed herein. It is envisioned that any of
slits 60, 62 can have any of the lengths shown in FIGS. 5-10.
[0053] In some embodiments, slits 60, 62 have different lengths, as
shown in FIGS. 8-10. That is, slits 60 may be longer than slits 62
or slits 62 may be longer than slits 60. This allows mattress 30a
to be flipped to allow different amounts of movement between
pockets 48. That is, when top surface 42 is positioned adjacent the
sleep surface, slits 60 will allow a first amount of movement
between pockets 48. When mattress 30a is flipped such that bottom
surface 44 is positioned adjacent the sleep surface, slits 62 will
allow a second amount of movement between pockets 48, wherein the
first amount of movement is different than the second amount of
movement. In some embodiments, the first amount of movement is
greater than the second amount of movement. In some embodiments,
the first amount of movement is less than the second amount of
movement. In some embodiments, increasing the length of slit 60 or
slit 62 increases the amount of movements between pockets 48.
Likewise, decreasing the length of slit 60 or slit 62 decreases the
amount of movements between pockets 48.
[0054] Slits 60, 62 can have different widths, as shown in FIGS.
5-10. In some embodiments, slits 60 and slits 62 have the same
width. In some embodiments, the width of slits 60 is different than
the width of slits 62. In some embodiments, the width of slits 60
is greater than the width of slits 62. In some embodiments, the
width of slits 60 is less than the width of slits 62.
[0055] Strings 32 can have different configurations of slits 60,
62. In one embodiment, shown in FIG. 11, string 32 includes slits
60, 62 between each adjacent pocket 48. That is, each vertical seam
46 includes both a slit 60 and a slit 62. Slit 60 in one vertical
seam 46 is parallel and/or coaxial with slit 62 in the same
vertical seam 46.
[0056] In one embodiment, shown in FIG. 12, string 32 includes
slits 60, 62 in every other vertical seam 46 and the vertical seams
46 between the vertical seams 46 that include slits 60, 62 do not
include slits 60, 62. That is, each vertical seam 46 includes
either no slits 60, 62 or both slit 60 and slit 62. Slit 60 in one
vertical seam 46 is parallel and/or coaxial with slit 62 in the
same vertical seam 46.
[0057] In one embodiment, shown in FIG. 13, string 32 includes
slits 60, 62 in every third vertical seam 46 and the vertical seams
46 between the vertical seams 46 that include slits 60, 62 do not
include slits 60, 62. That is, each vertical seam 46 includes
either no slits 60, 62 or both slit 60 and slit 62. Slit 60 in one
vertical seam 46 is parallel and/or coaxial with slit 62 in the
same vertical seam 46.
[0058] In one embodiment, shown in FIG. 14, string 32 includes
slits 60 in every other vertical seam 46 and slits 62 in every
other vertical seam 46, wherein the vertical seams 46 that include
a slit 60 do not include a slit 62 and the vertical seams 46 that
include a slit 62 do not include a slit 60.
[0059] Pockets 48 each include at least one spring 64 positioned
therein. In some embodiments, springs 64 each have the same
configuration. In some embodiments, at least one of springs 64 has
a configuration that is different than another one of springs 64.
For example, at least one of springs 64 may be more rigid than
another one of springs 64. In some embodiments, each of pockets 48
includes only one spring 64 positioned therein. In some
embodiments, each of pockets 48 includes more than one spring 64
positioned therein. In some embodiments, each of pockets 48
includes two springs 64 positioned therein, wherein the springs one
of the springs is positioned within the other spring in a nested
configuration. In some embodiments, at least one of pockets 48
includes only one spring 64 positioned therein and at least one of
pockets 48 includes a plurality of springs 64 positioned therein.
In some embodiments, the pockets 48 that include one spring 64
alternate with the pockets 48 that include more than one spring 64
such that every other pocket 48 includes only one spring 64 and
every other pocket 48 includes more than one spring 64.
[0060] In some embodiments, spring assembly 30 consists only of
strings 32. In some embodiment, spring assembly 30 comprises
strings 32 and one or a plurality of second strings, such as, for
example, strings 66, as shown in FIGS. 15-20. Strings 66 each
include a first ply of fabric and a second ply of fabric, similar
to plies 34, 36 of strings 32. In some embodiments, the plies that
strings 66 are made from are formed by folding a single piece of
material, such as for example, a material similar to material 38.
