JP2018508335A - mattress - Google Patents

Abstract

The present invention is a mattress including a cushion pocket layer secured to a coil pocket layer. The first layer of cushion pockets comprises first and second cushion pockets. Each of the first and second cushion pockets includes a pocket and a cushion member disposed within the pocket. The cushion pocket layer further comprises an attachment member including an upper surface and a lower surface. The first and second cushion pockets are engaged with the upper surface of the mounting member. The layer of coil pockets comprises first and second coil pockets. Each of the first and aforementioned coil pockets includes a pocket and a coil spring disposed within the pocket. The lower surface of the mounting member engages the layers of the coil pocket so that the first and second cushion pockets act directly on the first and second coil pockets, respectively. [Selection] Figure 18

Description

  With reference to FIGS. 1 and 2, a conventional mattress 50 generally has a layer 57 of pocket coil springs, otherwise known as a Marshall-type spring, engaged with a base 52. The mattress 50 further includes cushion layers 53 and 54 disposed above the pocket coil spring 57 and a mattress ticking cover 51. A Marshall-type spring is a coil spring 56 that is initially encased in a pocket 55 of material as described in US Pat. No. 6,851,160. The pocket coil assembly is made by inserting a coil spring 56 as a continuous pocket coil strip into each fabric coil pocket 55, typically aligned together.

  U.S. Pat. No. 2,236,007 discloses a Marshall type spring in which a pocket of fiber is added to the core of a pocket coil spring. This promotes absorption of the force applied to the actual pocket coil spring by absorbing part of the force of the fiber filler.

  U.S. Pat. No. 8,266,745 discloses a Marshall-type spring that uses a filling material that includes foam or fibers present in a pocket with a spring coil. This reduces and eliminates noise and prevents the fabric surrounding the spring from getting caught inside the pocket when a person gets on or off the bed.

  Most pocket coil mattresses have in common that the coil springs contained in individual fabric pockets are under padding and / or cushioning seats or multiple seats and are softer and softer when first ridden It provides a feeling of sleep, encourages the reduction of locally high pressure boundaries, reduces the feeling of lying directly on a metal spring, and contributes to conforming to the contours of the body. This type of mattress helps alleviate and eliminate the problems associated with body markings on one or more of the cushion layers as a sleeping person lies repeatedly in a similar position each night. As such, it is often flipped at some time interval.

  Referring to FIG. 3, another drawback of having single or multiple seat cushions 53 above the layer of pocket coil 58 is the compressive force caused by the weight of the body 49 ("the compressive force of a sleeping person"). ) Is transmitted on the surface of the cushion material 53, that is, generally on a surface perpendicular to and perpendicular to the vertical surface of the pocket coil unit. This results in the compressive force of the sleeping person being transmitted laterally to the adjacent pocket coil even when these same coils are not directly exposed to the sleeping person's force. Thereby, the hollow 60 is formed, and the person who is sleeping is drawn into the core of the mattress 50, and the mattress 50 makes the sleep uncomfortable.

  A further problem with the indentation effect occurs for a second sleeping person who uses the same mattress at the same time as the first sleeping person. The second sleeping person can often receive the depression effect of the first sleeping person and receive the force to pull the sleeping person into the same sleeping space as the first sleeping person. There is sex. Obviously, the reverse is also true, and the first sleeping person can be drawn into the indentation effect created by the second sleeping person. Both of these situations fall into a situation where neither sleeping person can be comfortable in his / her space due to the flaws in the behavior of the seat cushion in the current mattress configuration.

  A further disadvantage of the seat cushion above the pocket coil is that the seat cushion material elicits a trampoline effect when loaded from above. Seat cushions give you the first ride flexibility, softer comfort, help reduce the number of locally high pressure boundaries, reduce the feeling of lying directly on a metal spring, and adapt to the contours of the body Instead of simply serving as a cushioning material that contributes to this, it often additionally acts like a trampoline and exhibits its own spring effect. The magnitude of the trampoline effect is usually closely correlated with the tensile strength of the cushioning material. The cushioning material is held in place above the uncompressed pocket coil spring and resists downward strain in the area exposed to compressive forces due to the lateral, in-plane, and tensile strength of the material. doing. In essence, the sheet-like cushioning material itself acts like a spring unit because of the trampoline effect due to the tensile strength. This effect often differs from the desire for a cushioning material that provides the initial softness to the sleeping person. There are significant problems with mattresses in hospitals and nursing homes. Increased pressure at the mattress interface is associated with patients developing pressure ulcers. The purpose of the seat cushion above the pocket coil core of a hospital mattress is to reduce pressure ulcer formation by reducing locally high pressure at the patient interface. However, the trampoline effect exerted by the sheet-like cushion layer above the coil unit acts to adversely affect this goal.

  A further drawback associated with the seat cushion above the pocket coil relates to the mattress supply. It is well known in the industry that mattresses are usually shipped in a flat configuration in either a horizontal or vertical orientation. If the mattress is bent during initial delivery and setup, the mattress is often damaged and returned. Failure mechanisms within the mattress are often the result of shearing, permanent movement, or deformation of the sheet cushion. Furthermore, the need to ship mattresses in a flat orientation increases both the cost and logistics associated with mattress transport. In many cases, two men and a truck are needed to deliver a mattress to a consumer. It is inherently advantageous to eliminate the costs associated with shipping flat mattresses, which can be rolled and compressed and shipped. Furthermore, if the mattress can be rolled up and stored in a compressed form, the cost of storage is greatly reduced in terms of floor space for both the manufacturer and retailer.

  Existing problems when sleeping on various types of foam, including but not limited to various sheet-like cushioning materials, especially polyurethane, latex and memory foam, are unpleasant warmth when lying on a mattress There is a tendency to feel the heat. This is due in part to the fact that many of these sheet-like cushioning materials have shielding properties that limit the body from cooling against parts of the sleeping person's body that are in direct contact with the mattress. It depends on the facts. This property is combined with the property of the sheet-like cushion material that suppresses the flow of air through or around the cushion material, and exacerbates the cooling problem. Inclusion of a sheet-like cushioning material in the pocket coil mattress due to the fact that the sleeping person's wake-up mechanism is partially triggered by body temperature regulation, and the sleeping person's inability to adjust body temperature properly, It can be a significant factor in poor sleep related to mattresses.

  One of the main causes of damage to the mattress is deterioration of the sheet-like cushion material. This is a direct result of fatigue relief and is particularly prevalent in sheet-like foam cushions that are subjected to a shear load consistent with the sleeping person's force acting on the mattress. With continuous loading over time, the foam begins to be unable to resist compression. Due to the deterioration of this sheet-like cushioning material, mattress manufacturers have recommended turning the mattress over to mitigate and retard this deterioration.

  The seat cushion also acts to catch dust, house dust mites, and potentially other microorganisms. Over a long period of time, this can be a serious health hazard, especially for those who are allergic or highly immunosuppressed. In addition, hospitals and nursing homes alleviate this problem by covering the mattress with a barrier cloth.

  One object of the present invention is to provide a mattress that is difficult to form indentations.

  Another object of the present invention was to develop a mattress that allows air circulation of the core of the mattress and provides a cooler mattress for sleeping.

  Another object of the present invention was to develop a mattress having a pocket spring that allows for selective control of the flexibility or hardness of the mattress.

  Another object of the present invention was to develop a mattress that could be easily manufactured as a single-sided or double-sided mattress and that had a comfortable contour that was potentially different for each side.

  Another object of the present invention was to develop a mattress that better separates the movement of a sleeping person.

  Another object of the present invention is to develop a mattress that extends the life of the mattress by removing the sheet-like cushion layer that is subjected to the shearing force from the compressive load of the sleeping person and consequently exposed to premature breakage. Was that.

  Another object of the present invention was to develop a mattress that replaces a sheet cushion with individually contained foam cushion pockets. The cushioned pockets are individually stored in the fabric, and the cushion pockets capture dust, house dust mites, and other microorganisms and are essentially undamaged, so the health hazards associated with sheet cushions on conventional mattresses are significant. To reduce.

  Another object of the present invention is to develop a mattress that reduces the amount of cushioning material from 20% to 25% compared to existing pocket coil mattresses that use sheet-like foam cushioning material, thereby adding Reduce the corresponding cost and weight associated with seat cushions. This is accomplished by utilizing an improved pocket coil spring having a cushion material located only directly above the cushion pocket spring unit.

  Another object of the present invention was to develop a mattress that removed the sheet-like cushion layer associated with the development of pressure sores in nursing homes and hospital patients.

  Another object of the present invention is to develop a machine and method for constructing a pocket spring, each of which includes a coil pocket and a cushion pocket.

  In a first embodiment, the present invention is a mattress including a layer of coil pockets including first and second coil pockets. Each of the first and aforementioned coil pockets includes a pocket and a coil spring disposed within the pocket. The mattress further includes a layer of first cushion pockets including first and second cushion pockets. Each of the first and second cushion pockets includes a pocket and a cushion member disposed within the pocket. The cushion pocket layer further comprises an attachment member including an upper surface and a lower surface. The first and second cushion pockets are engaged with the upper surface of the mounting member. The lower surface of the mounting member engages the layers of the coil pocket so that the first and second cushion pockets act directly on the first and second coil pockets, respectively.

The following description of the invention will be better understood with reference to the following drawings.

