JP6736590B2 - mattress - Google Patents

Description

Referring to FIGS. 1 and 2, a conventional mattress 50 generally has a layer 57 of pocket coil springs, otherwise known as Marshall type springs, engaged with a base 52. The mattress 50 further includes cushion layers 53 and 54 arranged above the pocket coil spring 57, and a mattress ticking cover 51. The Marshall type spring is a coil spring 56 first encased in a pocket 55 of material as described in US Pat. No. 685,160. The pocket coil assembly is made by inserting a coil spring 56 into each of the fabric coil pockets 55, usually aligned together, as a continuous pocket coil strip.

U.S. Pat. No. 2,236,007 discloses a Marshall type spring in which the core of a pocket coil spring is padded with fibers. This absorbs a part of the force of the fiber filler, thereby promoting absorption of the force applied to the actual pocket coil spring.

U.S. Pat. No. 8,266,745 discloses a Marshall type spring that uses a fill material containing foam or fibers present in a pocket with a spring coil. This reduces and eliminates noise and prevents the fabric surrounding the spring from being caught inside the pocket when a person steps in or out of bed.

What most pocket coil mattresses have in common is that the coil springs contained in each fabric pocket are under the seating or cushioning seats or under the seats and are flexible when first ridden, softer It provides comfort and helps reduce localized high pressure boundaries, reducing the sensation of lying directly on a metal spring and helping to conform to the contours of the body. This type of mattress helps alleviate and eliminate problems associated with the body imprinting of one or more of the cushion layers from the sleeping person repeatedly lying in similar positions each night. As such, it is often turned over at some time interval.

Referring to FIG. 3, another drawback of having one or more sheet-like cushions 53 above the layer of pocket coils 58 is the compressive force (“compressive force of a sleeping person”) caused by the weight of the body 49. ) Is transmitted on the surface of the cushion material 53, that is, on the surface perpendicular to and perpendicular to the vertical surface of the pocket coil unit. This results in the sleeping person's compressive forces being transferred laterally to adjacent pocket coils, even if these same coils are not directly exposed to the sleeping person's forces. As a result, the recessed hole 60 is formed, and the sleeping person is drawn into the core of the mattress 50, which causes the mattress 50 to be uncomfortable for sleep.

A further problem of the pit effect occurs for a second sleeping person who utilizes the same mattress at the same time as the first sleeping person. The second sleeping person is often subject to the hollow hole effect of the first sleeping person, and may be subjected to the force of pulling the sleeping person into the same sleeping space as the first sleeping person. There is nature. Obviously, the reverse is also true, with the first sleeping person being able to be drawn into the wellbore effect created by the second sleeping person. In either of these situations, either sleeping person falls into a situation where he or she is not comfortable in his or her space due to the flaws in the manner in which the seat cushioning material behaves in current mattress configurations.

A further drawback of the sheet cushion above the pocket coil is that the sheet cushion material elicits a trampoline effect when loaded from above. Seat cushions provide first-time softness, softer sleeping comfort, help reduce localized high-pressure boundaries, reduce the sensation of lying directly on metal springs, and conform to body contours Instead of merely acting as a cushioning material to contribute to the action, it often additionally acts like a trampoline and exhibits its own spring effect. The magnitude of the trampoline effect usually correlates closely with the tensile strength of the cushion. The cushioning material is held in place above the uncompressed pocket coil spring to resist downward strain in areas exposed to compressive forces due to the material's lateral, in-plane, and tensile strength. doing. In essence, the sheet-like cushioning material acts itself like a spring unit, just because of the trampoline effect due to tensile strength. This effect frequently differs from the desire for a cushioning material that provides the sleeping person with initial softness. There are significant problems with mattresses in hospitals and nursing homes. Increased mattress interface pressure is associated with patients developing pressure ulcers. The purpose of the sheet 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 cushion layer above the coil unit acts to adversely affect this goal.

