CA3030739A1 - Coil spring mattress construction - Google Patents
Coil spring mattress construction Download PDFInfo
- Publication number
- CA3030739A1 CA3030739A1 CA3030739A CA3030739A CA3030739A1 CA 3030739 A1 CA3030739 A1 CA 3030739A1 CA 3030739 A CA3030739 A CA 3030739A CA 3030739 A CA3030739 A CA 3030739A CA 3030739 A1 CA3030739 A1 CA 3030739A1
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- Canada
- Prior art keywords
- coil springs
- mattress
- wire coil
- perimeter
- support region
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
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- 238000010276 construction Methods 0.000 title claims description 4
- 239000004744 fabric Substances 0.000 claims description 15
- 238000005452 bending Methods 0.000 claims description 12
- 230000036316 preload Effects 0.000 claims description 9
- 230000006835 compression Effects 0.000 abstract description 16
- 238000007906 compression Methods 0.000 abstract description 16
- 230000004044 response Effects 0.000 abstract description 3
- 239000000463 material Substances 0.000 description 10
- 239000000945 filler Substances 0.000 description 8
- 230000006872 improvement Effects 0.000 description 6
- 230000008901 benefit Effects 0.000 description 4
- 239000006260 foam Substances 0.000 description 3
- 230000008859 change Effects 0.000 description 2
- 230000003116 impacting effect Effects 0.000 description 2
- 238000011084 recovery Methods 0.000 description 2
- 208000036366 Sensation of pressure Diseases 0.000 description 1
- 238000004873 anchoring Methods 0.000 description 1
- 230000009118 appropriate response Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 230000008447 perception Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 238000009732 tufting Methods 0.000 description 1
Classifications
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/06—Spring inlays
- A47C27/063—Spring inlays wrapped or otherwise protected
- A47C27/064—Pocketed springs
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/06—Spring inlays
- A47C27/062—Spring inlays of different resiliencies
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/06—Spring inlays
- A47C27/066—Edge stiffeners
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/06—Spring inlays
- A47C27/07—Attaching, or interconnecting of, springs in spring inlays
Abstract
A more versatile pocket coil mattress provides increased support in the perimeter side regions of the mattress in combination with increased support in the main sleeping area. The shape, preloading and characteristics of the pocket coil springs has changed to decrease compression per unit of force applied while still maintaining the desired user response of a pocket coiled mattress.
Description
Coil Spring Mattress Construction FIELD OF THE INVENTION
The present invention is directed to pocket coil mattresses and in particular to improvements with respect to a perimeter support region and a main sleep area of the mattress.
BACKGROUND OF THE INVENTION
Pocket coil mattresses are known for having extremely appealing flex properties and the ability to resiliently conform to different users thereby providing a better night's sleep. These mattresses have individual coil springs maintained in a compressed state in their own fabric pocket. Typically the fabric pockets are sewn in long strips and secured to form the mattress core.
Many pocket coil mattresses include either an edge wire around the mattress that connects to edge coil springs and provides additional stiffness for seating at the edge of the mattress or; a hard compression foam encasement to replace the edgewire, as well as between 25% and 33% of the spring core itself to prove a strengthened seating edge. The edge wire although helpful in providing this additional support, is not desirable in that the mattress can be permanently damaged if subjected to significant bending. Bending of a mattress is often necessary to allow passage of the mattress through a restricted access such as a narrow staircase or other restriction.
Furthermore bending of the mattress is desirable for adjustable position leisure beds or hospital type beds. In the case of a foam encased seating edge, the end result does allow bending and does not have the sustainable performance and long term recovery level as an complete spring edge with the attached edgewire. A foam encasement seating edge is not a design that is applicable to the present invention of pocket coil spring core assembly.
The present invention is directed to pocket coil mattresses and in particular to improvements with respect to a perimeter support region and a main sleep area of the mattress.
BACKGROUND OF THE INVENTION
Pocket coil mattresses are known for having extremely appealing flex properties and the ability to resiliently conform to different users thereby providing a better night's sleep. These mattresses have individual coil springs maintained in a compressed state in their own fabric pocket. Typically the fabric pockets are sewn in long strips and secured to form the mattress core.
Many pocket coil mattresses include either an edge wire around the mattress that connects to edge coil springs and provides additional stiffness for seating at the edge of the mattress or; a hard compression foam encasement to replace the edgewire, as well as between 25% and 33% of the spring core itself to prove a strengthened seating edge. The edge wire although helpful in providing this additional support, is not desirable in that the mattress can be permanently damaged if subjected to significant bending. Bending of a mattress is often necessary to allow passage of the mattress through a restricted access such as a narrow staircase or other restriction.
Furthermore bending of the mattress is desirable for adjustable position leisure beds or hospital type beds. In the case of a foam encased seating edge, the end result does allow bending and does not have the sustainable performance and long term recovery level as an complete spring edge with the attached edgewire. A foam encasement seating edge is not a design that is applicable to the present invention of pocket coil spring core assembly.
- 2 -In our earlier patent US 6,295,676, a pocket coil mattress is disclosed that does not include an edge wire. This mattress allows bending of the mattress, however the edge of the mattress is substantially compressed when a user sits on the edge of the mattress. The ability to provide firm edge support and desirable flex for sleeping is challenging.