1 is a perspective view of a prior art pocket coil spring having a pocket and a coil spring disposed in the pocket. FIG. 1 is a perspective view of a prior art mattress having a plurality of pocket coil springs and a plurality of cushion sheets or layers. FIG. 1 is a diagram of a conventional mattress with formation of a recessed hole. 1 is a perspective view of a single-sided mattress according to a first embodiment of the present invention in an unloaded state, showing a plurality of pocket springs each comprising a coil pocket and a cushion pocket that engages and acts on the coil pocket. 1 is a perspective view of a pocket spring according to a first embodiment of the present invention in an unloaded state, showing a cushion pocket that engages and acts on a coil pocket having a single rate spring coil. FIG. FIG. 6 is a perspective view of a pocket spring according to another embodiment of the present invention in an unloaded state, with a first cushion pocket engaging and acting on the upper portion of the coil pocket, and engaging and acting on the lower portion of the coil spring. And a second cushion pocket. FIG. 5 is a perspective view of a pocket spring according to another embodiment of the present invention in an unloaded state, wherein the first cushion pocket engages and acts on the coil pocket, and engages and acts on the first cushion pocket. 2 shows a second cushion pocket. FIG. 2 is a perspective view of a pocket spring unit according to the present invention in an unloaded state, showing a plurality of pocket springs each including a coil pocket and a cushion pocket that engages and acts on the coil pocket. Each cushion pocket is self-supporting while each coil pocket is connected to an adjacent coil pocket. FIG. 6 is an exploded view of another embodiment of a pocket spring, showing the coil pocket and cushion pocket in the process of being attached to the coil pocket by an adhesive. FIG. 10 is a perspective view of the spring pocket of FIG. 9 showing a cushion pocket attached to the coil pocket by an adhesive. 1 is a perspective view of a pocket spring according to a first embodiment of the present invention in an unloaded state, showing a cushion pocket that engages and acts on a coil pocket having a multi-rate spring coil. FIG. FIG. 6 is a perspective view of a mattress according to another embodiment of the present invention, showing a plurality of pocket springs each including a coil pocket and a cushion pocket that engages and acts on the coil pocket in an unloaded state. While each coil pocket is connected to an adjacent coil pocket, each cushion pocket is self-supporting, allowing air circulation around the cushion pocket. FIG. 4 is a perspective view of a mattress according to another embodiment of the present invention, showing the layers of the coil pocket and the cushion pocket in an unloaded state. Each cushion pocket acts by engaging a corresponding coil pocket. In this embodiment, the cushion pocket is joined to the fabric sheet to form a cushion pocket layer. FIG. 6 is a perspective view of another embodiment of a pocket spring unit according to the present invention in an unloaded condition, showing a cushion pocket engaging and directly acting on a plurality of microcoil pockets. FIG. 5 is a perspective view of a machine according to another embodiment of the present invention for manufacturing a row or strip pocket spring, each including a coil pocket and a cushion pocket. FIG. 5 is a perspective view of a machine according to another embodiment of the present invention for manufacturing a row or strip pocket spring, each including a coil pocket and a cushion pocket. FIG. 4 is a view of a double-sided mattress according to another embodiment of the present invention, in a no-load condition, a first layer of cushion pockets disposed above the coil pocket layer and disposed below the coil pocket layer; 2 shows a second layer of cushion pockets. FIG. 6 is a view of a single-sided mattress according to another embodiment of the present invention, showing a layer of cushion pockets removably engaged with a layer of coil pockets in an unloaded condition. FIG. 5 is a view of a double-sided mattress according to another embodiment of the present invention, wherein the first layer of cushion pockets removably engaged with the top of the layer of coil pockets and the bottom of the layer of coil pockets in an unloaded state; And Fig. 2 shows a second layer of cushion pockets removably engaged. FIG. 4 is a view of a single-sided mattress according to another embodiment of the present invention, showing a plurality of cushion pocket strips removably engaged with a layer of coil pockets in an unloaded condition. FIG. 4 is an illustration of a double-sided mattress according to another embodiment of the present invention, a plurality of cushion pocket strips removably engaged with the top of the layer of coil pockets in an unloaded state, and the bottom and removal of the layer of coil pockets; Fig. 6 shows a plurality of straps of cushion pockets that engage in a possible manner. FIG. 6 is a view of a pocket spring according to another embodiment of the present invention comprising first and second microcushion pockets disposed and engaged over a single coil pocket. FIG. 2 is a diagram of a machine for producing a cushion pocket layer. 1 is a diagram of a machine for manufacturing a cushion pocket. FIG. FIG. 6 is a view of a single-sided mattress according to another embodiment of the present invention, showing a layer of microcushion pockets removably engaged with a layer of coil pockets in an unloaded condition. FIG. 6 is a view of a single-sided mattress according to another embodiment of the present invention, in a no-load condition, a first layer of a microcushion pocket removably engaged with a layer of a coil pocket, and a first of the microcushion pocket; Figure 2 shows a second layer of microcushion pockets secured to the top of the layer. FIG. 7 is a view of a single-sided mattress according to another embodiment of the present invention, showing a layer of cushion member removably engaged with a layer of coil pockets in an unloaded condition.

  Referring to FIG. 4, the mattress 10 according to the first embodiment of the present invention generally includes a plurality of pocket springs 90 arranged in horizontal and vertical rows on the base 14. Each pocket spring 90 includes a cushion pocket 36 disposed over and juxtaposed above the coil pocket 38. As more fully mentioned herein, the cushion pocket 36 engages and acts directly with the coil pocket 38. The pocket spring 90 has its upper surface and side surfaces covered with the mattress ticking cover 12. In this embodiment, in addition to the fiber filler that can be part of the quilted mattress ticking cover 12, there is no layer of cushioning material between the mattress ticking 12 and the cushion pocket 36. In the illustrated embodiment, the mattress 10 is a single sided or non-inverted mattress. However, as shown in further embodiments, the mattress 10 may be a double-sided or reversible mattress that does not require the base 14. The mattress 10 may be a single size, a queen size, a king size, or the like. In the single size, the mattress 10 has about 294 pocket springs 90.

  Referring to FIG. 5, a pocket spring 90 is shown with a cushion pocket 36 disposed above and juxtaposed above the coil pocket 38. This particular embodiment of the pocket spring 90 is utilized for a single-sided, non-inverted mattress. The cushion pocket 36 generates a force when pressed by the weight of the person. The cushion pocket 36 is engaged with and acts directly on the coil pocket 38 so that substantially all of the force from the cushion pocket 36 is transmitted to the coil pocket 38. In this embodiment, the coil pocket 38 includes a pocket 39 and a spring 20 disposed in the pocket 39. In the embodiment shown, the spring 20 is a single rate barrel spring. The spring 20 may be any other type of conventional or future developed coil spring. By way of example only, the spring 20 is made of Leggett & Plat Components Europe Limited, P.M. O. It may be a multirate coil spring available under the trade name SOFT TOUCH® from Box 681, Barnsley, S727 WB, United Kingdom (www.lpeurope.com/softtouch.asp). The pocket 39 may be sealed with the ultrasonic thermal bond 31 on the side surface. However, the spring 20 may be sealed in the pocket 39 with, but not limited to, a sewing seal or an adhesive pocket seal. In this embodiment, the pocket 39 is a nonwoven polyester fabric. However, the present invention includes many other fabrics including, but not limited to, woven fabrics such as cotton, polyester, polypropylene, nylon, and blends of fabrics, as well as nonwovens composed of blends of polyester, polypropylene, nylon and fabrics. Can be used in The cushion pocket 36 includes a pocket 37 and an elastic member 32 disposed in the pocket 37. The pocket 37 is formed from the same continuous fabric portion that is used to form the pocket 39 of the coil pocket 38. In this embodiment, the elastic member 32 is a cylindrical portion of open cell foam that resides in the pocket 37 of the cushion pocket 36, which is the same ultrasonic bond that forms the pocket 39 of the coil pocket 38. 31. Open Cell Foam is available from Foam Factory, Inc. , 17500 23 Mile Road, Macomb, MI 48044 (http://www.homefactory.com/opencellfoam/supersoft.html). Although a viscoelastic open cell foam having a cubic foot density of 4 lb is used as the elastic member 32, many other types of foam and cushion material may be individually or combined in the cushion pocket 36. It may include, but is not limited to, viscoelastic foams of various densities and thicknesses, latex foams, polyfoams, polyfibers, down fibers, wool fibers, or some combination of the foregoing. Further, in this embodiment, the separation between the pocket 39 of the coil pocket 38 and the pocket 37 of the cushion pocket 36 is performed using an ultrasonic thermal isolation bond 34. However, it is possible to create this separation between the cushion pocket 36 and the coil pocket 38 by, but not limited to, a separation by sewing or a separation by means of an adhesive line. In this particular embodiment, the coil pocket 38 is 7 inches long and is covered by a cushion pocket 36 that is 3 inches long. The width of the coil pocket 38 is about 2.75 inches, while the width of the cushion pocket 36 is about 2.5 inches. However, many other length and width combinations of cushion pocket 36 and coil pocket 38 are acceptable and in no way limit the scope of the invention.

  Referring to FIG. 6, in another embodiment, the pocket spring 90 includes a cushion pocket 36 juxtaposed against one side of the coil pocket 38 and a cushion pocket juxtaposed against the other side of the coil pocket 38. 35. The cushion pocket 35 includes a pocket 41 and an elastic member 42 disposed in the pocket 41. This particular embodiment can be utilized with, but not limited to, double-sided or reversible mattresses. In this embodiment and other embodiments, the elastic member 32 accommodated in the cushion pocket 36 may be the same as or different from the elastic member 42 accommodated in the cushion pocket 35. This allows the end user to effectively flip the mattress and have an overall different cushion response from one side of the mattress to the other. Similarly, the actual shape of the cushion pocket may vary, and the cushion pocket 36 may potentially have a diameter and / or length that is different from the diameter and / or length of the cushion pocket 35. This also creates different mattress cushion profiles depending on which side of the mattress is in direct contact with the sleeping person. In addition to this embodiment, both the coil pocket 38, the cushion pocket 36, and the cushion pocket 35 are formed from a single fabric, and in the case of the cushion pocket 36, made of ultrasonic thermal isolation bond 34, the cushion pocket In the case of 35, it is made of the same ultrasonic thermal separation bond 33 (not clearly visible in the drawing). However, it is contemplated that either one or both of the cushion pockets can be formed from separate materials and joined to the coil pocket 38 by any one of several known joining means. Further, the separation bond between the cushion pockets 36, 35 and the coil pocket 38 can be, but is not limited to, separation by sewing or separation by an adhesive line. This embodiment is not limited to a single cushion pocket on each side of the coil pocket. In addition, different cushion profiles can be created on each side of the mattress that can be turned over by stacking two or more cushion pockets on top of each other or stacked on top of the coil pockets.

  With reference to FIG. 7, in another embodiment, the pocket spring 90 includes a cushion pocket 36 on one side of the coil pocket 38 and a cushion pocket 46 on the top of the cushion pocket 36. The cushion pocket 46 includes a pocket 47 and an elastic member 48 disposed in the pocket 47. This particular embodiment is utilized for a single sided, non-inverted mattress. As can be seen in this embodiment, multiple cushion pockets can be stacked on top of each other to create different cushion profiles. This particular embodiment shows two cushion pockets 46 and 36 stacked in the coil pocket 38, but is not limited to this, and it is envisioned that multiple other cushion pockets can be stacked on top of each other. . It can also be seen that the length of the cushion pocket 46 is shorter than the length of the cushion pocket 36. As can be seen in this embodiment, the actual shape of the cushion pocket may be different and the cushion pocket 36 potentially has a different diameter and / or length than the cushion pocket 46. Further, according to this embodiment, both the coil pocket 38, the cushion pocket 36, and the cushion pocket 46 are formed from a single piece of fabric, and in the case of the cushion pocket 36, it is made of an ultrasonic heat isolation bond 34. In the case of the cushion pocket 46 separated from the cushion pocket 36, it is made from a similar ultrasonic thermal isolation bond 44 (not clearly visible in the drawing). However, it is envisioned that either or both of the cushion pockets can be formed from separate materials and can be joined to the coil pocket 38 and other cushion pockets by any one of several known joining means. The Further, the separation bond between the cushion pockets 36 and 46 and the coil pocket 38 can be, but is not limited to, separation by sewing, separation by thermal bonding, or separation by an adhesive line. It should further be noted that many length and width combinations of the cushion pocket 36, cushion pocket 46, and coil pocket 38 are acceptable and in no way limit the scope of the present invention.