That is, the first ply may be a first end of the material and the
second ply may be a second end of the material, wherein the
material is folded about a midsection of the material. In some
embodiments, the material is arranged such that the midsection
forms a top surface 66a of string 66 and the plies are joined at an
opposite bottom surface 66b of string 66. It is envisioned that
this configuration may be reversed such that the midsection forms
the bottom surface of string 66 and the plies are joined at the top
surface of string 66. Top and bottom surfaces 66a, 66b each extend
from end 68 to end 70. In some embodiment, the material can
comprise acrylic, acetate, cotton, linen, silk, polyester, wool,
nylon, rayon, spandex, lycra, hemp, manmade materials, natural
materials (e.g., hemp) and blends and/or combinations thereof
[0061] Strings 66 each extend along a longitudinal axis L1 between
opposite ends 68, 70 of strings 66, as shown in FIG. 16. The plies
are joined together at spaced apart portions of the material by
vertical seams 72 to define a plurality of pockets 74 along
longitudinal axis L1. Vertical seams 72 define opposite end
surfaces of string 66. In some embodiment, strings 66 each include
the same number of pockets 74. In some embodiment, strings 66 each
include different numbers of pockets 74. It is envisioned that
strings 66 may each include any number of pockets 74. In some
embodiments, strings 66 each include between about 2 and about 40
pockets 74. In some embodiments, strings 66 each include about 3
pockets 74, about 4 pockets 74, about 5 pockets 74, about 6 pockets
74, about 7 pockets 74, about 8 pockets 74, about 9 pockets 74,
about 10 pockets 74, about 11 pockets 74, about 12 pockets 74,
about 13 pockets 74, about 14 pockets 74, about 15 pockets 74,
about 16 pockets 74, about 17 pockets 74, about 18 pockets 74,
about 19 pockets 74, about 20 pockets 74, about 21 pockets 74,
about 22 pockets 74, about 23 pockets 74, about 24 pockets 74,
about 25 pockets 74, about 26 pockets 74, about 27 pockets 74,
about 28 pockets 74, about 29 pockets 74, about 30 pockets 74,
about 31 pockets 74, about 32 pockets 74, about 33 pockets 74,
about 34 pockets 74, about 35 pockets 74, about 36 pockets 74,
about 37 pockets 74, about 38 pockets 74, or about 39 pockets 74.
In some embodiments, strings 32 each include the same number of
pockets 48 as strings 66 include pockets 74. That is, the number of
pockets 48 in each of strings 32 is the same as the number of
pockets 74 in each of strings 66.
[0062] In some embodiments, vertical seams 72 are evenly spaced
apart from one another along longitudinal axis L1 such that each of
pockets 74 has the same width, the width of each of pockets 74
being defined by the distance from one of vertical seams 72 to an
adjacent one of vertical seams 72. In some embodiments, vertical
seams 72 are not evenly spaced apart from one another along
longitudinal axis L1 such that at least one of pockets 74 have a
width that is different than a width another one of other pockets
74, the widths of pockets 74 being defined by the distance from one
of vertical seams 72 to an adjacent one of vertical seams 72.
Vertical seams 74 each have a length defined by the distance from
the top surface of string 66 to the bottom surface of string 66. In
some embodiments, vertical seams 72 each have the same length. In
some embodiments, the length of at least one of vertical seams 72
is different than the length of at least another one of vertical
seams 72.
[0063] In some embodiments, vertical seams 72 are formed by sewing,
adhering, or welding the first ply to the second ply along at least
a portion of the length of each vertical seam 72. In some
embodiments, vertical seams 46 are formed by a horizontal weld
similar to horizontal weld 50. In some embodiments, vertical seams
72 are formed by a vertical weld similar to vertical weld 54.
[0064] Pockets 74 each include at least one spring, such as, for
example, a spring similar to spring 64 positioned therein. In some
embodiments, the springs within pockets 74 each have the same
configuration. In some embodiments, at least one of the springs
within pockets 74 has a configuration that is different than
another one of the springs within pockets 74.
