CN116648170A

CN116648170A - Pocketed spring assembly including cushioning pad

Info

Publication number: CN116648170A
Application number: CN202180073951.XA
Authority: CN
Inventors: J·V·朱伊特
Original assignee: L&p Property Rights Management Co
Current assignee: L&p Property Rights Management Co
Priority date: 2020-10-28
Filing date: 2021-08-12
Publication date: 2023-08-25
Also published as: EP4236727A1; AU2021367793B2; AU2021367793A1; WO2022093361A1; CA3197011A1

Abstract

A pocketed spring assembly (12, 12a, 12b, 12d, 12e, 12') includes a plurality of parallel strings (26, 26a, 26b, 26c, 26d, 26 e) of springs, each string being connected to at least one adjacent string, each string including a sheet of fabric folded into opposed first and second layers of fabric. An outer pocket (34, 34b, 98) is formed along each string by a transverse seam (52, 114) joining the first and second layers. A pocket spring and at least one cushion pad (54, 54a, 54', 94 ") are positioned in each outer pocket (34, 34b, 98). The cushions (54, 54a, 54', 94') may be individually bagged. The upper end (66) of each transverse seam (52, 114) may be below the upper surface (60) of the string (26, 26a, 26b, 26c, 26d, 26 e) to partially separate adjacent outer pockets (34, 34b, 98) within the string.

Description

Pocketed spring assembly including cushioning pad

Cross Reference to Related Applications

The present application is continued in part from U.S. patent application Ser. No. 15/897,687 filed on date 2/15 in 2018, the entire contents of which are incorporated herein by reference.

Technical Field

The present application relates generally to bedding and seating products, and more particularly to pocketed spring assemblies for use in bedding and seating products.

Background

Mattress spring core construction has been an area of continual advancement over the years as materials and machine technology have advanced. A well known form of spring core construction is known as a marshall spring construction, in which metal coil springs are enclosed in individual pockets of fabric and formed as an elongated or continuous string of pocketed coil springs. In early versions, these strings of coil springs were made by folding an elongated sheet of fabric in half longitudinally to form two layers of fabric, and sewing transverse and longitudinal seams to join the layers of fabric to define a pocket in which the spring is wrapped.

Recently, improvements in spring core construction have involved the use of heat-weldable or ultrasonically-weldable fabrics. By using such welding techniques, these fabrics have been advantageously used to make strings of individually pocketed coil springs, wherein transverse and longitudinal welds are used instead of stitching to form pockets that encapsulate the springs.

Once strings of pocketed springs are constructed, they can be assembled into pocketed spring cores or components of mattresses, cushions, and the like by various methods. For example, multiple or consecutive strings may be arranged in a row pattern corresponding to a desired size and shape of a mattress or the like, and adjacent rows of strings may be interconnected by various methods. The result is a pocketed coil spring which is a unitary assembly that functions as a complete spring core assembly.

Conventional pocketed spring cores incorporating strings of pockets of springs provide less transmission of motion between sleeping partners than conventional spiral-tie open coil spring assemblies. Each pocketed coil spring can move with greater independence and therefore less impact on adjacent pocketed coil springs than if the coil springs were not within separate pockets. However, with conventional pocketed spring mattresses, a foam sheet or other cushioning layer is attached to the upper surface of the pocketed spring assembly. The foam or cushioning sheet acts as a bridge such that a load applied to one side of the mattress affects the other side of the mattress, thereby providing an undesirable bridge effect. The present application eliminates the undesirable bridging effect by encapsulating a single cushioning member within the outer pocket of the string of springs.

U.S. patent No. 6,490,744 discloses a pocketed spring assembly incorporating a string having individual pocketed coil springs, wherein a cushion is inside the pocket. However, since the individual coil springs are non-pocketed, the coil springs may damage the cushion and/or affect the feel of the pocketed spring assembly as the coil springs press against the cushion. The ability of an individual pocketed spring to function independently of an adjacent pocketed spring in a string of springs can be compromised.

Thus, there remains a need to couple various techniques to improve the feel and motion transfer of bedding or seating products having pocketed spring cores.

Disclosure of Invention

In one aspect, a bedding or seating product is provided. The product includes a pocketed spring assembly and an edge support extending along each of two opposite sides of the pocketed spring assembly. Each edge support includes a plurality of parallel edge strings of springs, each edge string being connected to at least one adjacent edge string. Each edge string comprises a piece of fabric surrounding a plurality of pocketed springs and a plurality of cushioning pads, with opposed first and second layers of fabric on opposite sides of the pocketed springs and cushioning pads. The outer bag is formed by joining the first and second layers along the edge strings with longitudinal and transverse seams. At least one pocketed spring and at least one cushion are in each outer pocket. Each cushion can be individually bagged and can be of any desired size or shape.

Different coil springs may be located within the inner pockets of the edge strings. In one embodiment, each coil spring of each edge string has upper and lower end turns and a plurality of central convolutions between the end turns, the central convolutions having the same diameter. Regardless of the configuration of the coil springs, each coil spring is preferably made of one wire of uniform diameter, but this is not the case in all cases. In many embodiments, the coil springs of the edge strings are narrower than the coil springs of the inner strings described below. The pocketed springs of the edge string are typically coil springs, but may be any spring or resilient member.