  Referring to FIG. 8, a partially uninterrupted row or unit 92 is shown that includes a plurality of pocket springs 90 made from unbroken fabric of length. Individual coil pockets 38 are separated from the next or previous coil pockets by ultrasonic heat welding 31. The cushion pocket 36 is also formed from a single piece of fabric that is the same as the coil pocket 38. In this embodiment, the cushion pocket 36 is formed by ultrasonic thermal welding 31 and pocket delineation weld 34 and then separated from adjacent cushion pockets by cutting the fabric between each thermal welding. Please note that. Including, but not limited to, forming a cushion pocket 36 from a single piece of unbroken fabric and bonding the cushion pocket strip to the pocket coil strip with adhesive, heat welding or stitching. It can also be fixed by any of the known means that are not. In other embodiments, the cushion pockets may remain connected to one another and the fabric between each cushion is flexible enough to allow independent movement of each cushion pocket. Furthermore, each cushion pocket 36 can be formed from its own piece of fabric and secured to the coil pocket 38 by one of the means described above. In this embodiment, the cushion pockets 36 are not connected to each other so that each cushion pocket can act directly on the corresponding coil pocket, allowing air circulation within the mattress. The elastic member 32 of the cushion pocket 36 of the first pocket spring 90 has elasticity R1. The elastic member 32 of the cushion pocket 36 of the second pocket spring 90 has elasticity R2. In this embodiment, the elasticity R1 is equal to the elasticity R2. In other embodiments, the elasticity R1 may be greater or less than the elasticity R2. If the values of elasticity R1 and elasticity R2 are different, different comfort levels can be selectively designed.

  With reference to FIGS. 9-10, in another embodiment, the pocket spring 90 is formed of a hot melt adhesive that bonds the cushion pocket 36 to the coil pocket 38. A complete pocket spring 90 is shown in FIG. An adhesive applicator 144 for dispensing hot melt adhesive 146 on top of the previously formed coil pocket 38 is shown. Next, the pre-formed cushion pocket 36 is lowered onto the coil pocket 38 to form a complete pocket spring 90.

  Referring to FIG. 11, in another embodiment, the pocket spring 90 uses a multirate coil spring 132 as a spring element in the coil pocket 38. The multi-rate coil spring 132 can additionally be used in any of the previous embodiments that utilize two or more cushion pockets disposed on one or both sides of the coil pocket as described above.

  Referring to FIG. 12, in another embodiment, the mattress 10 includes a plurality of pocket units 92 (described above) arranged in horizontal and / or vertical rows. As shown, the pocket unit 92 provides improved air flow around each pocket spring 90 and the cushion pocket 36 of the adjacent coil pocket 36. As can be seen from this figure, air spreads over the quilting cover 12 and can freely circulate between adjacent cushion pockets 36 and between adjacent coil pockets 38. This is due to the fact that there is no cushion seat that acts to block and restrict the flow of air into and out of the mattress core. The cushion pockets 36 can be connected to each other with excess material so that each coil pocket can still act individually and still allow air circulation into and out of the mattress core.

  The present invention provides significant advantages over conventional mattresses. First, the use of pocket springs 90 results in a novel mattress that significantly reduces indentation formation, thereby increasing comfort and useful life over conventional mattresses. Second, the use of the pocket spring 90 provides better air circulation than conventional mattresses, thereby enabling a sleeping person to sleep more coolly. Third, by using the pocket spring 90, the flexibility or hardness of the cushion pocket over individual coil pockets can be selectively controlled, thereby consuming more complex cushion profiles. Provides more choice for mattress customization. This is accomplished by changing the contents, dimensions, or number of cushion pockets within a series of pocket springs. Prior to the present invention, it is only possible to change the coil spring parameters of the coil based on each coil, and it is not possible to change the characteristics of the sheet-like foam cushion material of the coil based on each coil. It was. Fourth, by using the pocket spring 90, the cushioning material is incorporated into the pocket spring 90, and no additional steps are required to insert and secure the seat cushion during mattress manufacture. Single-sided or double-sided mattresses can be easily manufactured. Fifth, the use of the pocket spring 90 minimizes transmission of the sleeping person's compressive force in a plane orthogonal to the plane of the pocket spring so as to better separate the sleeping person's movement. Prompt. Sixth, the use of the pocket spring 90 eliminates the sheet-like cushion layer that receives the shearing force due to the compressive load of the sleeping person and the resulting early breakage, resulting in a longer life mattress. . Seventh, the use of pocket springs 90 eliminates the seat cushion layer and replaces it with individually stored foam cushion pockets. Cushioned pockets are individually housed in the fabric, so they don't essentially pass dust, dust mites, and other microorganisms, greatly reducing the health damage associated with sheet cushions on traditional mattresses. To do. Eighth, by using the pocket spring 90, the seat cushion layer is eliminated, and as a result, the amount of cushion material is between 20% and 25% with respect to the existing pocket coil mattress using the seat cushion material. , Thereby reducing the corresponding cost and weight associated with additional seat cushions. By using the pocket spring 90, any sheet-like cushioning material between the pocket coils of the conventional mattress is eliminated. In addition, the pocket spring 90 allows the mattress to be manufactured without a sheet-like cushion layer associated with the development of pressure sores in nursing homes and hospital patients.

  Referring to FIG. 13, in another embodiment of the present invention, the mattress 150 includes a cushion pocket layer 156 that is clearly separated from the coil pocket layer 158 comprised of the coil pocket 38. Consists of. In this embodiment, the cushion pocket 36 is joined to an attachment member 152, which is a fabric sheet in the illustrated embodiment. Further, the fabric sheet is ideally made from a material that is quasi-isotropic in a single plane. The method of joining the cushion pocket 36 to the mounting member 152 may be thermal bonding or bonding with an adhesive, but is not limited thereto. The spacing and position of the cushion pockets 36 ensures that each cushion pocket is located directly above the coil pocket 38 where it acts directly. In this embodiment, the attachment member 152 is used to place and secure the cushion pocket 36 over the coil pocket 158. However, other means of placing and securing the cushion pocket layer 156 over the coil pocket layer 158 may be employed. For example, the attachment member 152 can be placed over the cushion pocket 36 or between the cushion pockets. Further, the attachment member 152 can be made of a porous material, but is not limited thereto. Because it is air permeable or perforated, it does not restrict the flow of air between the coil pocket layer 158 and the cushion pocket layer 156.

  Many problems of using sheet-like foam with mattresses, from the pit hole effect to the trampoline effect, are described in this application. However, one advantage of using sheet-like foam in a mattress is to impart lateral stability to the mattress core. In the case of a pocket coil spring unit, the sheet-like foam layer above the pocket coil spring unit restrains the spring core, which contributes to resist lateral movement of the sleeping person. Also, the same factors that reduce sleep comfort prevent the mattress core from shifting under the load and movement of a sleeping person in the lateral direction. A significant advantage of using a mounting layer between the pocket coil layer and the cushion pocket layer is to provide the spring core with the lateral stability that is lost when the sheet-like foam is removed. This is due to the fact that the attachment layer has the property of providing in-plane strength, quasi-isotropic, indicating the in-plane shear strength consistent with the fabric fibers dispersed on the fabric surface. To do. This in-plane strength urges the pocket coil unit to stabilize when subjected to a lateral load.

  Another advantage of a cushion pocket that is attached to a separate attachment layer is that it creates an independent pocket cushion layer. This layer can be manufactured and stored separately from the pocket coil layer. This provides the manufacturer with much greater flexibility during the manufacturing process that combines the different cushion layers and their associated properties with the different pocket coil spring layers and their properties. Then the possible number of custom combinations is an exponential expansion of the number of base pocket coil spring units in combination with the base cushion pocket layer. For example, by combining three different pocket coil spring elements with three different cushion elements, the manufacturer obtains nine possible custom combinations. Using five different cushion pocket element layers and increasing the number of pocket coil spring units to five, there are then 25 possible custom units. Adding a second cushion layer increases the number of possible custom units to 125 units. This allows the manufacturer to gain considerable custom manufacturing flexibility and requires only a limited number of basic component inventory. A further advantage of using a separate attachment layer is that it can be placed above all pocket coil core units from as few as two attachment points to as many attachment points as a full pocket coil. Further, the type of attachment location may vary according to the mattress manufacturer's goals. To make the cushion pocket layer removable, replaceable and washable, a clip-type fitting can be utilized. Then, it is conceivable that the mattress retailer changes the comfort layer, for example from soft to hard, in response to customer demand. The retailer then re-reserves the mattress by simply unlocking one pocket cushion layer by simply storing different pocket cushion layers in the store and clipping another pocket cushion layer with different cushion characteristics. Can be configured. This allows the retail store to present multiple beds within a single bed space, thereby reducing floor space and general administrative costs. Similarly, retailers can reduce inventory by customizing the final bed to customer specifications while storing only the base unit. In addition, a plurality of pocket cushion attachment layers can be placed on top of each other and each layer can be clipped to the previous layer to create a different cushion profile. For example, the cushion layer of an individual gel cushion pocket can be placed above the foam cushion pocket layer and clipped onto it to create a completely different look and feel than the mattress. Linking this to different heights, removable mattress covers, and retail customization levels is endless. At the same time, by mixing and combining the different mattress components, the customer can create a purely custom bed in the retail store to their taste and greatly improve the customer experience.

  A disadvantage of manufacturing a pocket coil spring with an integral cushion pocket is that the cushion pockets need to be separated from each other after manufacturing, as will be described in connection with FIGS. This requirement requires that the cushion pocket be smaller than the pocket coil pocket. This is because additional material needs to be sealed between the cushion pockets and separated from each other. This is a serious drawback because the smaller the cushion pocket, the smaller the area that supports the sleeping person. When joining the cushion pocket to the attachment layer, the diameter of the cushion pocket may be equal to the diameter of the pocket coil, and in some cases may be larger than the pocket coil diameter. Thereby, the cross-sectional area of a pocket cushion increases and it can further support the person who is sleeping.

  In a further embodiment, it is envisaged that instead of attaching all of the cushion pockets to a single attachment layer, an individual attachment layer strip is utilized and a series of pocket coils are attached to the attachment layer strip. The mounting strip is attached to the coil pocket strip such that the direction of the cushion pocket mounting strip is perpendicular to the direction of the pocket coil strip. In this way, the pocket coil core is provided with lateral stability support. It is also possible to apply a single strip around one or two rows outside the pocket coil, effectively creating a framing mechanism that further increases the lateral support of the pocket coil core unit.