A further drawback associated with the seat cushion above the pocket coil concerns the delivery of the mattress. It is well known in the industry that mattresses are typically shipped in a flat configuration in either a horizontal or vertical orientation. Bending the mattress during initial delivery and setup often results in damaged and returned mattresses. Failure mechanisms within mattresses are often the result of shearing, permanent movement, or deformation of sheet cushions. In addition, the need to ship the mattress in a flat orientation increases both the cost and logistics associated with shipping the mattress. Often, two men and a truck are needed to deliver a mattress to a consumer. It is an advantage in nature that the mattress can be rolled and compressed for shipping, eliminating the costs associated with shipping flat mattresses. Furthermore, if the mattress can be rolled up and stored in a compressed form, the cost of storage is significantly reduced in terms of floor space for both manufacturers and retailers.

An existing problem when sleeping on various types of cushioning materials, especially various types of foams including, but not limited to polyurethane, latex and memory foam, is the uncomfortable warmth of the sleeping person when lying on the mattress. It tends to make you feel hot. It is said that, in part, many of these sheet-like cushioning materials have shielding properties that limit the cooling of the sleeping person's body in direct contact with the mattress. It depends on the facts. This property is combined with the property of sheet cushioning materials to reduce the flow of air through or around the cushioning material and exacerbates the cooling problem. The inclusion of sheet cushions in pocket coil mattresses due to the inability of the sleeping person to properly regulate body temperature, coupled with the fact that the sleeping person's wake-up mechanism is partially triggered by body temperature regulation, It can be a significant factor in poor quality sleep associated with mattresses.

One of the main causes of damage to the mattress is deterioration of the sheet cushion material. This is a direct result of fatigue relief and is especially prevalent in sheet foam cushions that are subjected to shear loads acting on the mattress that match the forces of the sleeping person. With continuous loading over time, the foam begins to be unable to resist compression. This deterioration of the sheet cushion material has led mattress manufacturers to recommend turning the mattress over to mitigate and delay this deterioration.

Sheet cushions also act to trap dust, dust mites, and potentially other microorganisms. Over the long term, this can be a serious health hazard, especially for severely allergic or immunosuppressive individuals. 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 resistant to the formation of depressions.

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

Another object of the present invention was to develop a mattress with pocket springs that allows the flexibility or hardness of the mattress to be selectively controlled.

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

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

Another object of the present invention is to develop a mattress that removes the sheet-like cushioning layer that is subjected to shear forces from the compressive load of the sleeping person, resulting in premature failure, thus extending the life of the mattress. Was that.

Another object of the invention was to develop a mattress that replaces sheet cushions with individually stored foam cushion pockets. The cushioned pockets are individually stored in fabric, and the cushion pockets are essentially non-damaged by trapping dust, house dust mites, and other microorganisms, greatly reducing the health hazards associated with sheet cushions on conventional mattresses. 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 costs and weight associated with sheet cushions. This is accomplished by utilizing an improved pocket coil spring having a cushioning material located just above the spring unit of the cushion pocket.

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

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

In a first embodiment, the present invention is a mattress that includes a layer of coil pockets that includes 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 comprises 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 layer of cushion pockets further comprises a mounting member including an upper surface and a lower surface. The first and second cushion pockets engage the upper surface of the mounting member. The lower surface of the mounting member engages a layer of coil pockets such 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 accompanying drawings.