In at least one embodiment, the pocketed spring assembly includes a plurality of parallel inner strings of springs, each inner string being connected to at least one adjacent inner string. Each inner string comprises a sheet of fabric surrounding a plurality of pocketed springs and a plurality of cushioning pads, with opposed first and second layers of fabric on opposite sides of the pocketed springs and cushioning pads. The outer bag is formed by longitudinal and transverse seams joining the first and second layers along the length of the inner string. At least one pocketed spring and at least one cushion are in each outer pocket. Each cushion is individually bagged and may be of any desired size or shape. The pocketed springs of the inner string are typically coil springs, but may be any spring or resilient member.

The inner string of pocketed spring assemblies can extend longitudinally (from one end to the other) or transversely (from side to side). By incorporating different internal strings into the pocketed spring assembly, the pocketed spring assembly can be posed into zones or regions of different stiffness.

Cushioning material may be placed on top of and/or below the pocketed spring assembly. A cover, typically a padded cover, encloses the pocketed spring assembly, the edge support and the cushioning material.

In another aspect, a bedding or seating product includes a pocketed spring assembly and an edge support extending around a perimeter of the pocketed spring assembly. The edge support includes a plurality of peripheral strings. Each peripheral string is connected to at least one adjacent peripheral string. Each peripheral string comprises a plurality of interconnected outer pockets made of one piece of fabric. Each outer pocket contains at least one inner pocket spring and at least one cushion pad. The fabric sheet is attached to itself along a longitudinal seam and has opposed first and second layers of fabric on opposite sides of the inner pocketed spring. The first and second layers of fabric are joined by a transverse seam between adjacent inner pocketed springs.

In at least some embodiments, the pocketed spring assembly includes a plurality of parallel inner strings. Each internal string is connected to at least one adjacent internal string. Each inner string comprises a plurality of interconnected outer pockets made of one piece of fabric. Each outer pocket of the inner string contains at least one inner pocket spring and at least one cushion. The inner string of fabric pieces are attached to themselves along a longitudinal seam and have opposed first and second layers of fabric on opposite sides of the inner pocketed spring. The first and second layers of fabric are joined by a transverse seam between adjacent inner pocketed springs of the inner string.

In a double sided bedding or seating product, two cushioning pads are in each outer pocket of the peripheral and inner strings. At least one internal pocketed spring is between the cushions. Each cushion pad may be individually bagged. Each cushion pad may be made at least in part of foam or any other resilient member including gel or fibrous pads.

In another aspect, a bedding or seating product includes a pocketed spring assembly and an edge support extending around a perimeter of the pocketed spring assembly. The edge support includes at least one peripheral string of springs. Each peripheral string comprises a plurality of interconnected outer pockets made of one piece of fabric. Each outer pocket contains at least one inner pocket spring and at least one cushion pad. The fabric sheet is attached to itself along a longitudinal seam and has opposed first and second layers of fabric on opposite sides of the inner pocketed spring. The fabrics of the first and second layers are joined by a transverse seam. The transverse seam may be of any desired length.

The pocketed spring assembly can be any known pocketed spring assembly. In some embodiments, the pocketed spring assembly includes a plurality of parallel inner strings of springs. Each internal string is connected to an adjacent internal string. Each inner string comprises a plurality of interconnected outer pockets made of one piece of fabric. Each outer pocket contains at least one inner pocket spring and at least one cushion pad. The fabric sheet is attached to itself along a longitudinal seam and has opposed first and second layers of fabric on opposite sides of the inner pocketed spring. The fabrics of the first and second layers are joined by a transverse seam, which may be of any desired length.

In most embodiments of the product, the inner pocketed springs within the one or more peripheral strings have a smaller diameter than the inner pocketed springs of the pocketed spring assembly. However, they may have different diameters.

In most embodiments of the product, the peripheral strings are about the same height as the inner strings of pocketed spring assemblies. However, they may have different heights.

One advantage of the present application is that when manufacturing bedding or seating products (such as mattresses), the manufacturer does not need to place one or more pieces of cushioning material on the pocketed spring assembly before the unit is padded. Mattress manufacturers can simply place a cover around the pocketed spring assembly without using any sheet of cushioning material.

Another advantage of the present application is that the internally pocketed coil spring does not press into the cushion above/below it when loaded. Because the inner pocketed springs are retained in their own inner pocket independently of the one or more cushioning pads, the inner pocketed springs do not exert a force on the one or more cushioning pads, thereby maintaining the design characteristics of the one or more cushioning pads, such as firmness. The inner pocket of fabric surrounding the coil spring and/or the fabric surrounding each cushion maintains the integrity of the cushion and increases the life of the pocketed spring assembly. As a result, the user "feels" more of the one or more cushioning pads.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the application and, together with a general description of the application given above, and the detailed description of the drawings given below, serve to explain the principles of the application.

Drawings

Fig. 1 is a partially exploded perspective view of a bedding or seating product incorporating a pocketed spring assembly according to the principles of the present application.

Fig. 1A is a partially exploded perspective view of a bedding or seating product incorporating another pocketed spring assembly.

FIG. 1B is a partially exploded perspective view of a dual sided bedding article incorporating another pocketed spring assembly.