The present invention provides an improved pocket coil mattress that allows for the bending thereof while providing substantially improved edge support and without impacting on the uniform comfort of the balance of the mattress spring underlying its sleep surface when fully finished with upholstery padding material. These advantages are realized while still providing a main sleep area and perimeter support region that has the comfort advantages that is now expected with a pocket coil mattress.
SUMMARY OF THE INVENTION
A mattress according to the present invention, comprises a main sleep area surrounded by a perimeter support region. The main sleep area and the perimeter support region are defined by wire coil springs contained within individual fabric pockets. The wire coil springs in the main sleep area are arranged in a honeycomb offset series of rows. The wire coil springs in the perimeter support region are of a different wire construction and have different flex characteristics from the wire coil springs in the main sleep area. The wire coil springs in the perimeter support region are arranged in side by side rows and thus define a non-honeycomb arrangement.
The perimeter support region has at least two side by side rows about the mattress.
The perimeter support region includes four corner configurations that each have at least eight cross connected wire coil springs. These coil springs are cross connected to join coil springs of the same row and opposite rows. Between the corner configurations wire coil springs of the perimeter region are only connected across
The present invention provides an improved pocket coil mattress that allows for the bending thereof while providing substantially improved edge support and without impacting on the uniform comfort of the balance of the mattress spring underlying its sleep surface when fully finished with upholstery padding material. These advantages are realized while still providing a main sleep area and perimeter support region that has the comfort advantages that is now expected with a pocket coil mattress.
SUMMARY OF THE INVENTION
A mattress according to the present invention, comprises a main sleep area surrounded by a perimeter support region. The main sleep area and the perimeter support region are defined by wire coil springs contained within individual fabric pockets. The wire coil springs in the main sleep area are arranged in a honeycomb offset series of rows. The wire coil springs in the perimeter support region are of a different wire construction and have different flex characteristics from the wire coil springs in the main sleep area. The wire coil springs in the perimeter support region are arranged in side by side rows and thus define a non-honeycomb arrangement.
The perimeter support region has at least two side by side rows about the mattress.
The perimeter support region includes four corner configurations that each have at least eight cross connected wire coil springs. These coil springs are cross connected to join coil springs of the same row and opposite rows. Between the corner configurations wire coil springs of the perimeter region are only connected across
- 3 -rows. The mattress is made without an edge wire about the perimeter of the mattress. The coil springs of the perimeter region cooperate to accommodate substantial resilient bending of the mattress in a length thereof while providing improved support for side seating.
According to an aspect of the invention, the wire coil springs of the perimeter support region are of a smaller coil diameter relative to the diameter of the wire coil springs of the main sleep area.
According to a further aspect of the invention, the wire coil springs of the perimeter region have a gauge of about 14.5.
In a further aspect of the invention, the wire coil springs of the main sleep area are of a gauge of about 15.5.
According to a preferred aspect of the invention, the wire coil springs of the perimeter support region are of a diameter of about 2 inches at the ends thereof and the springs taper inwardly to a narrow waist of about 50 millimeters.
In a further aspect of the invention, the perimeter support region includes at least three rows of wire coil springs of a gauge between 14 and 15.
In yet a further aspect of the invention, the perimeter support region at the top surface thereof, is connected by a flexible high-strength plastic mesh extending over the mattress. Preferably the bottom surface of the mattress is also connected a flexible high strength plastic mesh.
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According to an aspect of the invention, the wire coil springs of the perimeter support region are of a smaller coil diameter relative to the diameter of the wire coil springs of the main sleep area.
According to a further aspect of the invention, the wire coil springs of the perimeter region have a gauge of about 14.5.
In a further aspect of the invention, the wire coil springs of the main sleep area are of a gauge of about 15.5.
According to a preferred aspect of the invention, the wire coil springs of the perimeter support region are of a diameter of about 2 inches at the ends thereof and the springs taper inwardly to a narrow waist of about 50 millimeters.
In a further aspect of the invention, the perimeter support region includes at least three rows of wire coil springs of a gauge between 14 and 15.
In yet a further aspect of the invention, the perimeter support region at the top surface thereof, is connected by a flexible high-strength plastic mesh extending over the mattress. Preferably the bottom surface of the mattress is also connected a flexible high strength plastic mesh.