1 is a perspective view of a prior art pocket coil spring having a pocket and a coil spring disposed within the pocket. FIG. 3 is a perspective view of a prior art mattress having multiple pocket coil springs and multiple cushion sheets or layers. FIG. 7 is a view of a conventional mattress with the formation of recessed holes. FIG. 3 is a perspective view of a single-sided mattress according to the first embodiment of the present invention in an unloaded state, showing a plurality of pocket springs each having a coil pocket and a cushion pocket that acts by engaging the coil pocket. FIG. 3 is a perspective view of the pocket spring according to the first embodiment of the present invention in an unloaded state, showing a cushion pocket that acts by engaging a coil pocket having a single rate spring coil. FIG. 6 is a perspective view of a pocket spring according to another embodiment of the present invention in an unloaded state, the first cushion pocket acting by engaging the upper portion of the coil pocket, and the lower cushion spring acting by engaging the lower portion of the coil spring. And a second cushion pocket. FIG. 6 is a perspective view of a pocket spring according to another embodiment of the present invention in an unloaded state, the first cushion pocket engaging and acting on the coil pocket, and the first cushion pocket engaging and acting on the first cushion pocket. 2 shows a second cushion pocket. FIG. 3 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 acts by engaging the coil pocket. Each cushion pocket is connected to an adjacent coil pocket, while each cushion pocket is self-supporting. 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. FIG. 3 is a perspective view of the pocket spring according to the first embodiment of the present invention in an unloaded state, showing a cushion pocket that acts by engaging a coil pocket having a multi-rate spring coil. 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 acts by engaging 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. 6 is a perspective view of a mattress according to another embodiment of the present invention, showing a layer of coil pockets and a layer of cushion pockets in an unloaded condition. Each cushion pocket engages and acts on a corresponding coil pocket. In this embodiment, the cushion pocket is joined to the fabric sheet to form a layer of cushion pocket. FIG. 6 is a perspective view of another embodiment of a pocket spring unit according to the present invention in an unloaded state, showing a cushion pocket engaging and directly acting on a plurality of microcoil pockets. FIG. 7 is a perspective view of a machine according to another embodiment of the present invention for manufacturing a row or strip of pocket springs each including a coil pocket and a cushion pocket. FIG. 7 is a perspective view of a machine according to another embodiment of the present invention for manufacturing a row or strip of pocket springs each including a coil pocket and a cushion pocket. FIG. 6 is a view of a double-sided mattress according to another embodiment of the present invention, with a first layer of cushion pockets located above a layer of coil pockets and an underlayer of a layer of coil pockets in an unloaded condition. And 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 releasably engaged with a layer of coil pockets in an unloaded condition. FIG. 6 is a view of a double-sided mattress according to another embodiment of the present invention, the first layer of cushion pockets releasably engaged to the top of the layers of coil pockets and the bottom of the layers of coil pockets in an unloaded state. FIG. 6B illustrates a second layer of cushion pockets that is releasably engaged with. FIG. 6 is a view of a single sided mattress according to another embodiment of the present invention showing a strip of cushion pockets releasably engaged with a layer of coil pockets in an unloaded condition. FIG. 6 is a view of a two-sided mattress according to another embodiment of the present invention, with a strip of cushion pockets releasably engaging the top of a layer of coil pockets and a bottom and removal of the layer of coil pockets in an unloaded condition. And a plurality of straps of cushion pockets for possible engagement. FIG. 6 is a view of a pocket spring according to another embodiment of the present invention with first and second micro-cushion pockets disposed over and engaging a single coil pocket. FIG. 5 is a view of a machine for producing layers of cushion pockets. FIG. 7 is a view of a machine for manufacturing cushion pockets. FIG. 6 is a view of a single sided mattress according to another embodiment of the present invention showing a layer of micro-cushion pockets releasably engaged with a layer of coil pockets in an unloaded state. FIG. 6 is a view of a single-sided mattress according to another embodiment of the present invention, in a non-loaded state, a first layer of microcushion pockets releasably engaged with a layer of coil pockets and a first layer of microcushion pockets. Figure 3 shows a second layer of microcushion pockets secured to the top of the layer. FIG. 6 is a view of a single-sided mattress according to another embodiment of the present invention, showing a layer of cushioning member in releasable engagement 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 includes a plurality of pocket springs 90 arranged generally in horizontal and vertical rows on the base 14. Each pocket spring 90 includes a cushion pocket 36 located above and juxtaposed with a coil pocket 38. The cushion pocket 36 engages and acts directly on the coil pocket 38, as more fully referred to herein. The upper surface and the side surface of the pocket spring 90 are covered with the mattress ticking cover 12. In this embodiment, there is no layer of cushioning material between the mattress ticking 12 and the cushion pocket 36, other than the fiber filler, which may be part of the quilted mattress ticking cover 12. In the illustrated embodiment, mattress 10 is a one-sided or non-inverted mattress. However, as shown in a further embodiment, mattress 10 may be a double-sided or reversible mattress that does not require base 14. The mattress 10 may be a single size, a queen size, a king size, or the like. When single size, the mattress 10 has about 294 pocket springs 90.