FIG. 1C is a partially exploded perspective view of another bedding article incorporating the pocketed spring assembly of FIG. 1.

Fig. 2 is a partially exploded perspective view of a portion of the string of springs of fig. 1 in an unloaded state.

Fig. 2A is a partially exploded perspective view of a portion of another string of springs in an unloaded state.

Fig. 3A is a partially exploded cross-sectional view of the string of springs of fig. 2 in an unloaded state.

FIG. 3B is a view similar to FIG. 3A with a portion of the string of springs in FIG. 3A in a loaded state.

Fig. 3C is a partially exploded cross-sectional view of a string of springs with different springs in an unloaded state.

Fig. 3D is a partially exploded cross-sectional view of a string of springs with different springs in an unloaded state.

Fig. 4 is a perspective view of a portion of the pocketed spring assembly of fig. 1 in a relaxed state.

Fig. 5 is a perspective view of a portion of another pocketed spring assembly in a relaxed state, strings of springs being offset from each other.

Fig. 6 is a partially exploded cross-sectional view of another string of springs in an unloaded state.

Fig. 7 is a partially exploded cross-sectional view of a double sided string of springs in an unloaded state.

Fig. 8 is a top view of a pocketed spring assembly being set into a particular attitude.

Fig. 9 is a top view of another pocketed spring assembly being set into a particular attitude.

Fig. 10 is a partially exploded cross-sectional view of another string of springs in an unloaded state.

Fig. 11 is a partially exploded cross-sectional view of another string of springs in an unloaded state.

FIG. 12 is a partially exploded perspective view of a single facer product incorporating the pocketed spring assembly of FIG. 1 but with a different edge support.

Fig. 13 is a top view of the pocketed spring assembly and edge support of fig. 12.

Fig. 14 is a partially exploded perspective view of a portion of the edge string of fig. 13 in an unloaded state.

Fig. 15 is a cross-sectional view taken along line 15-15 of fig. 13.

Fig. 16 is a partially exploded cross-sectional view similar to fig. 15 showing a portion of a double-sided product.

Fig. 17 is a partially exploded cross-sectional view of another two-sided product similar to fig. 16.

Fig. 18 is a top view of another embodiment of an edge support surrounding a pocketed spring assembly.

Detailed Description

Referring initially to fig. 1, a bedding article in the form of a one-sided mattress 10 incorporating the principles of the present application is shown. The product or mattress 10 includes a pocketed spring assembly 12 on top of which is placed a conventional cushion or cushioning layer 14, 16, which may be foam, fiber, gel, pocketed spring blanket, or any other suitable material or any combination thereof. Pocket spring assembly 12 is surrounded by a border 17 (only a portion of which is shown in fig. 1) of foam or any other suitable material. Although one type of border 17 is shown, the border may take other forms or shapes of any desired size, such as a pocketed coil spring. Alternatively, boundary 17 may be omitted in this embodiment or any of the embodiments described or illustrated herein. This complete assembly is mounted on the base 18 and is completely enclosed within the padded covering material 20. Regardless of the type of boundary, the substrate and boundary are referred to in the industry as a "bucket" into which the pocketed spring assembly is inserted before the "bucket" is covered by one or more liners or cushioning layers.

As shown in fig. 1, the length "L" of the product 10 is defined as the linear distance between the opposing end surfaces 22 (only one of which is shown in fig. 1) after complete assembly. Similarly, the width "W" of the assembled product 10 is defined as the linear distance between the opposing side surfaces 24 (only one side surface is shown in fig. 1). In the product shown in fig. 1, the length is shown as being greater than the width. However, within the scope of the application, the length and width may be the same, as in a square product.

As shown in fig. 1, pocketed spring assembly 12 is made up of a plurality of strings 26 of pocketed springs 28 connected together. Each string 26 of pocketed springs extends longitudinally or from head to foot along the entire length of the product 10.

While pocketed spring strings 26 are shown as extending longitudinally or from head to foot in the pocketed spring assembly 12 of fig. 1, they may extend laterally or from side to side as shown by the pocketed spring assembly 12a shown in the product 10a shown in fig. 1A. Pocket spring assembly 12a includes a plurality of strings 26a of pocket springs that are identical to strings 26 of springs, but are shorter in length.

Fig. 1B shows a double sided mattress 10B that includes pocketed spring assemblies 12B and the same boundaries 17 as those shown in mattress 10 of fig. 1. However, the mattress 10B of fig. 1B has conventional cushion layers 14, 16 above and below the double-sided pocketed spring assembly 12B. Double sided pocketed spring assembly 12b includes a plurality of strings 26b of pocketed springs, one of which is partially shown in cross-section in fig. 7.

Fig. 1C shows a one-sided mattress 10C that includes pocketed spring assemblies 12 and borders 17 identical to those shown in mattress 10 of fig. 1. However, the mattress 10C of fig. 1C has a pocketed top 19 that includes miniature pocketed coil springs in addition to the cushion layers 14, 16 above the pocketed top 19. A coarse cloth layer 21 separates the pocketed top 19 from the pocketed spring assembly 12. Although one configuration of the bagged top 19 is shown, any bagged top known in the art may be used.