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- 4 -BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in the drawings wherein:
Figure 1 is a perspective view of the new mattress showing resilient deformation of a corner region of the mattress;
Figure 2 is a perspective view of the mattress showing bending of the mattress to accommodate variable position beds;
Figure 3 is a perspective view of the mattress showing bending thereof about a midpoint of the mattress;
Figure 4 is a partial perspective view of the corner configuration of the mattress;
Figure 5 is a top view showing a number of individual components the mattress;
Figure 6 is a partial top you showing the wire coil springs of the perimeter region and the wire coil springs of the main sleep area;
Figure 7 is a partial perspective view of coil springs preloaded and maintained in their own individual fabric pocket:
Figure 8 is a partial top view of the twin mattress having two rows of wire coil springs defining the perimeter support region;
Figure 9 is a partial perspective view of a prior art mattress showing resilient deformation of the edge of the mattress when a person sits thereon;
Figure 10 shows the improved perimeter support region of the present invention with a person sitting thereon;
Figure 11 is a partial perspective view showing details of the perimeter support region and main sleep area;
Figure 12 is a partial perspective view similar to figure 11 showing our prior art arrangement;
Figure 13 is a perspective view of the new coil spring used in the perimeter support region;
Preferred embodiments of the invention are shown in the drawings wherein:
Figure 1 is a perspective view of the new mattress showing resilient deformation of a corner region of the mattress;
Figure 2 is a perspective view of the mattress showing bending of the mattress to accommodate variable position beds;
Figure 3 is a perspective view of the mattress showing bending thereof about a midpoint of the mattress;
Figure 4 is a partial perspective view of the corner configuration of the mattress;
Figure 5 is a top view showing a number of individual components the mattress;
Figure 6 is a partial top you showing the wire coil springs of the perimeter region and the wire coil springs of the main sleep area;
Figure 7 is a partial perspective view of coil springs preloaded and maintained in their own individual fabric pocket:
Figure 8 is a partial top view of the twin mattress having two rows of wire coil springs defining the perimeter support region;
Figure 9 is a partial perspective view of a prior art mattress showing resilient deformation of the edge of the mattress when a person sits thereon;
Figure 10 shows the improved perimeter support region of the present invention with a person sitting thereon;
Figure 11 is a partial perspective view showing details of the perimeter support region and main sleep area;
Figure 12 is a partial perspective view similar to figure 11 showing our prior art arrangement;
Figure 13 is a perspective view of the new coil spring used in the perimeter support region;
- 5 -Figure 14 is a side view of the new coil spring of Figure 11 showing the narrow waist;
Figure 15 is a side view of the coil spring used in the main sleep region illustrating the barrel shape profile thereof;
Figure 16 is a side view of the coil spring used in the main sleep area in an initial uncompressed state and transitioning to the preloaded state maintained in the fabric pocket as shown on the right-hand side;
Figure 17 is a side view showing the different preloaded compressed states of the coil springs of the perimeter support region and the main sleep area;
Figure 17a is a sectional view showing the gauge of the wire coil spring of the perimeter support region;
Figure 17b is a sectional view showing the gauge of the wire coil spring of the main sleep area;
Figure 18 is a side view showing the spring of the border region relative to the main sleep area Figure 19 is a partial perspective view of a corner configuration of the mattress with the fabric cover mattress secured above; and Figures 20 and 21 are partial side views of same coil spring shown enclosed into different types of fabric pocket.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Figures 1 through 3 in the application, illustrate various bent configurations of the mattress that commonly occur. In figure 1, one of the corners of the mattress has been bent upwardly. In figure 2, one end of the mattress has been raised as may be necessary for hospital beds or variable leisure beds that are moveable to a sitting configuration. This type of bending of the mattress intermediate its length, is now a common requirement. The bending of the mattress into the 'U' configuration of , .
Figure 15 is a side view of the coil spring used in the main sleep region illustrating the barrel shape profile thereof;
Figure 16 is a side view of the coil spring used in the main sleep area in an initial uncompressed state and transitioning to the preloaded state maintained in the fabric pocket as shown on the right-hand side;
Figure 17 is a side view showing the different preloaded compressed states of the coil springs of the perimeter support region and the main sleep area;
Figure 17a is a sectional view showing the gauge of the wire coil spring of the perimeter support region;
Figure 17b is a sectional view showing the gauge of the wire coil spring of the main sleep area;
Figure 18 is a side view showing the spring of the border region relative to the main sleep area Figure 19 is a partial perspective view of a corner configuration of the mattress with the fabric cover mattress secured above; and Figures 20 and 21 are partial side views of same coil spring shown enclosed into different types of fabric pocket.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Figures 1 through 3 in the application, illustrate various bent configurations of the mattress that commonly occur. In figure 1, one of the corners of the mattress has been bent upwardly. In figure 2, one end of the mattress has been raised as may be necessary for hospital beds or variable leisure beds that are moveable to a sitting configuration. This type of bending of the mattress intermediate its length, is now a common requirement. The bending of the mattress into the 'U' configuration of , .
- 6 -figure 3, may be necessary to move the mattress through a restricted space such as a narrow stairwell. In recent years, larger mattresses are more popular and access to the bedroom may be limited or restricted. Having a pocket coil mattress without a perimeter edge wire, provides this flexibility and easily accommodates varying the components of the mattress that may be required for different models.
Our earlier United States Patent 6,295,676 discloses a pocket coil mattress that does not include an edge wire and as such the mattress can bend intermediate its length.
Although this structure has many advantages over existing mattresses, it has some disadvantages with respect to edge seat support. In pocket coil mattresses, the ability of the mattress to independently respond to the movement of two users and allow for significant isolation of these movements, is a primary advantage.