Referring to FIG. 5, a pocket spring 90 is shown with the cushion pocket 36 positioned above and juxtaposed with the coil pocket 38. This particular embodiment of pocket spring 90 is utilized for a one-sided, non-inverted mattress. The cushion pocket 36 produces a force when pushed by the weight of a person. The cushion pocket 36 engages and acts directly on the coil pocket 38 so that substantially all of the force from the cushion pocket 36 is transferred to the coil pocket 38. In this embodiment, the coil pocket 38 comprises a pocket 39 and a spring 20 located in the pocket 39. In the illustrated embodiment, the spring 20 is a single rate barrel spring. Spring 20 may be any other type of conventional or future developed coil spring. By way of example only, the spring 20 may be the spring of Leggett & Plat Components Europe Limited, P. O. It may be a multi-rate coil spring available under the trade name SOFT TOUCH® from Box 681, Barnsley, S72 7WB, United Kingdom (www.lpeurope.com/softtouch.asp). The side surface of the pocket 39 may be sealed by the ultrasonic thermal bond 31. However, the spring 20 may be sealed within the pocket 39 by, without limitation, a sewn seal or an adhesive pocket seal. In this embodiment, the pocket 39 is a non-woven polyester fabric. However, many other fabrics, 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, are contemplated by the present invention. Can be used in. The cushion pocket 36 includes a pocket 37 and an elastic member 32 arranged in the pocket 37. Pocket 37 is formed from the same continuous piece of fabric that is used to form pocket 39 of coil pocket 38. In this embodiment, the elastic member 32 is a cylindrical portion of open cell foam that resides within 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 is formed. Open cell foam is available from Foam Factory, Inc. , 17500 23 Mile Road, Macomb, MI 48044 (http://www.thefoamfactory.com/opencellfoam/supersoft.html). Viscoelastic open cell foam with a cubic foot density of 4 lbs is used as the elastic member 32, although many other types of foam and cushioning material may be individually or in combination in the cushion pocket 36. It may include, but is not limited to, viscoelastic foams, latex foams, polyfoams, polyfibers, downfibers, wool fibers of various densities and thicknesses, 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, without limitation, a sewing separation or an adhesive line separation. 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 approximately 2.75 inches, while the width of the cushion pocket 36 is approximately 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, pocket spring 90 includes cushion pocket 36 juxtaposed to one side of coil pocket 38 and cushion pocket 36 juxtaposed to the other side of coil pocket 38. 35 and. The cushion pocket 35 includes a pocket 41 and an elastic member 42 arranged in the pocket 41. This particular embodiment can be utilized in a non-limiting, double-sided or reversible mattress. In this and other embodiments, the elastic member 32 housed in the cushion pocket 36 may be the same as or different from the elastic member 42 housed in the cushion pocket 35. This allows the end user to effectively flip the mattress over and have a totally different cushioning response from one side of the mattress to the other. Similarly, the actual shape of the cushion pocket may be different and there is the potential that the cushion pocket 36 will have a different diameter and/or length than the diameter and/or length of the cushion pocket 35. It 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 with an ultrasonic thermal isolation bond 34. In the case of 35, it is made with a similar ultrasonic thermal isolation bond 33 (not clearly visible in the drawing). However, it is also 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, without limitation, a sewing separation or an adhesive line separation. This embodiment is not limited to a single cushion pocket on each side of the coil pocket. Additionally, two or more cushion pockets can be stacked on top of each other or side by side on top of the coil pockets to create different cushion profiles on each side of the everted mattress.