  Referring to FIG. 14, in another embodiment, a pocket spring unit 200 according to the present invention generally includes a cushion pocket 210 that engages and directly acts on a plurality of microcoil pockets 220. In the illustrated embodiment, the cushion pocket is positioned above the microcoil pocket 220 and juxtaposed. Each of the microcoil pockets 220 includes a pocket 224 and a microcoil spring 222. The cushion pocket 210 includes a pocket 212 and an elastic member 214 disposed in the pocket 212. Pocket 212 is sealed by thermal welding 215. The cushion pocket 210 is engaged and acts directly on the microcoil pocket 220 such that substantially all of the force from the cushion pocket 210 is transmitted to the microcoil pocket 220. The pockets 224 of the microcoil pockets 220 may be connected to each other by thermal welding 226. As in other embodiments, the pocket 224 of the microcoil pocket 220 is made from a non-woven fabric. The microcoil spring 222 may be any conventional microcoil such as a single rate microcoil spring. As in other embodiments, the pocket 212 of the cushion pocket 210 may be made of non-woven fabric and connected to the microcoil pocket 220 by an adhesive. As in other embodiments, the elastic member 214 may be a foam cushion having any desired elasticity. The multi-rate pocket spring 200 is created by changing the spring characteristics of the microspring 222 disposed in the pocket 220.

  Referring to FIG. 15, a machine 300 according to another embodiment of the present invention is shown for producing a row or strip of pocket springs 340 identical to the pocket springs 90 described above. The machine 300 generally includes a base conveyor 302 that supports multiple layers of fabric and is adapted to be moved to various forming and cutting stations. The machine 300 further includes a lower fabric roll 304 that includes a bottom fabric 305 and an upper fabric roll 306 that includes a top fabric 307. The lower fabric roll 304, together with the upper fabric roll 306, supplies both the bottom fabric 305 and the top fabric 307 to the base conveyor 302 simultaneously. Many fabrics are used in the present invention, including, but not limited to, woven fabrics such as cotton, polyester, polypropylene, nylon, and blends of fabrics, as well as nonwovens composed of blends of polyester, polypropylene, nylon, and fabrics. be able to. The side surface of the coil pocket 308 is formed by a pocket coil drawing line 310 formed by the ultrasonic bonding horn 312. The side surface of the cushion pocket 314 is formed by a cushion pocket drawing line 316 formed by the ultrasonic bonding horn 319. In this embodiment, all drawn lines are made via ultrasonic welding and an ultrasonic welding horn. However, it is envisioned that other types of bonding devices and bonding horns, such as heat bonding horns and heat bondable fabrics that can be heat bonded, can also be used. The cushion pocket 314 exists just above the coil pocket 308. However, there are twice as many cushion pocket strokes 316 as there are pocket coil strokes 310. This is due to the fact that the fabric needs to be cut between the cushion pockets 314 so that each cushion pocket 314 can be compressed independently without affecting adjacent cushion pockets 314. Furthermore, the ultrasonic bonding horn 318 forms a drawn line 320 between the coil pocket 308 and the corresponding cushion pocket 314. Initially, the uncompressed spring 322 is compressed into a compression coil spring 324 by any one of known compression devices and techniques. A compression coil spring 324 is inserted into the previously formed coil pocket 308 from between the upper and lower fabric portions. Note that a compression coil spring 324 is loaded into each coil pocket 308 in a direction tangential to the vertical direction of the final cushion pocket 314. After the assembly process and after the fourth side of the coil pocket 308 is sealed, the compression coil spring 324 is designed to re-orient the compression coil spring 324 to the non-compression coil spring 322. Reorienting to the correct plane by hitting with any of the means. The compression coil spring 324 has sufficient potential energy stored in the compressed state so that it can be reoriented in the coil pocket 308 when it is slightly stimulated to turn itself in the correct orientation. It is. Almost simultaneously with the compression coil spring 324 being loaded into the coil pocket 308, the cushion foam cylinder 326 is inserted into the cushion pocket 314. Unlike the coil spring 324, the foam cushion cylinder 326 is compressed by any one of several known means and inserted into the cushion pocket 314 in the correct final orientation. If the cushion cylinder is not initially oriented correctly, the potential energy stored in the compression foam cushion cylinder 326 is not sufficient to correct the orientation of the cushion cylinder, so that the correct orientation is obtained when the foam cushion cylinder 326 is inserted. To maintain. Another unique aspect of the present invention is that individual foam cushion cylinders 326 are cut from longer foam cylinders 328 by a cutting knife 330. It should be noted that the knife 330 may be, but is not limited to, a shear knife, hot knife, or ultrasonic cutting knife, or any other cutting device or method. A great advantage of using a long foam cylinder 328 in the assembly is to ensure that the foam cushion cylinder 326 is always in the correct orientation relative to the cushion pocket 314. For purposes of illustrating this, and to better illustrate the overall process, the top fabric layer is removed from this view after the initial coil pocket 308 and cushion pocket 314 are formed. As the top and bottom fabrics continue to advance on the conveyor 302, the coil pocket 308 is sealed by an ultrasonic bonding horn 332 that forms a coil pocket seal line 334. At the same time, the cushion pocket 314 is sealed by an ultrasonic bonding horn 336 that forms a cushion pocket seal line 338. After the complete pocket spring 340 is formed, an ultrasonic cutting horn 342 is used to cut the fabric portion 344 between adjacent cushion pocket strokes 316. This results in a finished pocket coil, cushion pocket string of any length preprogrammed to be manufactured. By resizing and / or adjusting the size of the ultrasonic bonding horn, it can be cut into different pocket lengths, so that it can be immediately cut into various cushion pocket lengths. Facilitates customizing individual mattresses and creating more flexible manufacturing systems that allow different styles of foam cushions to be created for different customers.

  Referring to FIG. 16, a machine 400 according to another embodiment of the present invention is shown for manufacturing a row or strip 440 of pocket springs. The machine 400 generally comprises a base conveyor 402 adapted to support multiple layers of fabric and move it to various forming and cutting stations. The machine 400 further includes a fabric roll 404 that includes an unfolded fabric 405 that passes through any of the known fabric folding mechanisms into a folded fabric 406. The fabric roll 404 feeds the fabric 405 into a known folding mechanism and onto the base conveyor 402. Many fabrics are used in the present invention including, but not limited to, woven fabrics such as cotton, polyester, polypropylene, nylon, and blends of fabrics, as well as non-woven fabrics composed of blends of polyester, polypropylene, nylon and fabrics. obtain. The side surface of the coil pocket 408 is formed by a pocket coil drawing line 410 formed by the ultrasonic bonding horn 412. The side of the cushion pocket 414 is formed by a cushion pocket drawing line 416 formed by the ultrasonic bonding horn 419. In this embodiment, all drawn lines are made via ultrasonic welding and an ultrasonic welding horn. However, it is envisioned that other types of bonding devices and bonding horns, such as heat bonding horns and heat bonding with heat bondable fabrics, can also be used. The cushion pocket 414 exists directly above the coil pocket 408. However, there are twice as many cushion pocket lines 416 as there are pocket coil lines 410. This is due to the fact that it is necessary to cut the fabric between the cushion pockets 414 and allow each cushion pocket 414 to be compressed independently without affecting adjacent cushion pockets 414. The foam cushion cylinder 426 is compressed by any one of several known means and inserted into the cushion pocket 414 in the correct final orientation. If the cushion cylinder is not initially oriented correctly, the potential energy stored in the compressed foam cushion cylinder 426 is not sufficient to correct the orientation of the cushion cylinder, so the foam cushion cylinder 426 remains in the correct orientation. To do. Another unique aspect of the present invention is that individual foam cushion cylinders 426 are cut from longer foam cylinders 428 by a cutting knife 430. Note that knife 430 may be, but is not limited to, a shear knife, hot knife, or ultrasonic cutting knife, or any other cutting device or method. A great advantage of using a long foam cylinder 428 in the assembly is to ensure that the foam cushion cylinder 426 is always in the correct orientation relative to the cushion pocket 414. After the foam cushion cylinder 426 is placed in the cushion pocket 414, the ultrasonic bonding horn 418 forms a drawn line 420 between the coil pocket 408 and the corresponding cushion pocket 414. The folded fabric 406 is then advanced to the coil spring loading station. Uncompressed spring 422 is compressed into compression coil spring 424 by any one of known compression devices and techniques. The compression coil spring 424 is inserted between the upper fold and the lower fold of the folded fabric 406 and into the coil pocket 408 formed in advance. Note that compression coil springs 424 are loaded into each coil pocket 408 in a direction that is tangential to the vertical direction of the final cushion pocket 414. After the assembly process, after the fourth side of the coil pocket 408 is sealed, the compression coil spring 424 is designed to reorient the compression coil spring 424 relative to the non-compression coil spring 422. By hitting any of the known means, it is reoriented to the correct plane. The compression coil spring 424 has sufficient potential energy stored in the compressed state so that it can be reoriented in the coil pocket 408 when it is slightly stimulated so that it can turn itself in the correct orientation. It is. For purposes of illustrating this, and to better illustrate the overall process, after formation of the initial coil pocket 408 and cushion pocket 414, the top portion of the folded fabric 406 is removed from this view. As the folded fabric 406 continues to advance the conveyor 402, the coil pocket 408 is sealed by the ultrasonic bonding horn 432 that forms the coil pocket seal line 434. Note that the cushion pocket 414 need not be sealed. This is because the folds in the fabric 406 provide a natural seal of the cushion pocket 414. After the complete pocket spring 440 is formed, an ultrasonic cutting horn 442 is used to cut the fabric portion 444 between adjacent cushion pocket strokes 416. This produces a pre-programmed finished pocket coil, cushion pocket string of any length.

  In another embodiment, the method uses a cylindrical tube cushion to form a cushion pocket so that the cushion is always accurately oriented relative to the pre-formed pocket. Including the steps of: The method further includes slicing individual lengths of foam from the cylindrical tube of cushion material prior to insertion into the pocket. The method further includes the step of pre-compressing the foam using a compressed set of jaws that is easily inserted into the pocket and maintaining its final orientation in the insertion process. Alternatively, the end of the foam cylinder is pre-compressed using a compression set of jaws, the foam cylinder is inserted into a prefabricated fabric pocket, and the foam is cut after insertion to create individual foam cylinders in the fabric pocket.

  In another embodiment, the method includes folding an uninterrupted piece of fabric. The method further includes forming two pockets tangent to the fabric movement defining the sides of the first cushion pocket. Insert the foam into the pocket from the open side of the fabric and place the foam or coil in contact with the crease at the top of the fabric. The method further includes sealing the fourth side of the first cushion pocket. This method further creates an intermediate cushion pocket fabric length that allows the first cushion pocket to be fully compressed without causing distortion in the uncompressed second cushion pocket. Moving the fabric and the first cushion pocket by a sufficient distance. The method further includes forming a stroke of the two pockets tangent to the fabric movement that defines the sides of the second cushion pocket. The method further includes inserting the foam into the pocket from the open side of the fabric and placing the foam or coil in contact with the crease at the top of the fabric. The method further includes sealing the fourth side of the second cushion pocket. Continue to form cushion pocket strips continuously in a prescribed manner. The method further includes bonding the continuous cushion pocket strip onto a pre-made pocket coil strip. Here, each cushion pocket is located directly above or below the pocket coil spring, and excess fabric between the cushion pockets can compress each cushion pocket without affecting adjacent cushion pockets.