The perimeter support region of the mattress includes two or more rows of coil springs that have different flex characteristics relative to the coil springs of the interior main sleep area. The border springs intermediate the corners, although stiffer than the coil spring of the main sleep area, still deform significantly and seating support on an edge mattress causes unwanted sidewall distortion as shown in the prior art mattress of Figure 9. The present invention provides a structure, where these disadvantages are overcome.
The mattress 2 as shown in figure 4, includes a mattress core 6 having a perimeter support region 10 about the main sleep area 50 of the mattress. The perimeter region 10 includes an outer row 12 of pocket coil springs, a middle row 14 of pocket coil springs and in the mattress of Figure 4, an inner row 16 of pocket coil springs. The main sleep area 50 has the coil springs thereof arranged in a honeycomb pattern.
Pocket coil springs of the main sleep area are of a lighter gauge wire and are more compressible than coil springs of the perimeter support region 10.
Our earlier United States Patent 6,295,676 discloses a pocket coil mattress that does not include an edge wire and as such the mattress can bend intermediate its length.
Although this structure has many advantages over existing mattresses, it has some disadvantages with respect to edge seat support. In pocket coil mattresses, the ability of the mattress to independently respond to the movement of two users and allow for significant isolation of these movements, is a primary advantage.
The perimeter support region of the mattress includes two or more rows of coil springs that have different flex characteristics relative to the coil springs of the interior main sleep area. The border springs intermediate the corners, although stiffer than the coil spring of the main sleep area, still deform significantly and seating support on an edge mattress causes unwanted sidewall distortion as shown in the prior art mattress of Figure 9. The present invention provides a structure, where these disadvantages are overcome.
The mattress 2 as shown in figure 4, includes a mattress core 6 having a perimeter support region 10 about the main sleep area 50 of the mattress. The perimeter region 10 includes an outer row 12 of pocket coil springs, a middle row 14 of pocket coil springs and in the mattress of Figure 4, an inner row 16 of pocket coil springs. The main sleep area 50 has the coil springs thereof arranged in a honeycomb pattern.
Pocket coil springs of the main sleep area are of a lighter gauge wire and are more compressible than coil springs of the perimeter support region 10.
- 7 -The perimeter support region 10 includes four corner configurations 30 and in the case of a queen or king mattress, each corner configuration is defined by 15 connected pocket coil springs. Each of these pocket coil springs are mechanically connected to adjacent pocket coil springs as indicated by the mechanical connectors 32. These mechanical connections are preferably upholstery stables located at the point of contact between adjacent pocket coil springs. With this arrangement a linked series of pocket coil springs is provided in each corner of the mattress. These connected coil springs are in contrast to the coil springs of the main sleep area that are independent. The mattress 2, with the four corner configurations 30, provide a more rigid configuration supporting the coil springs of the perimeter support region 10 between corner configurations.
The coil springs, between two corner configurations of the perimeter support region, are merely connected to adjacent pocket coil springs of the respective row or rows.
As can be appreciated these connected coil spring do not move independently due to the common mechanical connection 32 but have more independent movement than the coil springs of the corner configurations.
The corner configuration 30, as shown in Figure 4, provides an integrated support structure at each corner of the mattress that act to stabilize other pocket coil springs of the perimeter support region 10 as well as the coil springs of the main sleep area 50. The stable corner configurations 30 and the individual coils of the mattress 2 are connected by an upper high strength plastic mesh 60 and a lower high strength plastic mesh 62. In addition to the various mechanical connections of the coils to each other shown at the upper surface or top of the coils springs, the coil springs are also preferably connected in a similar manner on the lower surface of the mattress.
These connections pass through the fabric pockets 36.
The coil springs, between two corner configurations of the perimeter support region, are merely connected to adjacent pocket coil springs of the respective row or rows.
As can be appreciated these connected coil spring do not move independently due to the common mechanical connection 32 but have more independent movement than the coil springs of the corner configurations.
The corner configuration 30, as shown in Figure 4, provides an integrated support structure at each corner of the mattress that act to stabilize other pocket coil springs of the perimeter support region 10 as well as the coil springs of the main sleep area 50. The stable corner configurations 30 and the individual coils of the mattress 2 are connected by an upper high strength plastic mesh 60 and a lower high strength plastic mesh 62. In addition to the various mechanical connections of the coils to each other shown at the upper surface or top of the coils springs, the coil springs are also preferably connected in a similar manner on the lower surface of the mattress.
These connections pass through the fabric pockets 36.
- 8 -Figure 5 shows a queen-size mattress having the perimeter support region 10 surrounding the main sleep area 50. The spring coils of the main sleep area 50, laid out in a honeycomb configuration in contrast to the spring coils of the perimeter support region 10 that are positioned in a side by side configuration. Only a portion .. of the upper plastic grid mesh 60 is shown in the lower left corner of figure 5, and locates the corner configuration shown in greater detail in figure 6. For better understanding, the fabric pockets 36 of the coil springs are only partially shown.
The corner configuration 30 of figure 6 (corresponding to a queen or king size mattress) includes the first four coil springs in each of the three rows of coil springs in both the length and the width of the mattress and are mechanically secured.
The mechanical fasteners 32 connect t each coil spring to its abutting adjacent coil springs. Some of the coil springs include four mechanical connection points.