In accordance with the present application, any liner or cushioning layer, including the bagged top 19, may be omitted in any of the embodiments shown or described herein. The novel feature is a pocketed spring assembly.

These strings 26, 26a and 26b of pocketed springs, as well as any other strings of springs described or illustrated herein, may be joined in side-by-side relationship, for example, by bonding the sides of the strings together in an assembler to form an assembly or matrix of springs having rows and columns of pocketed springs bonded together by gluing, welding, or any other conventional assembly process commonly used to create pocketed spring cores or assemblies.

Referring to fig. 4 and 5, strings 26 of pocketed springs may be connected together such that individual pocketed springs 28 are arranged in transversely extending rows 30 and longitudinally extending columns 32. Alternatively, the strings 26 of pocketed springs may be offset from each other in the pocketed spring assembly. In this arrangement, as shown in FIG. 5, the individual pocketed springs 28 are not aligned in rows and columns; instead, individual pocketed springs 28 fill gaps or voids 70 of adjacent strings 26. Fig. 5 shows a portion of a pocketed spring assembly 12' having a plurality of strings 26 arranged in this manner. Any of the alignment of strings may be incorporated into any pocketed spring assembly or core shown or described herein. Although fig. 4 and 5 show strings 26, the same alignment may be used in any pocketed spring assembly having strings 26a or 26 b.

As best shown in fig. 2, 3A and 3B, each string 26 of pocketed springs 28 includes a row of interconnected fabric outer pockets 34. Each fabric outer pocket 34 contains at least one inner pocketed coil spring 82 and at least one cushion pad 54. Each inner pocketed coil spring 82 includes a coil spring 36 enclosed in an inner pocket 35 having two side seams 37. The inner bag 35 may be made of a single piece of fabric or any number of pieces of fabric.

Fig. 2, 3A and 3B show a face string 26 for use in a single face pocketed spring assembly, such as pocketed spring assembly 12. In the string 26, a cushion 54 is placed on the fabric of the inner pocket 35 above the individual pocketed coil springs 36. In this orientation, the coil spring 36 is prevented from contacting and damaging the material of the cushion 54.

For ease of understanding, fig. 2 shows the leftmost outer pocket 34 shown in phantom and the inner pocket 35 shown in solid. In fig. 2, the other outer pockets 34 of the string 26 are shown in solid lines and the inner pockets 35 are shown in broken lines.

As best shown in fig. 2, the cushion 54 has a shape such as a puck or disk shape. Cushion 54, as shown in fig. 2, has a rounded upper surface 76, a rounded lower surface 78, and side walls 80.

Fig. 2A shows the same string 27 as string 26, but with a different cushion 54a. The cushion 54a has a different shape than the cushion 54 within the inner pocket 35 of the string 27. Fig. 2A shows a cushion 54a having a rectangular upper surface 76a, a rectangular lower surface 78a, and four rectangular side walls 80 a. Although fig. 2A shows square upper, lower, and side walls, one or more surfaces or side walls may be other rectangles. Although fig. 2 and 2A show cushions 54, 54a having particular sizes and shapes, respectively, the figures are not intended to limit the size or shape of the cushions.

Each cushion 54, 54a is shown as a single piece of material, such as foam, but may be any desired material of any number of sheets joined together. Alternatively, the cushioning pads 54, 54a may be made of fiber, cotton, gel, or any combination thereof.

The coil spring 36 is preferably made of one wire having a uniform diameter, but may be made of other materials, stranded wires, and/or may have a non-uniform diameter. As best shown in FIG. 2, each coil spring 36 has a central or longitudinal axis A, an upper end turn 38, a lower end turn 40, and a plurality of central convolutions 42 between the end turns. Fig. 2 and 3A show a cylindrical coil spring 36 in which the end turns 38, 40 have a diameter that is less than the diameter of the central convolution 42, the central convolution 42 tapering or decreasing in diameter and pitch as one moves from the center or middle portion 44 of the coil spring toward the end turns. As best shown in fig. 2, each of the barrel coil springs 36 has two different end portions, an upper end portion 46 and a lower end portion 48. The upper end portion 46 has more convolutions than the lower end portion 48, as shown in fig. 3A and 3B.

Preferably, one piece of fabric is used to form the outer pocket 34 of the string 26 of pocketed springs 36, the piece of fabric being folded onto itself around the inner pocketed coil spring 82 and cushion 54. As best shown in fig. 2, the opposite sides or layers 47, 49 of the fabric are stitched, welded or otherwise secured together to form a longitudinal seam 50 and a plurality of separate or transverse seams 52. Fig. 2 shows layer 47 closest to the reader and layer 49 behind spring 36.

Although the seams or welds in the embodiments shown herein are shown as welded, spaced rectangles, any seam may be spaced points, triangles, or solid line segments without spacing.

As shown in fig. 2, the opposite edges 56 of the fabric sheet used to form the string 26 of pocketed springs are aligned with and spaced apart from the longitudinal seam 50 by a distance indicated by reference numeral 58. Although the figures indicate that the longitudinal seam 50 is below the free edge 56 of the fabric sheet, the longitudinal seam 50 may be above the free edge 56 of the fabric sheet.