Referring 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 top of the cushion pocket 36. The cushion pocket 46 includes a pocket 47 and an elastic member 48 arranged in the pocket 47. This particular embodiment is utilized for a one-sided, non-inverted mattress. As seen in this embodiment, multiple cushion pockets can be stacked on top of each other to create different cushion profiles. Although this particular embodiment shows two cushion pockets 46 and 36 stacked in a coil pocket 38, it is not limited thereto and it is envisioned that other cushion pockets may 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 seen in this embodiment, the actual shape of the cushion pocket may be different, with the cushion pocket 36 potentially having 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, in the case of the cushion pocket 36, an ultrasonic thermal isolation bond 34. In the case of the cushion pocket 46, which has been 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 also 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. It Further, the separation bond between the cushion pockets 36 and 46 and the coil pocket 38 can be, but is not limited to, a sewing separation, a thermal bond separation, or an adhesive line separation. It is further noted that many length and width combinations of cushion pocket 36, cushion pocket 46, and coil pocket 38 are acceptable and in no way limit the scope of the invention.

Referring to FIG. 8, a partially unbroken row or unit 92 is shown that includes a plurality of pocket springs 90 made from unbroken length of fabric. The individual coil pockets 38 are separated from the next or preceding coil pockets by ultrasonic heat welding 31. The cushion pocket 36 is also formed from the same unbroken piece of fabric as the coil pocket 38. In this embodiment, the cushion pockets 36 are formed by ultrasonic heat welding 31 and pocket delineation welds 34, which are then separated from adjacent cushion pockets by cutting the fabric between each heat weld. Please note that. Cushion pockets 36 are formed from a single piece of discrete unbroken fabric, including but not limited to adhesively bonding, heat welding or stitching the cushion pocket strips to the pocket coil strips. It is also possible to fix it by any known means which is not provided. In other embodiments, the cushion pockets may remain connected to each other and the fabric between each cushion is flexible enough to allow independent movement of each cushion pocket. Further, each cushion pocket 36 may be formed from its own piece of fabric and secured to the coil pocket 38 by one of the means previously described. In this embodiment, since the cushion pockets 36 are not connected to each other, 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, elasticity R1 may be greater or less than elasticity R2. If the values of elasticity R1 and elasticity R2 are different, different comfort levels can be selectively designed.

Referring to FIGS. 9-10, in another embodiment, the pocket spring 90 is formed by a hot melt adhesive that adheres the cushion pocket 36 to the coil pocket 38. The complete pocket spring 90 is shown in FIG. Adhesive applicator 144 is shown dispensing a hot melt adhesive 146 on top of the previously formed coil pocket 38. The preformed cushion pocket 36 is then lowered onto the coil pocket 38 to form the complete pocket spring 90.

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

Referring to FIG. 12, in another embodiment, 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 airflow 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 quilted cover 12 and is free to circulate between adjacent cushion pockets 36 and adjacent coil pockets 38. This is due to the fact that there is no cushioning sheet that acts to block and limit the flow of air in and out of the mattress core. The cushion pockets 36 may also be connected to each other with excess material, allowing each coil pocket to still act individually and still allow air circulation in and out of the mattress core.

The present invention offers significant advantages over conventional mattresses. First, the use of pocket springs 90 significantly reduces the formation of depressions, resulting in a new mattress with increased comfort and useful life over conventional mattresses. Second, the use of pocket springs 90 provides better air circulation than conventional mattresses, which allows the sleeping person to sleep cooler. Third, the use of pocket springs 90 allows for selective control of the flexibility or stiffness of the cushion pocket above the individual coil pockets, thereby allowing a more complex cushion profile to be desired. Give the person more options for customizing the mattress. This is accomplished by varying the content, size, or number of cushion pockets in a series of pocket springs. Prior to the present invention, it is only possible to change the parameters of the coil spring of the coil on a coil-by-coil basis, and it is not possible to change the characteristics of the sheet-form foam cushion material of the coil on a coil-by-coil basis. It was Fourth, the use of the pocket spring 90 allows the cushioning material to be incorporated into the pocket spring 90 and does not require the additional step of inserting and securing the sheet-like cushioning material during mattress manufacture. One-sided or two-sided mattresses can be easily manufactured. Fifth, the use of the pocket spring 90 minimizes transmission of compressive forces for the sleeping person in a plane orthogonal to the plane of the pocket spring to better isolate the sleeping person's movements. prompt. Sixth, the use of pocket springs 90 eliminates the sheet cushion layer and resulting premature failure that is subject to shear forces from the sleeping person's compressive load, resulting in a longer life mattress. .. Seventh, the use of pocket springs 90 eliminates the sheet-like cushion layer and replaces it with an individually housed foam cushion pocket. Cushioned pockets are individually stored in the fabric and essentially impermeable to dust, dust mites, and other microorganisms, significantly reducing health hazards associated with conventional sheet cushions on mattresses To do. Eighth, the use of the pocket spring 90 eliminates the sheet-like cushioning layer, resulting in an amount of cushioning material from between 20% to 25% over existing pocket coil mattresses that use sheet-like cushioning material. , Thereby reducing the corresponding cost and weight associated with the additional sheet cushion material. By using the pocket spring 90, all sheet cushion material between the pocket coils of a conventional mattress is eliminated. In addition, the pocket spring 90 allows the mattress to be manufactured without the sheet-like cushioning layer associated with the development of pressure ulcers in nursing home and hospital patients.