The corner configuration 30 includes the first four coil springs in each of the rows of the perimeter support region 10 in both the length and width direction. The coil springs of the perimeter region 10 located between corner configurations, only include mechanical connections 32 that join the coil springs in adjacent rows not along a row.
The top and bottom high strength plastic mesh 60 and 62 connect the spring coils of the perimeter support region as well as the spring coils of the main sleep area 50.
These corner configurations in combination with the high strength mesh, anchor and secure the remaining coil springs of the perimeter support region between the corner configurations. Each of the wire coil springs of the perimeter support region, is of a reduced overall diameter relative to the diameter of the wire coil springs of the main sleep area 50. Furthermore, the coil springs in the main sleep area 50, are in the honeycomb configuration and provide independent movement while also supporting each other as the coil springs are closely packed.
, .
The corner configuration 30 of figure 6 (corresponding to a queen or king size mattress) includes the first four coil springs in each of the three rows of coil springs in both the length and the width of the mattress and are mechanically secured.
The mechanical fasteners 32 connect t each coil spring to its abutting adjacent coil springs. Some of the coil springs include four mechanical connection points.
The corner configuration 30 includes the first four coil springs in each of the rows of the perimeter support region 10 in both the length and width direction. The coil springs of the perimeter region 10 located between corner configurations, only include mechanical connections 32 that join the coil springs in adjacent rows not along a row.
The top and bottom high strength plastic mesh 60 and 62 connect the spring coils of the perimeter support region as well as the spring coils of the main sleep area 50.
These corner configurations in combination with the high strength mesh, anchor and secure the remaining coil springs of the perimeter support region between the corner configurations. Each of the wire coil springs of the perimeter support region, is of a reduced overall diameter relative to the diameter of the wire coil springs of the main sleep area 50. Furthermore, the coil springs in the main sleep area 50, are in the honeycomb configuration and provide independent movement while also supporting each other as the coil springs are closely packed.
, .
- 9 -Figure 7 shows an example of wire coil springs located within their connected fabric pockets 36. The pockets are of a fixed length and maintain the wire coil springs in a partially compressed or preloaded state.
Figure 8 shows part of a twin size mattress with a reduced perimeter support region having only two rows of wire coil springs surrounding the main sleep area 50.
In this case the first three coil springs of the corner configuration 30 in each direction, are mechanically connected by fasteners 32.
Figure 8 shows part of a twin size mattress with a reduced perimeter support region having only two rows of wire coil springs surrounding the main sleep area 50.
In this case the first three coil springs of the corner configuration 30 in each direction, are mechanically connected by fasteners 32.
10 One of the problems associated with pocketed coil spring design mattresses, is that a person sitting on a side portion of a prior art mattress, as shown in figure 9, creates significant compression and distortion of the side wall 42 of the mattress as indicated by outward distortion of the sidewall of the mattress and distortion ripples 54.
A mattress with the new comer configuration having the improved coil wire springs in the perimeter support region, undergoes less compression and less sidewall outward distortion and therefore fewer distortion ripples occur as the perimeter support region is stiffer. With this improvement there is still some distortion of the side wall of the mattress as evident at 56, however the distortion is limited and improved seat support is provided. Furthermore although the perimeter support region has been stiffened, the desirable sleeping comfort of the mattress is maintained.
Figures 11 and 12 provide a comparison of new pocket coil spring mattress shown in figure 11 and the prior art pocket coil spring mattress as shown in figure 12.
For a better understanding, the filler springs 28 are shown in an uncompressed state and are of a length of 10 inches indicated at 53. The end diameter indicated by 57 is 2 inches. The spring is barrel shaped with a waist of 55mm. In contrast the , uncompressed state of the prior art filler spring 28a is 9.5 inches indicated at 55, the end diameter 59 is 2.25 inches and the waist of the barrel shape is 58mm.
Improvements with respect to the flex and shape of the wire coil springs and the relationship of the wire coil springs of the perimeter support region to the coil springs of the main area 50, can be appreciated from a review of figures 13 through 15. The heavier gauge wire of the coil springs in the perimeter support region has a tensile strength in the range 240,000 to 280,000 psi whereas the wire of the lighter gauge coil springs of the main sleep area has a tensile strength in the range of 290,000 to 310,000 psi.
Wire coil spring 24 of the perimeter region, is preferably of a gauge of 14.5.
The height of the spring before compression is approximately 10 to 10.5 inches and the spring end diameter is 2 1/8 inches. The number of turns of the spring is six.
As shown in figure 14, the spring is formed to taper inwardly to a reduced waist having a diameter of approximately 50 mm in the preferred embodiment. The perimeter support springs are compressed from the uncompressed state and received in a pocket that accommodates a spring length of about 6 1/2 inches. Our prior art spring used at the sides of the mattress, has a barrel type shape that tends to distort outwardly when compressed. In addition, the uncompressed state of the spring was 9 to 9.5 inches. The tapered waist of the new spring reduces outward distortion during substantial compression that may occurs when a person sits on the side edge of the mattress and also has higher support load due to the increased compression due to its longer uncompressed length. The load lift capability of the spring has been increased without changing the overall length, gauge or strength of the wire.