[0065] For example, at least one of the springs within pockets 74
may be more rigid than another one of the springs within pockets
74. In some embodiments, each of pockets 74 includes only one
spring positioned therein. In some embodiments, each of pockets 74
includes more than one spring positioned therein. In some
embodiments, each of pockets 74 includes two springs positioned
therein, wherein one of the springs one spring is positioned within
the other spring in a nested configuration. In some embodiments, at
least one of pockets 74 includes only one spring positioned therein
and at least one of pockets 74 includes a plurality of springs
positioned therein. In some embodiments, the pockets 74 that
include one spring alternate with the pockets 74 that include more
than one spring such that every other pocket 74 includes only one
spring and every other pocket 74 includes more than one spring.
[0066] In some embodiments, top surface 66a extends continuously
from end 68 to end 70. That is, there are no gaps in top surface
66a from end 68 to end 70. This is in contrast to strings 32 that
include slits 60, 62 in top surface 42 and/or bottom surface 44
between ends 35, 45. Stated another way, strings 32 include slits
60 and/or slits 62 and strings 66 do not include any vertical slits
in vertical seams 72. It is envisioned that because strings 66 are
free of such vertical slits, that movement between pockets 74 is
limited. That is, slits 60, 62 in strings 32 allow greater movement
between pockets 48 than is permitted between pockets 74.
[0067] In some embodiments, spring assembly 30 comprises a
plurality of zones, such as, for example, a zone Z1 and a zone Z2,
as shown in FIGS. 15-20. In some embodiments, spring assembly 30
comprises one or a plurality of zones Z1 and one or a plurality of
zones Z2. In some embodiments, zone Z1 includes strings 32 and zone
Z2 includes strings 66. That is, zone Z1 includes one or a
plurality of strings 32 and zone Z2 includes one or a plurality of
strings 66. It is envisioned that zones Z1, Z2 may be selectively
positioned in spring assembly 30 such that zones Z1 are positioned
at areas of mattress 30a where greater movement between pockets 48
is desired and that zones Z2 are positioned at areas of mattress
30a wherein less movement between pockets 74 is desired.
[0068] In one embodiment, shown in FIG. 15, spring assembly 30
comprises zones Z1 at a top end 76 of spring assembly 30 and at an
opposite bottom end 78 of spring assembly 30. Zone Z1 at end 76
extends along and/or defines an end surface of end 76 and zone Z1
at end 78 extends along and/or defines an end surface of end 78.
Zones Z1 at ends 76, 78 each extend continuously from a side 80 of
spring assembly 30 to an opposite side 82 of spring assembly 30.
Spring assembly 30 includes an additional zone Z1 at a midsection
84 of spring assembly 30 such that zone Z1 at midsection 84 is
positioned between zones Z1 at ends 76, 78. Midsection 84 is
positioned between ends 76, 78 and extends from side 80 to side 82.
Zone Z1 at midsection 84 extends from side 80 to side 82. Zone Z1
at end 76 is spaced apart from zone Z1 at midsection 84 by a zone
Z2 and zone Z1 at end 78 is spaced apart from zone Z1 at midsection
84 by a zone Z2. In some embodiments, zones Z1 at ends 76, 78 are
equally spaced apart from zone Z1 at midsection 84. In some
embodiments, zones Z2 each extend continuously from side 80 to side
82.
[0069] In some embodiments, end 76 is configured to be positioned
at a head of mattress 30a and end 78 is configured to be positioned
at a foot of mattress 30a. As such, zone Z1 at end 76 is configured
to support a sleeper's head, zone Z2 is configured to support the
sleeper's legs and/or feet and zone Z1 at midsection 82 is
configured to support the sleeper's midsection or torso. It is
envisioned that lengths of zones Z1 between ends 76, 78 can be
selectively adjusted such that each of zones Z1 supports all or a
portion of the sleeper's head, the sleeper's legs and/or the
sleeper's feet and midsection or torso, respectively.
[0070] In some embodiments, zones Z1 at ends 76, 78 of spring
assembly 30 shown in FIG. 15 each include the same number of
strings 32. In some embodiments, zone Z1 at end 76 of spring
assembly 30 shown in FIG. 15 includes more or less strings 32 than
zone Z1 at end 78. In some embodiments, zones Z1 of spring assembly
30 shown in FIG. 15 each include the same number of strings 32. In
some embodiments, zone Z1 at midsection 84 of spring assembly 30
shown in FIG. 15 includes more strings 32 than zones Z1 at ends 76,
78. In some embodiments, zone Z1 at midsection 84 of spring
assembly 30 shown in FIG. 15 includes fewer strings 32 than zones
Z1 at ends 76, 78. In some embodiments, zones Z2 at ends 76, 78 of
spring assembly 30 shown in FIG. 15 each include the same number of
strings 66. In some embodiments, zone Z2 at end 76 of spring
assembly 30 shown in FIG. 15 includes more or less strings 66 than
zone Z2 at end 78.