As shown in fig. 2 and 3A, the string 26 of pocketed springs has a generally planar top surface 60 in the top surface P1 and a parallel generally planar bottom surface 62 in the bottom surface P2. The linear distance between the top and bottom surfaces 60, 62 of the string 26 defines the height H of the string 26. The linear distance also defines the height H of the pocketed spring assembly 12 because each string 26 has the same height. However, it is within the scope of the application for different strings of springs of the pocketed spring assembly to have different heights.

In accordance with one embodiment, the transverse seams 52 forming adjacent outer pockets 34 are separated at 64 in the string 26, thereby forming cuts, slits or notches, such as by cutting, slitting, severing, melting, etc., inwardly (downwardly as shown) from the upper surface 60 of the string 26 to partially separate adjacent outer pockets 34. Preferably, the partition 64 extends beyond or below the cushion 54, but may be any desired length, including less than the height of the cushion 54. As best shown in fig. 2 and 3A, the transverse seams 52 of the strings 26 each have an upper end 66 and a lower end 68 at the bottom of each partition 64. As shown in fig. 3A, when the coil springs 36 are in a relaxed state and unloaded, the upper end 66 of each transverse seam 52 is positioned below an adjacent cushion pad 54.

The importance of the partition 64 can be understood with reference to fig. 3B. During initial deflection of the cushions 54, the partitions 64 substantially decouple each cushion 54 from its neighboring cushions 54. This creates more individual coil performance and allows the inner pocketed coil spring 82 to more quickly engage a person sleeping on the mattress 10 while giving a softer feel at the beginning of coil deflection. This arrangement is believed to provide a more comfortable pocketed spring assembly 12.

Fig. 6 shows another embodiment of a string 26c that may be used in any pocketed spring assembly or product shown or described herein. String 26c includes the same seams, the same inner pocketed springs 82, and the outer fabric pouches 34 as are incorporated into string 26. However, each cushion pad 54' includes a cushion pad 54 encapsulated in a fabric cover 84. Each cushion pad 54' has its own fabric covering 84 that prevents the coil springs 36 of the inner pocketed coil springs 82 from contacting and damaging the cushion pad or cushions over time, except for the inner pockets 35 of fabric of the inner pocketed coil springs 82.

Referring now to fig. 1B and 7, while the mattress 10 illustrated in fig. 1, 1A and 1C is a one-sided mattress, any of the other pocketed spring assemblies shown or described herein may be incorporated into any bedding or seating product, including a two-sided mattress or seat cushion.

Fig. 7 shows a portion of a string 26B of springs for use in a double sided pocketed spring assembly, similar to the pocketed spring assembly 12B shown in fig. 1B. The fabric outer pockets 34b of such strings 26b are slightly different from the fabric outer pockets 34 of the strings 26 of springs. Partitions 64 are provided along the top and bottom of the string 26 b.

Fig. 7 shows a double sided string 26B used in a double sided pocketed spring assembly 12B, as shown in fig. 1B. Two cushioning pads 54 are located inside each outer pocket 34b along with an inner pocket spring 82 located between each cushioning pad 54. One of the cushioning pads 54 is located above the inner pocketed coil spring 82b, and the other cushioning pad 54 is located below the inner pocketed coil spring 82 b. Although fig. 7 shows cushion 54 lacking a cover, an encapsulated cushion 54' or a cushion of a different shape (as shown in fig. 2A) may be used in double sided string 26b or any of the strings shown or described herein.

Further, the coil spring 36B of the inner pocketed spring 82B is different from the coil spring 36 of the inner pocketed spring 82 shown in fig. 3A and 3B. Each coil spring 36b includes a central or longitudinal axis A1, an upper end turn 38b, a lower end turn 40b, and a plurality of central convolutions 42b between the end turns. Fig. 1B and 7 show a cylindrical coil spring 36B in which the end turns 38B, 40B have a diameter that is smaller than the diameter of the central convolution 42B, the diameter and pitch of the central convolution 42a tapering or decreasing as one moves from the central or intermediate portion 44B of the coil spring toward the end turns. As best shown in fig. 7, each cylindrical coil spring 36b has two identical end portions 46b.

Referring now to fig. 8, a longitudinally extending string is shown as one preferred arrangement of spring cores for bedding or seating products, such as mattresses. It can be seen that the longitudinally extending strings are arranged in a plurality of areas on pocketed spring assembly 12 d. For example, two regions 72, 74 are shown, wherein these regions generally correspond to a "hard" side and a "soft" side. By way of further example, longitudinally extending strings of "soft" regions 72 each have split top features as shown and described herein. A longitudinally extending string of "hard" regions 74 is a string lacking any split top features. Of course, other arrangements are within the scope of the application. For example, the pocketed spring assembly 12d shown in fig. 8 may include laterally extending strings instead of longitudinally extending strings. In such an arrangement, each laterally extending string must be semi-rigid and semi-flexible. Thus, only half of each string has split top features, while the other half lacks such features.