  In other embodiments, the method includes folding on a piece of unbroken fabric. The method further includes forming two pocket strokes tangent to the fabric movement that define the sides of the first cushion pocket. Insert the foam into the pocket from the open side of the fabric and place the foam or coil in contact with the crease at the top of the fabric. The method further includes sealing the fourth side of the first cushion pocket. The method further includes cutting out individual cushion pockets. The method further includes joining the individual cushion pockets onto a pre-made pocket coil strip where each cushion pocket is located directly above or directly below the pocket coil spring. Continue to bond the individual cushion pockets to the pocket coil strip until the complete pocket coil cushion core is complete.

  Referring to FIG. 17, in another embodiment of the present invention, the mattress 500 includes a cushion pocket upper layer 508 secured to the top of the coil pocket layer 502 as described in the embodiment of FIG. The upper layer of the cushion pocket 508 is separate from the coil pocket layer 502 and is separate. In this embodiment, the mattress 500 further comprises a cushion pocket underlayer 518 secured to the bottom of the coil pocket layer 502. The cushion pocket lower layer 518 is separate from the coil pocket layer 502 and is separate. In this manner, the mattress 500 provides a double-sided mattress that can be turned over. Further, the upper layer of the cushion pocket 508 may have a resiliency R1 and / or softness that is different from the resiliency and / or softness of the cushion pocket lower layer 518. The coil pocket layer 502 includes a plurality of coil pockets 505. Each coil pocket 505 includes a pocket 504 and a coil spring 506 disposed within the pocket 505. The upper layer of the cushion pocket 508 includes a mounting member 510 having an upper surface 511 and a lower surface 513, and a plurality of cushion pockets 512 fixed to the upper layer 511. Each of the cushion pockets 512 includes a pocket 514 and a cushion member 516 disposed in each pocket 514. The lower layer 518 of the cushion pocket includes an attachment member 520 having an upper surface 521 and a lower surface 523, and a plurality of cushion pockets 522 fixed to the lower layer 523. Each of the cushion pockets 522 includes a pocket 524 and a cushion member 526 disposed within each pocket 524. As in the embodiment of FIG. 13, cushion pockets 512 and 522 are joined to attachment members 510 and 520, respectively, which in the illustrated embodiment are fabric sheets. The spacing and position of the cushion pockets 512 ensures that each cushion pocket in the upper layer of the cushion pocket 508 is positioned directly above the coil pocket 505 on which it acts directly. Similarly, the spacing and position of the cushion pockets 522 ensures that each cushion pocket in the lower layer 518 of the cushion pocket is located directly below the coil pocket 505 that it directly acts on. As in the previous embodiment, each of the pockets 504, 514, and 524 is a fabric material, and each of the cushion members 516 and 526 is a plurality of foams. The coil spring 506 can be any type of spring, such as a multi-rate coil spring.

  Referring to FIG. 18, in another embodiment, the mattress 600 is a cushion pocket attached to the top layer of the coil pocket 602 by a mechanical clip 620 inserted through the grommet 618 and through the coil spring 606. The upper layer 608 is provided. As in FIG. 13, the cushion pocket 612 is joined to an attachment member 610, which in this embodiment is a fabric sheet made from a quasi-isotropic material. Further, as shown in FIG. 13, the intervals and positions of the cushion pockets 612 are set to be directly above the coil pockets 604 on which the cushion pockets 612 act directly. Note that the upper layer 608 of the cushion pocket is separate from the coil pocket layer 602 and is separate. Although one type of clip and grommet combination is shown, those skilled in the art can clamp on the fabric attachment layer 610 and other forms that can be mechanically clamped to the coil pocket 604 and the housed coil spring 606. It should be clear that other mechanical clips are also feasible. Alternatively, the clip or fastener can be attached directly to the typically used border wire or rod. Such a mechanical clamping device can eliminate the need to provide a grommet 618 on the attachment layer 610. All of the advantages described in the description of the embodiment of FIG. 13 are available in this embodiment. Further, by using the mechanical fastener 620, a manufacturer, retailer, or end user can easily attach or remove the cushion pocket layer 608 from the coil pocket layer 602 by the attachment member 610. The ability to add or remove the upper layer 608 of the cushion pocket gives the manufacturer considerable manufacturing flexibility when manufacturing the mattress. For example, a manufacturer may reduce the inventory of mattress parts, simply store a few pocket coil units together with a cushion pocket layer assembly, and mix and match these two components together during assembly. A mattress model can be created. In the case of a retail store, the cushion pocket layer can be exchanged on a short-term basis, allowing the store to hold one demonstration unit with a coil spring layer 602 inside the mattress cover 12, which is the mattress cover. 12 can be accessed by removing the zipper 630, which allows the store to change the cushion layer 608 and present a number of different comfort levels. Further, the retailer can customize the mattress to the customer's exact comfort preference by mixing different matching cushion pocket layers 608 with the pocket coil layer 602. At the same time, an end user who may decide to change the comfort level of the mattress in the future removes the cushion pocket layer 608 by releasing the mechanical clip 620 and replaces the cushion pocket layer 608 with a different cushion member. There is a possibility that it can be exchanged for one having elasticity of 616.

  Referring to FIG. 19, in another embodiment of the present invention, the mattress 700 includes an upper layer 708 of a cushion pocket, which is inserted through a grommet 730 and by a mechanical clip 732 inserted through a coil spring 706. Secured to the top of the layer 702 of the coil pocket. The upper layer 708 of the cushion pocket is separate from the coil pocket layer 702 and is separate. In this embodiment, the mattress 700 further comprises a cushion pocket lower layer 718 that is secured to the bottom of the coil pocket layer 702 by a mechanical clip 736 that is inserted through the grommet 734 and through the coil spring 706. Is done. Although one type of clip and grommet combination is shown, it should be clear to those skilled in the art that other forms of mechanical clips are possible. In such a mechanical clamping device, it is possible to eliminate the necessity of providing the attachment layer 710 with the grommet 730 and the attachment layer 720 with the grommet 734. The cushion pocket lower layer 718 is separate from the coil pocket layer 702 and is separate. In this manner, mattress 700 provides a double-sided mattress that can be turned over. Furthermore, the upper layer 708 of the cushion pocket may have a resiliency E1 and / or softness that is different from the resiliency and / or softness of the cushion pocket lower layer 718. The coil pocket layer 702 includes a plurality of coil pockets 705. Each coil pocket 705 includes a pocket 704 and a coil spring 706 disposed within the pocket 705. The upper layer 708 of the cushion pocket includes a mounting member 710 having an upper surface 711 and a lower surface 713, and a plurality of cushion pockets 712 fixed to the upper surface 711. Each of the cushion pockets 712 includes a pocket 714 and a cushion member 716 disposed in each pocket 714. The lower layer 718 of the cushion pocket includes an attachment member 720 having an upper surface 721 and a lower surface 723, and a plurality of cushion pockets 722 fixed to the lower surface 723. Each of the cushion pockets 722 includes a pocket 724 and a cushion member 726 disposed in each pocket 724. As in the embodiment of FIG. 13, cushion pockets 712 and 722 are joined to attachment members 710 and 720, respectively, which are fabric sheets in the illustrated embodiment. The spacing and position of the cushion pockets 712 ensures that each cushion pocket in the upper layer 708 of the cushion pocket is located directly above the coil pocket 705 on which it acts directly. Similarly, the spacing and position of the cushion pockets 722 ensures that each cushion pocket in the cushion pocket lower layer 718 is located directly below the coil pocket 705 on which it acts directly. As in the previous embodiment, each of the pockets 704, 714 and 724 is a fabric material and each of the cushioning materials 716 and 726 is a plurality of foams. The coil spring 706 can be any type of spring, such as a multi-rate coil spring. As shown in FIG. 13, the cushion pocket 712 is joined to an attachment member 710, which is a fabric sheet made of a material having quasi-isotropic properties in this embodiment. The cushion pocket 722 is joined to an attachment member 720 which is a fabric sheet made of a material having quasi-isotropic properties in this embodiment. Also, as in FIG. 13, the spacing and position of the cushion pockets 712 is such that each cushion pocket 712 is positioned directly above the coil pocket 705 on which it acts directly. The spacing and position of the cushion pockets 722 ensures that each cushion pocket 722 is located directly below the coil pocket 705 on which it acts directly. All of the advantages described in the description of the embodiment of FIG. 13 are available in this embodiment. As described in the embodiment of FIG. 18, all of the advantages of using a mechanical fastener are available in this double-sided mattress embodiment.

  Referring to FIG. 20, in another embodiment, the mattress 800 comprises a top layer of compartmentalized cushion pockets, thereby imparting various pocket cushion properties in various areas of the sleeping surface. In this particular embodiment, the cushion layer is comprised of three alternating rows of cushion pockets. For the purposes of discussing this, each compartmental row of foam cushion elements varies in terms of foam resiliency. Other segmentation possibilities may include, but are not limited to, various cushion pocket shapes, various cushioning materials, and various combinations and shapes of cushion mounting layers. Zone number 1 includes a row of cushion pockets 807 that is attached to the top layer 802 of the coil pocket by a mechanical clip 820 that is inserted through the grommet 825 and through the coil spring 806. As in FIG. 13, the cushion pocket 812 is joined to the top surface 840 of the mounting member 810, and in this embodiment is a fabric sheet made from a quasi-isotropic material. Further, as shown in FIG. 13, the intervals and positions of the cushion pockets 812 are such that each cushion pocket 812 is positioned directly above the coil pocket 805 that directly acts. In this embodiment, the cushion pocket 812 has a foam cushion member 816 having elasticity R1. Note that the upper layer 812 of the cushion pocket is separate and separate from the coil pocket layer 802. Although one type of clip and grommet combination is shown, those skilled in the art can clamp on the fabric attachment layer 810 and other forms that can be mechanically clamped to the coil pocket 804 and the housed coil spring 806. It should be clear that other mechanical clips are feasible. In such a mechanical clamping device, it is possible to eliminate the necessity of providing the attachment layer 810 with the grommet 825. Zone number 2 includes a row of cushion pockets 808 attached to the top layer 802 of the coil pocket by a mechanical clip 822 that is inserted through the grommet 826 and through the coil spring 806. As in FIG. 13, the cushion pocket 832 is joined to the upper surface 847 of the mounting member 811, which in this embodiment is a fabric sheet made from a quasi-isotropic material. Further, as shown in FIG. 13, the intervals and positions of the cushion pockets 832 are set so that each cushion pocket 832 is located directly above the coil pocket 805 that directly acts. In this embodiment, the cushion pocket 832 has a foam cushion member 836 having elasticity R2. Note that the top layer of the cushion pocket 832 is separate from the coil pocket layer 802 and is separate. Although one type of clip and grommet combination is shown, those skilled in the art can clamp on the fabric attachment layer 811 and other forms that can be mechanically clamped to the coil pocket 804 and the housed coil spring 806. It should be clear that other mechanical clips are also feasible. In such a mechanical clamping device, it is possible to eliminate the necessity of providing the attachment layer 811 with the grommet 826. Zone number 3 includes a row of cushion pockets 809 that are attached to the top layer 802 of the coil pocket by a mechanical clip 824 that is inserted through a grommet 827 and through a coil spring 806. As shown in FIG. 13, the cushion pocket 842 is joined to the upper surface 844 of the attachment member 813, which in this embodiment is a fabric sheet made from a quasi-isotropic material. Further, as shown in FIG. 13, the intervals and positions of the cushion pockets 842 are positioned directly above the coil pockets 805 where the cushion pockets 842 directly act. In this embodiment, the cushion pocket 842 has a foam cushion member 846 having elasticity R3. Note that the upper layer of cushion pocket 842 is separate from and separate from coil pocket layer 802. While one type of clip and grommet combination is shown, those skilled in the art can clamp on the fabric attachment layer 813 and other mechanical clamps on the coil pocket 804 and housed coil spring 806. It should be clear that a mechanical clip of the form is also feasible. In such a mechanical clamping device, it is possible to eliminate the necessity of providing the attachment layer 813 with the grommet 827. All of the advantages described in the description of the embodiment of FIG. 13 are available in this embodiment. Further, the use of mechanical fasteners 820, 822, and 824 allows the manufacturer to easily attach or remove the compartmentalized layer of the cushion pocket from the coil pocket layer 802. By changing the compartmentalized layers of the cushion pockets 807, 808, 809 and the corresponding elastic compartmentalized areas R1, R2, R3, the comfortable configuration of the mattress can be completely changed, Manufacturers can get almost unlimited comfort profiles. At the same time, the manufacturer need only store a few different layers of cushion pockets to achieve this flexibility.