[0071] In one embodiment, shown in FIG. 17, spring assembly 30
comprises zones Z1 at end 76 of spring assembly 30 and at end 78 of
spring assembly 30. Zone Z1 at end 76 extends along and/or defines
a portion of the end surface of end 76 and zone Z1 at end 78
extends along and/or defines a portion of the end surface of end
78. Spring assembly 30 includes an additional zone Z1 at midsection
84 such that zone Z1 at midsection 84 is positioned between zones
Z1 at ends 76, 78. Zone Z1 at end 76 is spaced apart from zone Z1
at midsection 84 by a zone Z2 and zone Z1 at end 78 is spaced apart
from zone Z1 at midsection 84 by a zone Z2. Zones Z1, Z2 are each
positioned between one or a plurality of strings 66 that each
extend continuously from the end surface of end 76 to the end
surface of end 78. That is, zones Z1, Z2 are each spaced inwardly
from side surfaces of sides 80, 82 by strings 66. In some
embodiments, zones Z1 at ends 76, 78 are equally spaced apart from
zone Z1 at midsection 84.
[0072] In some embodiments, zones Z1 at ends 76, 78 of spring
assembly 30 shown in FIG. 17 each include the same number of
strings 32. In some embodiments, zone Z1 at end 76 of spring
assembly 30 shown in FIG. 17 includes more or less strings 32 than
zone Z1 at end 78. In some embodiments, zones Z1 of spring assembly
30 shown in FIG. 17 each include the same number of strings 32. In
some embodiments, zone Z1 at midsection 84 of spring assembly 30
shown in FIG. 17 includes more strings 32 than zones Z1 at ends 76,
78. In some embodiments, zone Z1 at midsection 84 of spring
assembly 30 shown in FIG. 17 includes less strings 32 than zones Z1
at ends 76, 78. In some embodiments, zones Z2 at ends 76, 78 of
spring assembly 30 shown in FIG. 17 each include the same number of
strings 66. In some embodiments, zone Z2 at end 76 of spring
assembly 30 shown in FIG. 17 includes more or less strings 66 than
zone Z2 at end 78.
[0073] In one embodiment, shown in FIG. 18, spring assembly 30
comprises zones Z1 at end 76 of spring assembly 30 and at end 78 of
spring assembly 30. Zone Z1 at end 76 is spaced apart from the end
surface of end 76 by a zone Z2 that extends along and/or defines
the end surface of end 76 and zone Z1 at end 78 is spaced apart
from the end surface of end 78 by a zone Z2 that extends along
and/or defines the end surface of end 78. Spring assembly 30
includes an additional zone Z1 at midsection 84 such that zone Z1
at midsection 84 is positioned between zones Z1 at ends 76, 78.
Zone Z1 at end 76 is spaced apart from zone Z1 at midsection 84 by
a zone Z2 and zone Z1 at end 78 is spaced apart from zone Z1 at
midsection 84 by a zone Z2. In some embodiments, zones Z1 at ends
76, 78 are equally spaced apart from zone Z1 at midsection 84.
[0074] In some embodiments, zones Z1 at ends 76, 78 of spring
assembly 30 shown in FIG. 18 each include the same number of
strings 32. In some embodiments, zone Z1 at end 76 of spring
assembly 30 shown in FIG. 18 includes more or less strings 32 than
zone Z1 at end 78. In some embodiments, zones Z1 of spring assembly
30 shown in FIG. 18 each include the same number of strings 32. In
some embodiments, zone Z1 at midsection 84 of spring assembly 30
shown in FIG. 18 includes more strings 32 than zones Z1 at ends 76,
78. In some embodiments, zone Z1 at midsection 84 of spring
assembly 30 shown in FIG. 18 includes less strings 32 than zones Z1
at ends 76, 78. In some embodiments, zones Z2 that extend along
and/or define the end surfaces of ends 76, 78 of spring assembly 30
shown in FIG. 18 each include the same number of strings 66. In
some embodiments, zone Z2 that extends along and/or defines the end
surface of end 76 of spring assembly 30 shown in FIG. 18 includes
more or less strings 66 than zone Z2 that extends along and/or
defines the end surface at end 78. In some embodiments, zones Z2
that are positioned between zone Z1 at end 76 and zone Z1 at
midsection 84 and between zone Z1 at end 76 and zone Z1 at
midsection 84 each include the same number of strings 66. In some
embodiments, zone Z2 positioned between zones Z1 at end 76 and
midsection 84 includes more or less strings 66 than zone Z2
positioned between zone Z1 at end 76 and zone Z1 at midsection 84.