In this way, the load lift capability has been increased while still maintaining uniform comfort balance across the finished mattress.
A mattress with the new comer configuration having the improved coil wire springs in the perimeter support region, undergoes less compression and less sidewall outward distortion and therefore fewer distortion ripples occur as the perimeter support region is stiffer. With this improvement there is still some distortion of the side wall of the mattress as evident at 56, however the distortion is limited and improved seat support is provided. Furthermore although the perimeter support region has been stiffened, the desirable sleeping comfort of the mattress is maintained.
Figures 11 and 12 provide a comparison of new pocket coil spring mattress shown in figure 11 and the prior art pocket coil spring mattress as shown in figure 12.
For a better understanding, the filler springs 28 are shown in an uncompressed state and are of a length of 10 inches indicated at 53. The end diameter indicated by 57 is 2 inches. The spring is barrel shaped with a waist of 55mm. In contrast the , uncompressed state of the prior art filler spring 28a is 9.5 inches indicated at 55, the end diameter 59 is 2.25 inches and the waist of the barrel shape is 58mm.
Improvements with respect to the flex and shape of the wire coil springs and the relationship of the wire coil springs of the perimeter support region to the coil springs of the main area 50, can be appreciated from a review of figures 13 through 15. The heavier gauge wire of the coil springs in the perimeter support region has a tensile strength in the range 240,000 to 280,000 psi whereas the wire of the lighter gauge coil springs of the main sleep area has a tensile strength in the range of 290,000 to 310,000 psi.
Wire coil spring 24 of the perimeter region, is preferably of a gauge of 14.5.
The height of the spring before compression is approximately 10 to 10.5 inches and the spring end diameter is 2 1/8 inches. The number of turns of the spring is six.
As shown in figure 14, the spring is formed to taper inwardly to a reduced waist having a diameter of approximately 50 mm in the preferred embodiment. The perimeter support springs are compressed from the uncompressed state and received in a pocket that accommodates a spring length of about 6 1/2 inches. Our prior art spring used at the sides of the mattress, has a barrel type shape that tends to distort outwardly when compressed. In addition, the uncompressed state of the spring was 9 to 9.5 inches. The tapered waist of the new spring reduces outward distortion during substantial compression that may occurs when a person sits on the side edge of the mattress and also has higher support load due to the increased compression due to its longer uncompressed length. The load lift capability of the spring has been increased without changing the overall length, gauge or strength of the wire.
In this way, the load lift capability has been increased while still maintaining uniform comfort balance across the finished mattress.
-11 -The new mattress with the perimeter support region of the revised shape and stronger coil springs, provides improved seat support between the anchoring corners. The improved load carrying capabilities of each spring is provided by reducing the diameter of the spring and changing the shape of the spring from a barrel shape to a tapered waist design. The length of the perimeter support region springs has been increased (preferably from 9.5 inches to 10.5) and the preload of each spring has increased and is in the range of 900 to 1000 grams whereas the prior art coil spring typically had a preload in the range of 750 to 780 grams. The diameter of the prior art spring was about 2.5 inches and the center waist diameter was mm. The wire length of about 47 inches was maintained. Therefore the wire coil spring 24 has been redesigned to provide additional support in a side region of the mattress that is prone to user distortion due to a concentrated load created by sitting on a side or end of the mattress. The enhanced load carrying capabilities of the modified spring and the stiffer corner configurations cooperate and reduce sidewall distortion while maintaining independent sleep support in the main sleep area of the mattress as well as compatible sleep support in the perimeter support region.
Also side seating on the mattress is improved as there is less compression.
The filler springs in the sleep central area preferably are also been modified to increase the length of the uncompressed spring to about 10 inches whereas our prior filler spring was of a length of 9 to 9.5 inches. The diameter of the spring is now preferably 2 inches whereas previously it was about 2.25 inches. The waist of its barrel shape is now 55mm compared to the previous 58mm. Both the new and old springs are 6 turn springs of the same 15.5 gauge that are pre-compressed and maintained in a 6.5 inch pocket. The preload of the filler spring has increased to 490 to 500 grams compared to the previous preload of about 430 grams. The changes to the filler spring cooperate with the new perimeter support region spring to provide ,
Also side seating on the mattress is improved as there is less compression.
The filler springs in the sleep central area preferably are also been modified to increase the length of the uncompressed spring to about 10 inches whereas our prior filler spring was of a length of 9 to 9.5 inches. The diameter of the spring is now preferably 2 inches whereas previously it was about 2.25 inches. The waist of its barrel shape is now 55mm compared to the previous 58mm. Both the new and old springs are 6 turn springs of the same 15.5 gauge that are pre-compressed and maintained in a 6.5 inch pocket. The preload of the filler spring has increased to 490 to 500 grams compared to the previous preload of about 430 grams. The changes to the filler spring cooperate with the new perimeter support region spring to provide ,
- 12 -an effective transition at the junction of the sleep central area and the perimeter support region.