  Referring to FIG. 21, in another embodiment, the mattress 900 comprises an upper layer and a lower layer of compartmentalized cushion pockets, thereby imparting various pocket cushion properties to different areas of the sleeping surface. Furthermore, the mattress 900 provides a double-sided mattress that can be turned over. Furthermore, the upper layer of the cushion pocket may have a resiliency E1 and / or flexibility that is different from the resiliency and / or flexibility of the lower layer of the cushion pocket. In this particular embodiment, the cushion layer on each side of the mattress is composed of three alternating rows of cushion pockets. For purposes of discussing this, the elements of each compartmented row of foam cushions are diverse in terms of foam resiliency. Other partitioning possibilities may include, but are not limited to, various cushion pocket shapes, various cushioning materials, and various combinations and shapes of cushion mounting layers. Zone number 1 includes a row of cushion pockets 910 attached to the top layer of the coil pocket 905 by a mechanical clip 917 inserted through the grommet 918 and through the coil spring 906. As shown in FIG. 13, the cushion pocket 914 is joined to the upper surface 912 of the attachment member 911 which is a fabric sheet made of a material having quasi-isotropic properties in this embodiment. Further, as shown in FIG. 13, the intervals and positions of the cushion pockets 914 are positioned directly above the coil pockets 905 on which the cushion pockets 914 act directly. In this embodiment, the cushion pocket 914 has a foam cushion member 916 having elasticity R1. Note that the top layer of the cushion pocket 914 is separate from and separate from the coil pocket layer 902. While one type of clip and grommet combination is shown, those skilled in the art can clamp on the fabric attachment layer 911 and other forms that can be mechanically clamped to the coil pocket 904 and the housed coil spring 906. It should be clear that other mechanical clips are also feasible. Such a mechanical clamping device can eliminate the need to provide a grommet 918 on the attachment layer 911. Zone number 2 includes a row of cushion pockets 920 attached to the top layer of coil pocket 902 by a mechanical clip 927 inserted through grommet 928 and through coil spring 906. As in FIG. 13, the cushion pocket 924 is joined to the upper surface 922 of the attachment member 921, which in this embodiment is a fabric sheet made from a quasi-isotropic material. Also, as in FIG. 13, the spacing and position of the cushion pockets 924 is such that each cushion pocket 924 is located directly above the coil pocket 905 on which it acts directly. In this embodiment, the cushion pocket 924 has a foam cushion member 926 having elasticity R2. Note that the top layer of the cushion pocket 924 is separate from the coil pocket layer 902 and is separate. While one type of clip and grommet combination is shown, those skilled in the art can clamp on the fabric attachment layer 921 and others that can be mechanically clamped on the coil pocket 904 and the housed coil spring 906. It should be clear that mechanical clips of the form Such a mechanical clamping device can eliminate the need to provide a grommet 928 on the attachment layer 921. Zone number 3 includes a row of cushion pockets 930 that are attached to the top layer of the coil pocket 902 by a mechanical clip 937 inserted through the grommet 938 and through the coil spring 906. As shown in FIG. 13, the cushion pocket 934 is joined to the upper surface 932 of the attachment member 931, which in this embodiment is a fabric sheet made of a quasi-isotropic material. Further, as shown in FIG. 13, the intervals and positions of the cushion pockets 934 are positioned directly above the coil pockets 905 on which the cushion pockets 934 directly act. In this embodiment, the cushion pocket 934 has a foam cushion member 936 having elasticity R3. Note that the top layer of the cushion pocket 934 is separate from the coil pocket layer 902 and is separate. Although one type of clip and grommet combination is shown, those skilled in the art can clamp on the fabric attachment layer 931 and other forms that can be mechanically clamped to the coil pocket 904 and the housed coil spring 906. It should be clear that other mechanical clips are also feasible. In such a mechanical clamping device, it is possible to eliminate the necessity of providing the attachment layer 931 with the grommet 938. All of the advantages described in the description of the embodiment of FIG. 13 are available in this embodiment. Further, by using mechanical fasteners 917, 927, and 937, a manufacturer can easily attach or remove a compartmentalized layer of cushion pockets from layer 902 of coil pockets. The comfortable construction of the mattress is completely changed by changing the compartments 910, 920 and 930 of the cushion pocket and the corresponding elastic compartments R1, R2 and R3. The manufacturer can obtain an almost infinite comfortable profile. At the same time, the manufacturer need only store a few different layers of cushion pockets to achieve this flexibility. Furthermore, the mattress is double-sided and is similarly partitioned on the side of the other mattress with zone 4, zone 5 and zone 6. Zone number 4 includes a row of cushion pockets 940 attached to the bottom layer 902 of the coil pocket by a mechanical clip 947 inserted through the grommet 948 and through the coil spring 906. The cushion pocket 940 is adhered to the bottom surface 941 of the attachment member 943, which is a fabric sheet made of a material having quasi-isotropic properties in this embodiment. As shown in FIG. 13, the interval and position of the cushion pockets 940 are set to be directly below the coil pockets 905 in which each cushion pocket 940 acts directly. In this embodiment, the cushion pocket 944 has a foam cushion member 946 having elasticity R4. Zone number 5 includes a row of cushion pockets 950 that are attached to the bottom layer 902 of the coil pockets by mechanical clips 957 inserted through grommets 958 and through coil springs 906. In this embodiment, the cushion pocket 950 is joined to the bottom surface 951 of the attachment member 953 which is a fabric sheet made of a material having quasi-isotropic properties. As shown in FIG. 13, the spacing and position of the cushion pockets 950 are set to be directly below the coil pockets 905 where the cushion pockets 950 directly act. In this embodiment, the cushion pocket 954 has a foam cushion member 956 having elasticity R5. Zone number 6 includes a row of cushion pockets 960 that are attached to the bottom layer 902 of the coil pocket by a mechanical clip 967 inserted through the grommet 968 and through the coil spring 906. In this embodiment, the cushion pocket 960 is joined to the bottom surface 961 of the attachment member 963 which is a fabric sheet made of a material having quasi-isotropic properties. As shown in FIG. 13, the interval and position of the cushion pockets 960 are positioned directly below the coil pockets 905 in which each cushion pocket 960 acts directly. In this embodiment, the cushion pocket 964 has a foam cushion member 966 having elasticity R6. Given the level of compartmentalization described above, the mattress 900 can be manufactured in a number of different configurations from a small number of cushion mounting layers and pocket coil springs.

  Referring to FIG. 22, in another embodiment, a pocket spring unit 1000 according to the present invention generally comprises a first cushion pocket 1008 that engages and acts directly on the coil pocket 1002. Furthermore, the second cushion pocket 1014 engages the coil pocket 1002 and acts directly on it. In the embodiment shown, each cushion pocket is positioned and juxtaposed above the coil pocket 1002. The coil pocket 1002 includes a pocket 1004 and a coil spring 1006. The cushion pocket 1008 includes a pocket 1010 and an elastic member 1012 disposed in the pocket 1010. The cushion pocket 1014 includes a pocket 1016 and an elastic member 1018 disposed in the pocket 1016. The cushion pocket 1008 is engaged with and acts directly on the coil pocket 1002, and almost all of the force from the cushion pocket 1008 is transmitted to the coil pocket 1002. The cushion pocket 1014 engages and acts directly on the coil pocket 1002, and substantially all of the force from the cushion pocket 1014 is transmitted to the coil pocket 1002. As in other embodiments, the pocket 1004 of the coil pocket 1002 is made from a non-woven fabric. The coil spring 1006 may be any conventional coil such as a single rate coil spring. As in other embodiments, the pocket 1010 of the cushion pocket 1008 may be made from a nonwoven fabric and connected to the coil pocket 1002 by an adhesive or other conventional means. As in other embodiments, the pocket 1014 of the cushion pocket 1016 may be made from a non-woven fabric and connected to the coil pocket 1002 by an adhesive. As in other embodiments, the elastic member 1012 may be a foam cushion having any desired elasticity R1. As in other embodiments, the elastic member 1018 may be a foam cushion having any desired elasticity factor R2. The elasticity R1 may be the same as the elasticity R2, or may be designed with different elasticity to create a multi-rate cushion assembly. It is also possible for the first cushion pocket 1008 to have a different shape than the second cushion pocket 1014. Based on the different shapes of the two cushion pockets, the R1 of the cushion pocket 1008 is different from the R2 of the cushion pocket 1014, thereby creating a multi-rate cushion assembly. Further, the present invention is not limited to the two microcushions of this embodiment, and may include more than two microcushions, such as three microcushions.