In some embodiments, zones Z2 that are positioned between zone Z1
at end 76 and zone Z1 at midsection 84 and between zone Z1 at end
76 and zone Z1 at midsection 84 each include the same number of
strings 66 as zones Z2 that extend along and/or define the end
surfaces of ends 76, 78. In some embodiments, at least one of zones
Z2 that are positioned between zone Z1 at end 76 and zone Z1 at
midsection 84 and between zone Z1 at end 76 and zone Z1 at
midsection 84 includes more of less strings 66 than at least one of
zones Z2 that extend along and/or define the end surfaces of ends
76, 78.
[0075] In one embodiment, shown in FIG. 19, spring assembly 30
comprises zones Z1 at end 76 of spring assembly 30 and at end 78 of
spring assembly 30. Zone Z1 at end 76 is spaced apart from the end
surface of end 76 by a zone Z2 that extends along and/or defines a
portion of the end surface of end 76 and zone Z1 at end 78 is
spaced apart from the end surface of end 78 by a zone Z2 that
extends along and/or defines a portion of the end surface of end
78. Spring assembly 30 includes an additional zone Z1 at midsection
84 such that zone Z1 at midsection 84 is positioned between zones
Z1 at ends 76, 78. Zone Z1 at end 76 is spaced apart from zone Z1
at midsection 84 by a zone Z2 and zone Z1 at end 78 is spaced apart
from zone Z1 at midsection 84 by a zone Z2. Zones Z1, Z2 are each
positioned between one or a plurality of strings 66 that each
extend continuously from the end surface of end 76 to the end
surface of end 78. That is, zones Z1, Z2 are each spaced inwardly
from the side surfaces of sides 80, 82 by strings 66. In some
embodiments, zones Z1 at ends 76, 78 are equally spaced apart from
zone Z1 at midsection 84.
[0076] In some embodiments, zones Z1 at ends 76, 78 of spring
assembly 30 shown in FIG. 19 each include the same number of
strings 32. In some embodiments, zone Z1 at end 76 of spring
assembly 30 shown in FIG. 19 includes more or less strings 32 than
zone Z1 at end 78. In some embodiments, zones Z1 of spring assembly
30 shown in FIG. 19 each include the same number of strings 32. In
some embodiments, zone Z1 at midsection 84 of spring assembly 30
shown in FIG. 19 includes more strings 32 than zones Z1 at ends 76,
78. In some embodiments, zone Z1 at midsection 84 of spring
assembly 30 shown in FIG. 19 includes less strings 32 than zones Z1
at ends 76, 78. In some embodiments, zones Z2 that extend along
and/or define the end surfaces of ends 76, 78 of spring assembly 30
shown in FIG. 19 each include the same number of strings 66. In
some embodiments, zone Z2 that extends along and/or defines the end
surface of end 76 of spring assembly 30 shown in FIG. 19 includes
more or less strings 66 than zone Z2 that extends along and/or
defines the end surface at end 78. In some embodiments, zones Z2
that are positioned between zone Z1 at end 76 and zone Z1 at
midsection 84 and between zone Z1 at end 76 and zone Z1 at
midsection 84 each include the same number of strings 66. In some
embodiments, zone Z2 positioned between zones Z1 at end 76 and
midsection 84 includes more or less strings 66 than zone Z2
positioned between zone Z1 at end 76 and zone Z1 at midsection 84.