Referring now to fig. 9, a laterally extending string is shown as one preferred arrangement of pocketed spring assemblies 12e for bedding or seating products, such as mattresses. It can be seen that the laterally extending strings are arranged in a plurality of areas on pocketed spring assembly 12 e. For example, three regions are shown, which generally correspond to the positions of the sleeper's head and shoulders, middle section, knees and feet. By way of further example, the two end "soft" regions 86 each include a string of springs having split top features as shown and described herein. The laterally extending strings of intermediate or "hard" regions 88 are strings lacking any split top features. Of course, other arrangements are within the scope of the application. For example, the mattress shown in fig. 9 may include longitudinally extending strings rather than laterally extending strings. In such an arrangement, each longitudinally extending string must be divided into three sections; a middle "hard" section and two end or "soft" sections. Thus, only the end third of each string has a split top feature, the middle third lacking such a feature.

Figures 3C and 3D show portions of other embodiments of strings 26D, 26e, respectively, which may be incorporated into any of the products shown or described herein. Strings 26d, 26e each include the same seams and outer pockets 34 as are incorporated into string 26. However, the springs 36d, 36e within the strings 26d, 26e are different from the springs 36 of the string 26, respectively. Although springs 36D, 36e are shown only in fig. 3C and 3D, they may be used in any of the strings shown or described herein, including double sided strings having cushioning above and below each coil spring.

As shown in fig. 3C, the coil springs 36d (only one shown) each have the same end turn 38d of smaller diameter than the central convolution 42d therebetween in their central portions 44 d. The central convolutions 42d of the coil springs 36d are identical and have the same diameter which is greater than the diameter of the end turns 38d.

As shown in fig. 3D, the coil springs 36e (only one shown) each have two identical end portions 46e and a central portion 44e therebetween. As shown in fig. 3D, the central portion 44e has more convolutions than each of the end portions 46 e. Each coil spring 36e has the same end turn 38e of a larger diameter than the central convolution 42e of the central portion 44e therebetween. Each central convolution 42e of the coil spring 36e has the same diameter that is greater than the diameter of the end turn 38e.

Fig. 10 shows another embodiment of a string 26d that may be used with any of the pocketed spring assemblies or products shown or described herein. The double-sided string 26d includes the same seams, the same coil springs 36b, and the outer fabric pocket 34b as are incorporated into the string 26b shown in fig. 7. However, each coil spring 36 lacks an inner pocket, but is surrounded by the outer pocket fabric and one or more individual pocket cushion pads 54'.

As with the cushions 54' shown in FIG. 6, each cushion 54' includes a cushion 54' encapsulated in a fabric covering 84. Each cushion pad 54' has its own fabric covering 84 that prevents the coil spring 36b from contacting and damaging the cushion pad or cushions over time.

Although string 26d is shown as a double sided string, the concepts presented herein of incorporating non-pocketed coil springs with pocketed cushions may be incorporated into any of the strings or pocketed spring assemblies shown or described herein, including single sided strings and single sided pocketed spring assemblies. Any of the coil springs shown or described herein may be used in versions where only one or more cushioning pads are pocketed and the coil spring has no inner pocket and only an outer pocket.

Fig. 11 shows another embodiment of a string 26e that may be used with any of the pocketed spring assemblies or products shown or described herein. The double-sided string 26e includes the same seams, the same inner pocketed springs 82b including the same coil springs 36b, the same cushioning pad 54, and the same outer fabric pocket 34b as incorporated into the string 26b shown in fig. 7. However, each string 26e lacks a divider 64 or "split top" feature. Any of the embodiments of the string or pocketed spring assemblies shown or described herein may lack a separator or "split top" feature, whether one or both sides.

Referring to fig. 12-15, a bedding article in the form of a one-sided mattress 10d incorporating the additional principles of the present application is shown. The product or mattress 10d includes the pocketed spring assembly 12 as shown and described above. However, any pocketed spring assembly described or illustrated herein may be used in the mattress 10 d. Mattress 10d uses pocketed springs for both sides 11 of the edge support. Each side 11 of the mattress 10d has an edge support 13 comprising at least one longitudinally extending edge string 90.

In the embodiment shown in fig. 12-15, each side 11 of mattress 10d has two strings of edges 90 secured to each other with an adhesive or any other known method. On each side 11, the innermost edge string 90 of the edge support 13 is secured to the outermost inner string 26 of the pocketed spring assembly 12 by adhesive or any other known method. Although the figures show two edge strings 90 per side 11, any number of edge strings 90 per side may be used.

As best shown in fig. 14 and 15, each edge string 90 of pocketed springs 92 includes a row of interconnected fabric outer pockets 98. Each fabric outer pocket 98 contains at least one inner pocketed coil spring 101 and at least one cushion pad 94. The embodiment of fig. 12-15 has one internally pocketed coil spring 101 and one cushion 94 within each fabric outer pocket 98. Each inner pocketed coil spring 101 comprises a coil spring 96 enclosed in an inner pocket 95 having two side seams 97. The inner bag 101 may be made of a single piece of fabric or any number of pieces of fabric.

Fig. 14 shows a side edge string 90 for use with a single-sided pocketed spring assembly, such as pocketed spring assembly 12. In the edge string 90, a cushion 94 is located on the fabric of the inner pocket 95 above the inner pocket 101 containing the coil spring 96. In this orientation, the coil spring 96 is prevented from contacting and damaging the material of the cushion 94.

For ease of understanding, fig. 14 shows the leftmost outer pocket 98 shown in phantom and the inner pocket 101 shown in solid. In fig. 14, the other outer pockets 98 of the edge string 90 are shown in solid lines and the inner pockets 95 are shown in phantom lines.