  Referring to FIG. 23, there is shown a machine 1100 according to another embodiment of the present invention for making individual pocket cushions 1130 and attaching them to a mounting layer 1134 fed from a mounting roll 1132. The machine 1100 generally includes a base conveyor 1108 adapted to support multiple layers of fabric and move them to various forming and cutting stations, and a mounting layer conveyor 1138 adapted to move the attachment layer fabric 1134. Is provided. Machine 1100 further includes a fabric roll 1110 that includes unfolded fabric 1112 that passes through any of the known fabric folding mechanisms to become folded fabric 1113. The fabric roll 1110 supplies the fabric 1112 to a known folding mechanism and on the base conveyor 1108. Many fabrics can be used in the present invention, including woven fabrics such as cotton, polyester, polypropylene, nylon, and fabric blends, as well as nonwovens composed of blends of polyester, polypropylene, nylon and fabrics, It is not limited to them. A cushion pocket line 1128 formed by the ultrasonic bonding horn 1116 forms the side surface of the cushion pocket 1126. In this embodiment, all drawn lines are made by ultrasonic welding and ultrasonic welding horn. However, it is envisioned that other types of bonding devices and bonding horns, such as heat bonding horns or heat bonding with heat bondable fabrics can also be used. The foam cushion cylinder 1122 is compressed by any one of several known means and inserted into the cushion pocket 1126 in the correct final orientation. If the cushion cylinder is not initially oriented correctly, the potential energy stored in the compressed foam cushion cylinder 1122 is not sufficient to correct the orientation of the cushion cylinder. Maintain the correct orientation. Another unique aspect of the present invention is that individual foam cushion cylinders 1122 are cut from longer foam cylinders 1120 by a cutting knife 1121. The method further includes slicing individual lengths of foam from the cylindrical tube 1120 of cushion material prior to insertion into the pocket. Thereby, the size of each cushion foam cylinder can be programmed and changed in advance. In doing this, various regions of the cushion pocket mounting layer having different sized foam cushion pockets 1130 can be partitioned. It is also envisioned that foam cylinders 1120 of different elasticity can be utilized to create a single cushion pocket mounting layer, thereby creating a compartmentalized cushion pocket attachment layer. Note that knife 1121 can be, but is not limited to, a shear knife, hot knife, or ultrasonic cutting knife, or any other cutting device or method. A great advantage of using a long foam cylinder 1120 in the assembly is to ensure that the foam cushion cylinder 1122 is always in the correct orientation relative to the cushion pocket 1126. The method further includes pre-compressing the foam using a jaw compression set so that it is easily inserted into the pocket and maintains its final orientation in the insertion process. Alternatively, the end of the foam cylinder is pre-compressed using a compression set of jaws, the foam cylinder is inserted into a prefabricated fabric pocket, and the foam is cut after insertion to create individual foam cylinders in the fabric pocket. After the foam cushion cylinder 1122 is placed in the cushion pocket 1126, the ultrasonic bonding horn 1114 forms a drawn line that seals the cushion pocket 1126. The folded fabric 1113 then proceeds to the pocket cushion spring cut-off station. For purposes of illustrating this, and to better illustrate the overall process, the top portion of the folded fabric 1113 is removed from this view after the formation of the initial cushion pocket 1126. As the folded fabric 1113 continues to advance on the conveyor 1108, the cushion pocket 1126 is separated from the advanced folded fabric 1113 by the ultrasonic cutting horn 1118. After the complete pocket cushion 1130 is formed, it is pushed towards the mounting layer 1134 and the mounting layer conveyor 1138. In this embodiment, an adhesive applicator 1136 places an adhesive layer between the pocket cushion 1130 and the attachment layer 1134. It should be apparent to those skilled in the art that other means of attaching the pocket cushion 1130 to the attachment layer 1134 are possible. These can include, but are not limited to, ultrasonic welding and hot melt adhesives. The total attachment layer 1134 and attachment layer conveyor 1138 are movable in two axes in the material plane of the attachment layer 1134, allowing the pocket cushion 1130 to be attached at any predetermined location on the attachment layer 1134.

  Referring to FIG. 24, a machine 1200 according to another embodiment of the present invention for producing individual pocket cushions 1230 is shown. The machine 1200 generally comprises a base conveyor 1208 that supports multiple layers of fabric and is adapted to move to various forming and cutting stations. The machine 1200 further includes a fabric roll 1210 that includes an unfolded fabric 1212 that passes through any one of the known fabric folding mechanisms and becomes a folded fabric 1213. Fabric roll 1210 feeds fabric 1212 into a known folding mechanism and onto base conveyor 1208. Many fabrics can be used in the present invention, including woven fabrics such as cotton, polyester, polypropylene, nylon, and fabric blends, as well as nonwovens composed of blends of polyester, polypropylene, nylon and fabrics, It is not limited to them. Forming the side surface of the cushion pocket 1226 is a cushion pocket line 1228 formed by the ultrasonic bonding horn 1214. In this embodiment, all drawn lines are made by ultrasonic welding and ultrasonic welding horn. However, it is envisioned that other types of bonding devices and bonding horns can be used, such as heat bonding with fabrics that can be heat bonded to the heat bonding horn. The foam cushion cylinder 1222 is compressed by any one of several known means and inserted into the cushion pocket 1226 in the correct final orientation. If the cushion cylinder is not initially oriented correctly, the potential energy stored in the compressed foam cushion cylinder 1222 is not sufficient to correct the orientation of the cushion cylinder, so insertion of the foam cushion cylinder 1222 Maintain the correct orientation. Another unique aspect of the present invention is that individual foam cushion cylinders 1222 are cut from longer foam cylinders 1220 by a cutting knife 1221. The method further includes slicing individual lengths of foam from the cushion cylindrical tube 1220 prior to insertion into the pocket. Note that the knife 1221 can be, but is not limited to, a shear knife, a hot knife, or an ultrasonic cutting knife, or any other cutting device or method. A great advantage of using a long foam cylinder 1220 in the assembly is to ensure that the foam cushion cylinder 1222 is always in the correct orientation relative to the cushion pocket 1226. The method further includes pre-compressing the foam using a jaw compression set so that it is easily inserted into the pocket and maintains the final orientation in the insertion process. Alternatively, the end of the foam cylinder is pre-compressed using a compression set of jaws, the foam cylinder is inserted into a prefabricated fabric pocket, and the foam is cut after insertion to create individual foam cylinders in the fabric pocket. After the foam cushion cylinder 1222 is placed in the cushion pocket 1226, the ultrasonic bonding horn 1216 forms a drawn line that seals the cushion pocket 1226. The folded fabric 1213 then advances to the pocket cushion spring cut-off station. For purposes of illustrating this, and to better illustrate the overall process, the top portion of the folded fabric 1213 is removed from this view after the formation of the initial cushion pocket 1226. As the folded fabric 1213 continues to advance on the conveyor 1208, the cushion pocket 1226 is separated from the advanced folded fabric 1213 by the ultrasonic cutting horn 1218. After the complete pocket cushion 1230 is formed, it is deposited in a hopper (not shown) and can later be used in an assembly machine to create a pocket cushion mounting layer.

  Referring to FIG. 25, in another embodiment, the mattress 1300 is a microcushion attached to the top layer 1302 of the coil pocket by a mechanical clip 1320 inserted through the grommet 1318 and through the coil spring 1306. The upper layer 1308 of the pocket is provided. As in FIG. 13, the microcushion pocket array 1311 is joined to the upper layer 1318 of the attachment member 1310, which in this embodiment is a fabric sheet made from a quasi-isotropic material. Note that the top layer 1308 of the microcushion pocket is separate from and separate from the layer of the coil pocket 1302. Further, as shown in FIG. 13, the interval and the position of the micro cushion pocket array 1311 are set so that each micro cushion pocket array 1311 is positioned directly above the coil pocket 1305 on which it directly acts. In this embodiment, the microcushion array 1311 is composed of three different microcushions, each having a different or the same elasticity R. One of the microcushions of the microcushion array 1311 has a fabric pocket 1312 that houses a foam element 1313 of elasticity R1. The second microcushion of the microcushion array 1311 has a fabric pocket 1314 that houses a foam element 1315 of elasticity R2. The third microcushion of the microcushion array 1311 has a fabric pocket 1316 that houses a foam element 1317 of elasticity R3. These three different foam element elasticities R1, R2, R3 that make up the cushion elements of the micro cushion array 1311 achieve variable speed cushioning with different flexibility depending on how strong and quickly the cushion elements are pressed can do. The fabric pocket 1312 may have a unique shape different from that of the fabric cushion pocket 1314 or the fabric cushion pocket 1316. Based on the different shapes of the cushion pocket, the R1 of the cushion pocket 1312 can have a different R2 of the cushion pocket 1314 than the R3 of 1316, thereby creating a multi-rate microcushion assembly. Although one type of clip and grommet combination is shown, those skilled in the art will recognize other forms of mechanical that can be clamped to the fabric attachment layer 1310 and mechanically clamped to the coil pocket 1304 and the housed coil spring 1306. It should be clear that clips are also feasible. The use of such a mechanical clamping device can eliminate the need to provide a grommet 1318 on the attachment layer 1310. All of the advantages described in the description of the embodiment of FIG. 13 are available in this embodiment. Further, by using the mechanical fastener 1320, a manufacturer, retailer, or end user can easily attach or remove the microcushion pocket layer 1308 from the coil pocket layer 1302 by the attachment member 1310. The ability to add or remove the top layer 1308 of the microcushion pocket gives the manufacturer considerable manufacturing flexibility when manufacturing the mattress. For example, a manufacturer can reduce the inventory of mattress parts, simply store a few pocket coil units along with cushion pocket layer arrangements, mix and combine these two components during assembly, A mattress model can be created. In the case of a retail store, the cushion pocket layer can be exchanged on a short order basis, allowing the store to hold one demonstration unit with a coil spring layer 1302 inside the mattress cover 12, which is the mattress cover. 12 can be accessed by removing it with a zipper 1330, which allows the store to change the microcushion layer 1308 to present a number of different comfort levels. Further, retailers can customize the mattress to the customer's exact comfort preference by mixing different matching microcushion pocket layers 1308 with the pocket coil layer 1302. At the same time, an end user who may decide to change the comfort level of the mattress to a future date may potentially remove the cushion pocket layer 1308 by releasing the mechanical clip 1320, It can be replaced with one having a different comfort level for the cushion member.