In some embodiments, zones Z2 that are positioned between zone Z1
at end 76 and zone Z1 at midsection 84 and between zone Z1 at end
76 and zone Z1 at midsection 84 each include the same number of
strings 66 as zones Z2 that extend along and/or define the end
surfaces of ends 76, 78. In some embodiments, at least one of zones
Z2 that are positioned between zone Z1 at end 76 and zone Z1 at
midsection 84 and between zone Z1 at end 76 and zone Z1 at
midsection 84 includes more of less strings 66 than at least one of
zones Z2 that extend along and/or define the end surfaces of ends
76, 78.
[0077] In one embodiment, shown in FIG. 20, spring assembly 30
comprises two spaced apart zones Z1 at end 76 of spring assembly 30
and two spaced apart zones Z1 at end 78 of spring assembly 30.
Zones Z1 at end 76 extend along and/or define a portion of the end
surface of end 76 and zones Z1 at end 78 extend along and/or define
a portion of the end surface of end 78. Zones Z1 at end 76 are
spaced apart from one another by a zone Z2 that extends
continuously from the end surface of end 76 to the end surface of
end 78. Zones Z1 at end 78 are spaced apart by the same zone Z2
that spaces zones Z1 at end 76 apart. The zone Z2 that spaces zones
Z1 at end 76 apart and zones Z1 at end 78 apart includes one or a
plurality of strings 66. Spring assembly 30 includes spaced apart
zones Z1 at midsection 84 such that zones Z1 at midsection 84 are
positioned between zones Z1 at end 76 and zones Z1 at end 78. The
zone Z2 that spaces zones Z1 at end 76 apart and zones Z1 at end 78
apart also spaces zones Z1 at midsection 84 apart.
[0078] Zones Z1 at end 76 are each spaced apart from zones Z1 at
midsection 84 by a zone Z2. Zones Z2 that space zones Z1 at end 76
apart from zones Z1 at midsection 84 are spaced apart by the zone
Z2 that spaces zones Z1 at end 76 apart, spaces zones Z1 at end 76
apart and spaces zones Z1 at midsection 84 apart. Zones Z1 at end
78 are each spaced apart from zones Z1 at midsection 84 by a zone
Z2. Zones Z2 that space zones Z1 at end 78 apart from zones Z1 at
midsection 84 are spaced apart by the zone Z2 that spaces zones Z1
at end 76 apart, spaces zones Z1 at end 78 apart and spaces zones
Z1 at midsection 84 apart.
[0079] As shown in FIG. 20, spring assembly 30 comprises zones Z1
adjacent side 80 at end 76, end 78 and midsection 84 that are
spaced apart from one another and zones Z1 adjacent side 82 at end
76, end 78 and midsection 84 that are spaced apart from one
another. Zones Z1 adjacent side 80 may be configured to accommodate
the head, the legs and/or feet and the torso or midsection,
respectively, of a first sleeper and that zones Z1 adjacent side 82
may be configured to accommodate the head, the legs and/or feet and
the torso or midsection, respectively, of a second sleeper. It is
envisioned that the zone Z2 that spaces zones Z1 at end 76 apart,
spaces zones Z1 at end 78 apart and spaces zones Z1 at midsection
84 apart will reduce or eliminate movement of at least one of zones
Z1 adjacent side 82 when there is movement within at least one of
zones Z1 adjacent side 80. Likewise, the zone Z2 that spaces zones
Z1 at end 76 apart, spaces zones Z1 at end 78 apart and spaces
zones Z1 at midsection 84 apart will reduce or eliminate movement
of at least one of zones Z1 adjacent side 80 when there is movement
within at least one of zones Z1 adjacent side 82. As such, spring
assembly 30 may be configured to reduce or eliminate movement on
one side of spring assembly 30 when a sleeper on an opposite side
of spring assembly 30 moves.
[0080] In some embodiments, wherein the first and second sleepers
each have the same preference as to mattress firmness, for example,
zone Z1 at end 76 adjacent side 80 has the same configuration as
zone Z1 at end 76 adjacent side 82 and/or zone Z1 at end 78
adjacent side 80 has the same configuration as zone Z1 at end 78
adjacent side 82 and/or zone Z1 at midsection 84 adjacent side 80
has the same configuration as zone Z1 at midsection 84 adjacent
side 82. When zones Z1 at ends 76, 78 and midsection 84 are the
same, mattress 30a may be flipped by rotating mattress 30a 180
degrees along an axis that extends from end 76 to end 78. That is,
mattress 30a is rotated side over side. Since zones Z1 at ends 76,
78 and midsection 84 are the side adjacent side 80 and adjacent
side 82, the sleepers will still sleep on top of zones Z1 that have
the same configuration as they did before mattress 30a was
flipped.