Diameters of both edge (border) coil and sleep central area (filler) coil, despite the difference in wire gauge are close in size so as not to distort the final assembled core in terms of resilient performance and responsive compliance across the core surface that translates above and below in the finished mattress. This describes desirable, uniform performance and compliance across the finished (upholstered and covered) mattress from side to side and head to foot. The springs cooperate to provide a proportional balance between the perimeter edge and the sleep central subassemblies placed in the final pocket spring core assembly.
Surprisingly, the additional pre-compression and changes to the perimeter coil springs, support the load of a person sitting on the side of the mattress with less compression of the mattress sidewall. These changes in combination with the increased load carrying capability of the main sleep area springs per unit of compression, provides a pocket coil mattress with the known desired sensation of pressure relief, great support and fast response to the user's movement. The modified perimeter and main sleep area springs have greater load carrying capability per unit of compression while still providing the desired response and without a load ridge at the junction of the perimeter support springs and the main sleep area springs. Both types of springs have a higher rate of recovery without impacting the user's perception of great support and appropriate response to user movement.
The extent of side edge compression of the mattress due to a user sitting thereon, has substantially decreased from 3 to 4 inches for example to preferably 1 to 2.5 inches.
This change provides the additional support and allows the mattress able to meet the
Diameters of both edge (border) coil and sleep central area (filler) coil, despite the difference in wire gauge are close in size so as not to distort the final assembled core in terms of resilient performance and responsive compliance across the core surface that translates above and below in the finished mattress. This describes desirable, uniform performance and compliance across the finished (upholstered and covered) mattress from side to side and head to foot. The springs cooperate to provide a proportional balance between the perimeter edge and the sleep central subassemblies placed in the final pocket spring core assembly.
Surprisingly, the additional pre-compression and changes to the perimeter coil springs, support the load of a person sitting on the side of the mattress with less compression of the mattress sidewall. These changes in combination with the increased load carrying capability of the main sleep area springs per unit of compression, provides a pocket coil mattress with the known desired sensation of pressure relief, great support and fast response to the user's movement. The modified perimeter and main sleep area springs have greater load carrying capability per unit of compression while still providing the desired response and without a load ridge at the junction of the perimeter support springs and the main sleep area springs. Both types of springs have a higher rate of recovery without impacting the user's perception of great support and appropriate response to user movement.
The extent of side edge compression of the mattress due to a user sitting thereon, has substantially decreased from 3 to 4 inches for example to preferably 1 to 2.5 inches.
This change provides the additional support and allows the mattress able to meet the
- 13 -need of various bed applications without using a border edge wire. Furthermore the springs are less likely to fatigue over the life of the mattress due to the higher strength.
Figure 16 illustrates one of the filler springs 28 undergoing compression and being retained in the fabric pocket 36 in a compressed state to preload the spring.
The individual fabric pockets 36 are of the appropriate size to maintain the desired initial compression of the springs. Although the fabric pocket is shown with spring 28 a similar pocket arrangement is used to maintain the initial compression of perimeter springs 26.
Figure 17 shows the assembled core of the mattress 2 together with top and bottom upholstery type cushioning material 93 that may vary between different mattress models. A fabric outer material would be present to finish the mattress. Other intermediary layers may also be present as found in existing pocket coil mattresses.
Figure 18 shows some movement of the coil spring when a weight is applied to the edge of the mattress. Figure 19 shows additional layers of the mattress 2 supported by the pocketed coil spring core 6. These various layers are preferably secured by tufting.
Figures 20 and 21 show the wire coil springs 28 received in pockets of different types of material 36a and 36b. The material of the pocket may vary depending upon the particular characteristics of the mattress. Some pocket material is thicker (pocket material 36b) than other pocket material (pocket material 36a) as exemplified in these figures. Somewhat surprisingly the number of coils provided in the length or width of the mattress may vary depending upon a change in the thickness of the pocket material.
Figure 16 illustrates one of the filler springs 28 undergoing compression and being retained in the fabric pocket 36 in a compressed state to preload the spring.
The individual fabric pockets 36 are of the appropriate size to maintain the desired initial compression of the springs. Although the fabric pocket is shown with spring 28 a similar pocket arrangement is used to maintain the initial compression of perimeter springs 26.
Figure 17 shows the assembled core of the mattress 2 together with top and bottom upholstery type cushioning material 93 that may vary between different mattress models. A fabric outer material would be present to finish the mattress. Other intermediary layers may also be present as found in existing pocket coil mattresses.
Figure 18 shows some movement of the coil spring when a weight is applied to the edge of the mattress. Figure 19 shows additional layers of the mattress 2 supported by the pocketed coil spring core 6. These various layers are preferably secured by tufting.
Figures 20 and 21 show the wire coil springs 28 received in pockets of different types of material 36a and 36b. The material of the pocket may vary depending upon the particular characteristics of the mattress. Some pocket material is thicker (pocket material 36b) than other pocket material (pocket material 36a) as exemplified in these figures. Somewhat surprisingly the number of coils provided in the length or width of the mattress may vary depending upon a change in the thickness of the pocket material.
- 14 -The applicant has found, that improvements to pocket coil mattresses can be realized by providing additional support created by the connected corner configurations.