  Referring to FIG. 26, in another embodiment, the mattress 1400 includes a cushion pocket attached to the top layer 1402 of the coil pocket by a mechanical clip 1420 inserted through the grommet 1418 and through the coil spring 1406. An upper layer 1408 is included. As in FIG. 13, the cushion pocket 1412 is joined to an attachment member 1410, which in this embodiment is a fabric sheet made from a quasi-isotropic material. Also, as in FIG. 13, the spacing and position of the cushion pockets 1412 ensures that each cushion pocket 1412 is located directly above the coil pocket 1405 on which it acts directly. The upper layer 1408 of the cushion pocket is separate from the coil pocket layer 1402 and is separate. The upper layer 1408 of the cushion pocket includes an attachment member 1410 that has a lower surface 1413 and an upper surface 1411, and a plurality of cushion pockets 1412 secured to the upper surface 1411, respectively. Although one type of clip and grommet combination is shown, those skilled in the art will appreciate that other forms that can be clamped on the fabric attachment layer 1410 and mechanically clamped on the coil pocket 1404 and the housed coil spring 1406 are shown. It should be clear that other mechanical clips are also feasible. Such a mechanical clamping device can eliminate the need to provide a grommet 1418 on the attachment layer 1410. All of the advantages described in the description of the embodiment of FIG. 13 are available in this embodiment. Further, the use of mechanical fasteners 1420 allows a manufacturer, retailer, or end user to easily attach or remove cushion pocket layer 1408 from coil pocket layer 1402 via attachment member 1410. Further, the second cushion pocket layer 1422 is composed of a cushion pocket 1424, which is joined to a mounting layer 1423 that is directly above the cushion layer 1408, and all the cushion pockets 1424 are connected to the cushion layer 1408. Directly engages and acts directly on the corresponding cushion pocket 1412. In this embodiment, the cushion layer 1422 through the attachment layer 1423 is directly bonded to the coil layer 1408 via an adhesive. However, it is envisioned that other joining means such as non-limiting mechanical joining may be used. The ability to add or remove the upper layers 1408 and 1422 of the cushion pocket gives the manufacturer considerable flexibility when manufacturing the mattress. For example, a manufacturer can reduce the inventory of mattress parts, simply store a few pocket coil units along with cushion pocket layer arrangements, mix and combine these two components during assembly, A mattress model can be created. In the case of a retail store, the cushion pocket layer can be exchanged on a short-term basis, allowing the store to hold one demonstration unit with a coil spring layer 1402 inside the mattress cover 12, which is the mattress cover. 12 can be accessed by removing the zipper 1430, which allows the store to change the cushion layers 1408 and 1422 to present a number of different comfort levels. Further, the retailer can customize the mattress to the customer's exact comfort preferences by mixing different matching cushion pocket layers 1408 and 1422 with the pocket coil layer 1402. By potentially mixing different layers of different pocket spring coils, manufacturers can increase product flexibility while requiring only minimal raw material components.

  Referring to FIG. 27, in another embodiment, the mattress 1500 includes a cushion attached to the top layer 1502 of the coil pocket by a mechanical clip 1520 inserted through the grommet 1518 and through the coil spring 1506. An upper layer 1508 is included. As shown in FIG. 13, the cushion 1512 is joined to an attachment member 1510 which is a fabric sheet made of a material having quasi-isotropy in this embodiment. Also, as in FIG. 13, the spacing and position of the cushions 1512 ensures that each cushion is located directly above the coil pocket 1505 where it acts directly. In this embodiment, the foam cushion element 1516 is not housed in the pocket fabric, but instead is joined directly to the top surface 1511 of the attachment layer 1510. Note that the upper layer 1508 of the cushion is separate and separate from the layer 1502 of the coil pocket. Although one type of clip and grommet combination is shown, those skilled in the art will recognize other forms of clamping that can be clamped onto the fabric attachment layer 1510 and mechanically clamped to the coil pocket 1504 and the stored coil spring 1506. It should be clear that mechanical clips are also feasible. The use of such a mechanical clamping device can eliminate the need to provide the attachment layer 1510 with a grommet 1518. All of the advantages described in the description of the embodiment of FIG. 13 are available in this embodiment. Further, by using the mechanical fastener 1520, a manufacturer, retailer, or end user can easily attach or remove the cushion layer 1508 from the coil pocket layer 1502 by the attachment member 1510. The ability to add or remove an upper layer 1508 of the cushion pocket gives the manufacturer considerable manufacturing flexibility when manufacturing the mattress. For example, manufacturers can reduce the stock of mattress parts, store a few pocket coil units along with cushion layer arrangements, and mix and harmonize these two components during assembly to create a large number of A mattress model can be created. In the case of a retail store, the cushion layer can be exchanged on a short-term order, allowing the store to hold one demonstration unit with a coil spring layer 1502 inside the mattress cover 12, which is the mattress cover 12. Can be accessed by removing the zipper 1530, which allows the store to change the cushion layer 1508 to present a number of different comfort levels. Further, the retailer can customize the mattress to the customer's exact comfort preference by mixing different matching cushion layers 1508 with the pocket coil layer 1502. At the same time, end-users who may decide to change future mattress comfort levels potentially remove the cushion layer 1508 by releasing the mechanical clip 1520 and replace the cushion layer 1508 with a different cushion member 1516. It can be replaced with one having elasticity.

  While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that changes and modifications can be made without departing from the scope of the invention as set forth in the claims.

Claims (36)

A mattress,
A layer of coil pockets including first and second coil pockets, wherein each of the first and the coil pockets includes a pocket and a coil spring disposed in the pocket. When,
A first layer of cushion pockets including first and second cushion pockets, each of the first and second cushion pockets including a pocket and a cushion member disposed in the pocket; The layer of the cushion pocket further comprises an attachment member including an upper surface and a lower surface, the first and second cushion pockets engage the upper surface of the attachment member, and the first and second cushion pockets are The first layer of the cushion pocket, wherein the lower surface of the mounting member is engaged with the layer of the coil pocket so as to act directly on the first and second coil pockets, respectively;
Including the mattress.   The mattress of claim 1, wherein the cushion pocket layer is disposed above the coil pocket layer.   The mattress according to claim 2, wherein the attachment member is made of a quasi-isotropic material.   The mattress according to claim 3, wherein the attachment member is a fabric sheet.   The mattress according to claim 4, wherein each of the cushion pockets is connected to an upper surface of the attachment member by an adhesive.   The mattress according to claim 5, wherein the lower surface of the attachment member is securely attached to the layer of the coil pocket by an adhesive.   The mattress of claim 6, wherein the pocket of each of the coil pockets and the pocket of each of the second cushion pockets are made from a piece of fabric.   The mattress according to claim 7, wherein the coil spring in each of the coil pockets is a multirate coil spring.   The mattress of claim 8, wherein the cushion member is a foam.   The mattress of claim 1, wherein the attachment member is removably engaged with the layer of the coil pocket.   The mattress of claim 10, further comprising a fastener that removably engages the attachment member to a layer of the coil pocket.   The mattress of claim 11, wherein the fastener comprises a female connector engaged with the mounting member and a male connector engaged with the coil pocket.   The mattress of claim 12, wherein the female connector is a grommet.   The mattress of claim 13, wherein the male connector is a clip. Further comprising a second layer of cushion pockets disposed below the layer of coil pockets;
The second layer of the cushion pocket includes first and second cushion pockets. Each of the first and second cushion pockets includes a pocket and a cushion member disposed in the pocket;
The second layer of the cushion pocket further includes an attachment member including an upper surface and a lower surface,
The first and second cushion pockets of the second layer of the cushion pocket are engaged with the upper surface of the mounting member;
The lower surface of the mounting member is engaged with the layer of the coil pocket so that the first and second cushion pockets of the second layer of the cushion pocket directly act on each of the first and second coil pockets. Combined,
The mattress according to claim 1. A first microcoil pocket including a pocket and a coil spring in the pocket;
A second microcoil pocket including a pocket and a coil spring in the pocket;
A cushion pocket including a pocket and a cushion member in the pocket, wherein the first cushion pocket is disposed above and acts on the first and second microcoil pockets;
Including, pocket spring.   The pocket spring according to claim 16, wherein the first cushion pocket is directly fixed to the first and second microcoil pockets. The pocket spring of claim 17, wherein the pockets of the first and second microcoil pockets and the pockets of the cushion pocket are made from a single piece of fabric.   The pocket spring according to claim 18, wherein the coil springs of the first and second microcoil pockets are multirate coil springs.   20. A pocket spring according to claim 19, wherein the cushion member is a foam. A coil pocket including a pocket and a coil spring in the pocket;
A first micro cushion pocket including a pocket and a cushion member in the pocket, wherein the first cushion pocket is disposed above and acts on the coil pocket;
A second micro cushion pocket including a pocket and a cushion member in the pocket, wherein the second cushion pocket is disposed above and acts on the coil pocket;
Including, pocket spring.   The pocket spring according to claim 21, wherein the first and second microcushion pockets are fixed directly to the coil pocket.   23. The pocket spring of claim 22, wherein the pockets of the first and second microcushion pockets and the pocket of the coil pocket are made from a single piece of fabric.   The pocket spring according to claim 23, wherein the coil spring is a multirate coil spring.   25. The pocket spring of claim 24, wherein the cushion members of the first and second microcushion pockets are a foam. A method of forming a cushion spring,
a) supplying at least one fabric;
b) forming a first cushion pocket from the fabric;
c) supplying an uninterrupted piece of cushioning material;
d) cutting a cushion member from the one uninterrupted cushion material;
e) inserting the cushion material into the first cushion pocket;
f) sealing the first cushion pocket.   27. The method of claim 26, further comprising attaching the cushion pocket to an attachment member. A pocket spring unit comprising a first layer of cushion pockets comprising first and second cushion pockets,
Each of the first and second cushion pockets includes a pocket and a cushion member disposed in the pocket;
The cushion pocket layer further comprises an attachment member including an upper surface and a lower surface;
The first and second cushion pockets are engaged with the top surface of the mounting member;
The pocket spring unit, wherein the lower surface of the mounting member is engaged with a layer of the coil pocket such that the first and second cushion pockets directly act on the first and second coil pockets, respectively. .   The pocket spring unit according to claim 28, wherein the attachment member is a fabric sheet.   30. A pocket spring unit according to claim 29, wherein the cushion members of the first and second cushion pockets are one foam. A coil pocket including a pocket and a coil spring in the pocket;
A first micro-cushion pocket including a pocket and a cushion member in the pocket, wherein the first cushion pocket is disposed above and acts on the coil pocket, and the cushion member has elasticity R1; ,
A second microcushion pocket including a pocket and a cushion member in the pocket, wherein the second microcushion pocket is disposed and acts above the coil pocket, and the cushion member of the second microcushion pocket is different from R1 The second cushion pocket having elasticity R2, and
Including multi-rate pocket spring.   32. The multi-rate pocket spring of claim 31, wherein the pockets of the first and second microcushion pockets and the pockets of the coil pocket are made from a single piece of fabric.   33. A multirate pocket spring according to claim 32, wherein the coil spring is a multirate coil spring.   34. The multirate pocket spring of claim 33, wherein the cushion members of the first and second microcushion pockets are a foam. The cushion member of the first microcushion pocket includes a first shape that creates the elasticity R1;
The cushion member of the second microcushion pocket includes a second shape that creates the elasticity R2.
35. A multirate pocket spring according to claim 34. The cushion member of the first microcushion pocket comprises one foam that creates the elasticity R1;
The cushion member of the second microcushion pocket comprises one foam that creates the elasticity R2.
34. A multirate pocket spring according to claim 33.

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