[0081] In some embodiments, at least one of zones Z1 adjacent side
80 is different than at least one of zones Z1 adjacent side 82.
This allows spring assembly 30 to be customized to suit the
preferences of the first and second sleepers. For example, if the
sleeper that sleeps adjacent side 80 desires a firmer mattress than
the sleeper that sleeps adjacent side 82, at least one of zones Z1
adjacent side 80 may be firmer than at least one of zones Z1
adjacent side 82. In some embodiments, the firmness (or softness)
of zones Z1 may be altered by changing the material springs 64 or
made from a harder or more rigid material to a softer or less rigid
material, for example. In some embodiments, the firmness (or
softness) of zones Z1 may be altered by changing the number of
springs 64 within pockets 48 and/or changing the configuration of
springs 64. For example, where a firmer mattress is desired,
pockets 48 can each include more than one spring 64 therein. In
some embodiments, the firmness (or softness) of zones Z1 may be
altered by changing the depth and/or width of slits 60 and/or slits
62, as discussed herein. Indeed, because there may be a direct
correlation between the depth and/or width of slits 60, 62 and the
amount of movement between pockets 48, it is envisioned that
increasing the depth and/or width of slits 60 and/or slits 62 may
allow greater movement between pockets 48, thus resulting in a less
firm feel, for example.
[0082] In embodiments wherein zones Z1 at ends 76, 78 adjacent side
80 are the same and zones Z1 at ends 76, 78 adjacent side 82 are
the same, to maintain the configuration that the sleeper that
sleeps adjacent side 80 prefers and that the sleeper that sleeps
adjacent side 82 prefers, the depth and/or width slits 60 in a
given one of the zones Z1 at ends 76, 78 should be the same as the
depth and/or width of slits 60 in that zone Z1. Mattress 30a may
then be flipped in a manner that maintains the preferences of the
sleepers by rotating mattress 30a 180 degrees along an axis that
extends perpendicular to an axis that extends from end 76 to end
78. That is, mattress 30a is rotated end over end.
[0083] In some embodiments, zones Z1 at end 76 of spring assembly
30 shown in FIG. 20 each include the same number of strings 32
and/or zones Z1 at end 78 each include the same number of strings
32. In some embodiments, zones Z1 at end 76 of spring assembly 30
shown in FIG. 15 each include more or less strings 32 than zones Z1
at end 78. In some embodiments, zones Z1 of spring assembly 30
shown in FIG. 15 each include the same number of strings 32. In
some embodiments, zones Z1 at midsection 84 of spring assembly 30
shown in FIG. 20 each include more strings 32 than zones Z1 at ends
76, 78. In some embodiments, zones Z1 at midsection 84 of spring
assembly 30 shown in FIG. 20 each include less strings 32 than
zones Z1 at ends 76, 78. In some embodiments, zones Z2 at ends 76,
78 of spring assembly 30 shown in FIG. 20 each include the same
number of strings 66. In some embodiments, zones Z2 at end 76 of
spring assembly 30 shown in FIG. 20 include more or less strings 66
than zones Z2 at end 78.
[0084] In some embodiments, shown in FIGS. 21 and 22, mattress 30a
includes one of spring assemblies 30 discussed herein, a cushioning
material 86 and/or a base material 88. As shown in FIG. 22,
cushioning material 86 is positioned above spring assembly 30 such
that a bottom surface of cushioning material 86 engages the top
surfaces of strings 32 and/or strings 66 and base material 88 is
positioned below spring assembly 30 such that a top surface of base
material 88 engages the bottom surfaces of strings 32 and/or
strings 66. That is, spring assembly 30 is positioned between
cushioning material 86 and base material 88. In some embodiments,
spring assembly 30 is fixed and/or coupled to cushioning material
86 and/or base material 88 by sewing, adhesives, etc.
[0085] It will be understood that various modifications may be made
to the embodiments disclosed herein. For example, features of any
one embodiment can be combined with features of any other
embodiment. Therefore, the above description should not be
construed as limiting, but merely as exemplification of the various
embodiments. Those skilled in the art will envision other
modifications within the scope and spirit of the claims appended
hereto.
* * * * *