As best shown in fig. 14, the cushion 94 is shaped like an ice ball or a disk. The cushion 94 as shown in fig. 14 has a rounded upper surface 100, a rounded lower surface 102, and side walls 104. However, any configuration of cushioning pad may be used in the edge string 90.

Fig. 15 shows one edge support 13 (two edge strings 90) secured to one side of the pocketed spring assembly 12. Those skilled in the art will appreciate that the other side of mattress 10d is a mirror image thereof.

The coil spring 96 is preferably made of one wire having a uniform diameter, but may be made of other materials, stranded wires, and/or may have a non-uniform diameter. As shown in FIG. 14, each coil spring 96 has a central or longitudinal axis AA, an upper end turn 106, a lower end turn 108, and a plurality of central convolutions 110 between the end turns. Fig. 14 and 15 show a coil spring 96 in which the end turns 106, 108 have diameters that are smaller than the diameters of the central convolutions 110, with the diameters of the central convolutions being approximately the same. Although one configuration of coil spring 96 is shown, the figures are not intended to be limiting; the coil spring 96 may be of other known construction.

Preferably, one piece of fabric is used to form the outer pocket 98 of the edge string 90 of pocketed springs 92, the piece of fabric being folded onto itself around the inner pocketed coil spring 101 and cushion 94. As best shown in fig. 14, the opposite sides or layers 107, 109 of the fabric are stitched, welded or otherwise secured together to form a longitudinal seam 112 and a plurality of separate or transverse seams 114. Fig. 14 shows layer 107 closest to the reader, and layer 109 behind internally pocketed coil spring 101 and cushion 94.

As best shown in fig. 14, the opposite edges 116 of the fabric sheet used to form the edge strings 90 are aligned with the longitudinal seams 112 and spaced apart by a distance indicated by reference numeral 118. Although the figures indicate that the longitudinal seam 112 is below the free edge 116 of the fabric sheet, the longitudinal seam 112 may be above the free edge 116 of the fabric sheet.

As shown in fig. 14 and 15, the edge string 90 has a generally planar top surface 120 in the top surface P1 and a parallel generally planar bottom surface 122 in the bottom surface P2. The linear distance between the top and bottom surfaces 120, 122 of the edge string 90 defines the height H of the edge string 90. The linear distance also defines the height H of the pocketed spring assembly 12 because each edge string 90 has the same height H as the inner string 26 of the pocketed spring assembly 12. However, it is within the scope of the application for different strings of springs of the pocketed spring assembly to have different heights.

Fig. 16 shows a view similar to fig. 15 showing a cross-sectional view of the double-sided pocketed spring assembly 12b and the opposite side edge support 13' (only one shown in fig. 16). Each edge support 13 'comprises two edge strings 90'. Fig. 16 shows a portion of a pocketed spring assembly 12b having a double sided string 26b in a double sided pocketed spring assembly 12b, identical to the pocketed spring assembly 12b shown in fig. 7.

In each edge string 90', two cushions 94 are located inside each outer pocket 98' along with an inner pocket spring 101' located between the cushions 94. Each inner pocketed coil spring 101' includes a coil spring 96' enclosed in an inner pocket 95 '. One of the cushions 94 is located above the inner pocketed coil spring 101', and the other cushion 94 is located below the inner pocketed coil spring 101'. Although fig. 16 shows the cushion 94 lacking a covering, as shown in fig. 2A, an encapsulated cushion 94 "or a cushion of a different shape may be used in the double-sided edge string 90' or any of the strings shown or described herein.

Fig. 17 illustrates another embodiment of a double sided edge string 90 "that may be used with any of the double sided pocketed spring assemblies or products shown or described herein. The double-sided edge string 90 "includes the same seams, the same coil springs 96', and the outer fabric pocket 98' as are incorporated into the double-sided edge string 90' shown in fig. 17. However, each coil spring 96 'lacks an inner pocket, but is surrounded by the fabric of an outer pocket 98' and one or more individual pocket cushions 94 ".

Fig. 18 is a top view of another embodiment of a bedding or seating product 10 e. The product or mattress 10e includes the pocketed spring assembly 12 as shown and described above. However, any pocketed spring assembly described or illustrated herein can be used in the mattress 10 e. Mattress 10e uses pocketed springs as four sides of the edge support. Each side 111 and each end of the mattress 113 has an edge support 124 that includes at least one continuous peripheral string 190. In the embodiment shown in fig. 18, two continuous peripheral strings 190 are secured around the periphery of pocketed spring assembly 12. The innermost peripheral string 190 is bonded to the pocketed spring assembly 12 with an adhesive, and the outermost peripheral string 190 is bonded to the innermost peripheral string 190 with an adhesive. Each peripheral string 190 may be a single sided string as described herein for use with a single sided pocketed spring assembly. Alternatively, each peripheral string 190 may be a double sided string for use with a double sided pocketed spring assembly as described herein.