Further improvements in the characteristics of the side edge of the mattress can be .. realized by changing the shape and load carrying capacity of the wire coil springs used in the perimeter support region. Further improvements can be realized by utilizing wire coil springs in the main sleep region that are of reduced diameter and of greater load carrying capabilities relative to the prior art mattresses.
.. Although the invention has been described herein in detail appreciated the variations may be made thereto without departing from the attached claims. The detailed description has focused on applicant's preferred embodiments however the attached claims define the applicant's invention.
Further improvements in the characteristics of the side edge of the mattress can be .. realized by changing the shape and load carrying capacity of the wire coil springs used in the perimeter support region. Further improvements can be realized by utilizing wire coil springs in the main sleep region that are of reduced diameter and of greater load carrying capabilities relative to the prior art mattresses.
.. Although the invention has been described herein in detail appreciated the variations may be made thereto without departing from the attached claims. The detailed description has focused on applicant's preferred embodiments however the attached claims define the applicant's invention.
Claims (12)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A mattress comprising a main sleep area surrounded by perimeter support region with both the main sleep area and the perimeter support region being defined by wire coil springs contained within fabric pockets;
the wire coil springs in the main sleep area are arranged in honeycomb offset rows; the wire coil springs in the perimeter support region are of a different wire construction having different flex characteristics relative to the wire coil springs in the main sleep area; said wire coil springs in said perimeter support region are arranged to define at least two side by side rows about the mattress; and wherein said wire coil springs of said perimeter support region define four corner regions of the mattress with each corner region including at least 8 wire coil springs cross connected and joining adjacent wire coil springs of the respective row and adjacent wire coil springs of opposite rows;
said wire coil springs of the perimeter region cooperating to allow said wire coil springs between said corner regions to accommodate substantial resilient bending of said mattress in a length thereof.
the wire coil springs in the main sleep area are arranged in honeycomb offset rows; the wire coil springs in the perimeter support region are of a different wire construction having different flex characteristics relative to the wire coil springs in the main sleep area; said wire coil springs in said perimeter support region are arranged to define at least two side by side rows about the mattress; and wherein said wire coil springs of said perimeter support region define four corner regions of the mattress with each corner region including at least 8 wire coil springs cross connected and joining adjacent wire coil springs of the respective row and adjacent wire coil springs of opposite rows;
said wire coil springs of the perimeter region cooperating to allow said wire coil springs between said corner regions to accommodate substantial resilient bending of said mattress in a length thereof.
2. A mattress as claimed in claim 1 wherein said wire coil springs of said perimeter region are of a smaller spring coil diameter relative to the diameter of the wire coil springs of said main sleep area.
3. A mattress as claimed in claim 2 wherein said wire coil springs of said perimeter region have a gauge of about 14.5.
4. A mattress as claimed in claim 3 wherein said wire coil springs of said main sleep area have a gauge of about 15.5.
5. A mattress as claimed in claim 3 wherein said wire coil springs of said perimeter region are of a diameter of about 2 inches at the ends thereof and taper inwardly to a narrow waist of about 50 mm.
6. A mattress as claimed in claim 2 wherein said perimeter support region includes at least 3 rows of wire coil springs and said wire coil springs are of a gauge of between 14 and 15.
7. A mattress as claimed in claim 6 wherein said wire coil springs of said perimeter region are connected at both ends of said coil springs.
8. A mattress as claimed in claim 7 wherein said perimeter support region on a top surface and a bottom surface is connected by a flexible high strength plastic mesh.
9. A mattress as claimed in claim 1 wherein the wire coil springs in said perimeter support region have a preload force of at least 970 grams.
10. A mattress as claimed in claim 9 wherein the wire coil springs in said main sleep area have a preload force of at least 490 grams.
11. A mattress as claimed in claim 10 wherein the wire coil springs in said perimeter support region have a preload force in the range of 970 to 1000 grams.
12. A mattress as claimed in claim 11 wherein the wire coil springs in said main sleep area have a preload force in the range of 490 to 520 grams.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA3030739A CA3030739A1 (en) | 2019-01-21 | 2019-01-21 | Coil spring mattress construction |
| US16/747,158 US20200229609A1 (en) | 2019-01-21 | 2020-01-20 | Coil spring mattress construction |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA3030739A CA3030739A1 (en) | 2019-01-21 | 2019-01-21 | Coil spring mattress construction |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA3030739A1 true CA3030739A1 (en) | 2020-07-21 |
Family
ID=71610290
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA3030739A Pending CA3030739A1 (en) | 2019-01-21 | 2019-01-21 | Coil spring mattress construction |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US20200229609A1 (en) |
| CA (1) | CA3030739A1 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11412861B1 (en) * | 2019-02-13 | 2022-08-16 | Protscel, LLC | Mattress comprising a core of pocket springs disposed within a periphery of outer springs |
| US11627813B2 (en) * | 2021-03-02 | 2023-04-18 | Avocado Green Brands, LLC | Multiple zone mattress core element with multiple coil configurations |
-
2019
- 2019-01-21 CA CA3030739A patent/CA3030739A1/en active Pending
-
2020
- 2020-01-20 US US16/747,158 patent/US20200229609A1/en not_active Abandoned
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|---|---|
| US20200229609A1 (en) | 2020-07-23 |
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