The various embodiments of the present application shown and described are for illustrative purposes only, as the figures and description are not intended to limit or restrict the scope of the claims in any way. Those skilled in the art will appreciate that various adaptations, modifications and improvements of the present application may be made without departing from the spirit or scope thereof. The application in its broader aspects is therefore not limited to the specific details and representative apparatus and method shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the general inventive concept. For example, more than two cushioning pads or more than one inner pocketed spring may be located within an outer pocket. The application resides in each and every individual feature described herein, and all combinations of any and all of the features. Accordingly, the scope of the application should be limited only by the following claims and equivalents thereof.

Claims

1. A bedding or seating product comprising:

a pocketed spring assembly;

edge supports extending along each of two opposite sides of the pocketed spring assembly, each edge support comprising a plurality of parallel edge strings of springs, each edge string being connected to at least one adjacent edge string, each edge string comprising a sheet of fabric surrounding a plurality of pocketed springs and a plurality of cushioning pads, opposite first and second layers of fabric being on opposite sides of the pocketed springs and cushioning pads, a plurality of outer pockets being formed along the string by connecting the first and second layers of longitudinal and transverse seams, at least one pocketed spring and at least one cushioning pad being in each of the outer pockets;

a buffer material; and

a cover encasing the pocketed spring assembly and cushioning material.

2. A bedding or seating product comprising:

a pocketed spring assembly;

an edge support extending along each of two opposite sides of the pocketed spring assembly, each edge support comprising a plurality of parallel edge strings of springs, each said edge string being connected to at least one adjacent edge string, each said edge string comprising a sheet of fabric surrounding a plurality of pocketed springs and a plurality of cushioning pads, opposite first and second layers of fabric being on opposite sides of the pocketed springs and cushioning pads, a plurality of outer pockets being formed along the string by connecting the first and second layers of longitudinal and transverse seams, at least one pocketed spring and at least one cushioning pad being in each said outer pocket.

3. The product of claim 2, wherein each of the cushioning pads is individually bagged.

4. The product of claim 2, wherein the pocketed spring assembly comprises a plurality of parallel inner strings of springs, each of the inner strings being connected to at least one adjacent inner string, each of the inner strings comprising a sheet of fabric surrounding a plurality of pocketed springs and a plurality of cushioning pads, opposite first and second layers of fabric being on opposite sides of the pocketed springs and cushioning pads, a plurality of outer pockets being formed along the strings by longitudinal and transverse seams connecting the first and second layers, at least one pocketed spring and at least one cushioning pad being in each of the outer pockets.

5. The product of claim 2, wherein the longitudinal seam of each edge string is a side seam.

6. The product of claim 2, wherein two cushioning pads are in each of the outer pockets.

7. The product of claim 2, wherein each edge support comprises two parallel strings of springs.

8. A bedding or seating product comprising:

a pocketed spring assembly;

an edge support extending around the perimeter of the pocketed spring assembly, the edge support comprising a plurality of perimeter strings of springs, each of the perimeter strings being connected to at least one adjacent perimeter string, each of the perimeter strings comprising a plurality of interconnected outer pockets made of one sheet of fabric, each of the outer pockets containing at least one inner pocketed spring and at least one cushion pad, the sheet of fabric being connected to itself along a longitudinal seam and having opposing first and second layers of fabric on opposite sides of the springs, the first and second layers being connected by a transverse seam between adjacent inner pocketed springs.

9. The product of claim 8, wherein two cushioning pads are in each of the outer pockets.

10. The product of claim 9, wherein the at least one internal pocketed spring is between the cushions.

11. The product of claim 8, wherein the pocketed spring assembly comprises an inner string of springs.

12. The product of claim 11, wherein each inner string comprises a plurality of interconnected outer pockets made of one piece of fabric, each outer pocket containing at least one inner pocketed spring and at least one cushion, the piece of fabric being connected to itself along a longitudinal seam and having opposing first and second layers of fabric on opposite sides of the spring, the first and second layers being connected by a transverse seam between adjacent inner pocketed springs.

13. The product of claim 8, wherein each cushion is at least partially made of foam.

14. The product of claim 8, wherein each cushion is individually bagged.

15. A bedding or seating product comprising:

a pocketed spring assembly;

an edge support extending around the perimeter of the pocketed spring assembly, the edge support comprising at least one perimeter string of springs, each of the at least one perimeter string comprising a plurality of interconnected outer pockets made of one piece of fabric, each of the outer pockets containing one inner pocketed spring and at least one cushion pad, the piece of fabric being connected to itself along a longitudinal seam and having opposed first and second layers of fabric on opposite sides of the inner pocketed spring, the fabrics of the first and second layers being connected by transverse seams.

16. The product of claim 15, wherein the pocketed spring assembly comprises a plurality of internal strings of springs.

17. The product of claim 16, wherein the inner string of springs extends longitudinally.

18. The product of claim 16, wherein the inner string of springs extends laterally.

19. The product of claim 15, wherein each of the inner strings comprises a plurality of interconnected outer pockets made of one sheet of fabric, each of the outer pockets containing at least one inner pocketed spring and at least one cushion, the sheet of fabric being connected to itself along a longitudinal seam and having opposed first and second layers of fabric on opposite sides of the spring, the first and second layers being connected by a transverse seam between adjacent inner pocketed springs.

20. The product of claim 19, wherein each inner pocketed spring within the at least one peripheral string has a smaller diameter than an inner pocketed spring of the pocketed spring assembly.