Referring to FIG. 13, in another embodiment of the invention, mattress 150 includes a layer of cushion pockets 156, which is a distinct cushion pocket 36 that is distinct from a layer of coil pockets 158 comprised of coil pockets 38. Composed of. In this embodiment, the cushion pocket 36 is joined to a mounting member 152, which in the illustrated embodiment is a fabric sheet. Further, the fabric sheet is ideally made from a material that is quasi-isotropic in a single plane. The method for joining the cushion pocket 36 to the attachment member 152 may be, but is not limited to, a thermal bond or an adhesive. The spacing and location of the cushion pockets 36 is such that each cushion pocket is located directly above the coil pocket 38 with which it directly acts. In this embodiment, the mounting member 152 is used to position and secure the cushion pocket 36 over the coil pocket 158. However, other means of disposing and securing the cushion pocket layer 156 over the coil pocket layer 158 may be employed. For example, the attachment member 152 can be located on or between the cushion pockets 36. Further, the mounting member 152 can be constructed of, but is not limited to, a porous material. It is air permeable or perforated so it does not restrict the flow of air between layer 158 of coil pockets and layer 156 of cushion pockets.

From the pit effect to the trampoline effect, many of the problems of using sheet-like foam in mattresses are described in this application. However, one of the advantages of using sheet-like foams in mattresses 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 resisting lateral movement of the sleeping person. The same elements that reduce sleep comfort also prevent the mattress core from shifting under the load and movement of the lateral sleeper. A major advantage of using a mounting layer between the layer of pocket coils and the layer of cushion pockets is that it imparts lateral stability to the spring core that is lost when the sheet foam is removed. This is due to the fact that the attachment layer has the property of providing quasi-isotropic, in-plane strength, indicating in-plane shear strength, consistent with the fibers of the fabric being dispersed in the plane of the fabric. To do. This in-plane strength helps stabilize the pocket coil unit when subjected to lateral loads.

Another advantage of a cushion pocket attached to a separate attachment layer is that it creates a separate pocket cushion layer. This layer can be manufactured and stored separately from the pocket coil layer and independently. This provides the manufacturer with much greater flexibility during the manufacturing process of matching different cushion layers and their associated properties with different pocket coil spring layers and their properties. The possible number of custom combinations is then in combination with the base cushion pocket layer, which is an exponential expansion of the number of base pocket coil spring units. For example, by combining 3 different pocket coil spring elements with 3 different cushioning elements, the manufacturer gets 9 possible custom combinations. Using 5 different cushion pocket element layers, increasing the number of pocket coil spring units to 5 would result in 25 possible custom units. The addition of the second cushion layer increases the number of possible custom units to 125 units. This provides the manufacturer with considerable custom manufacturing flexibility, requiring only a limited number of basic component inventories. A further advantage of using separate mounting layers is that they can be located above all pocket coil core units, from as few as two attachment points to as many as full pocket coils. Further, the type of attachment site may vary depending on the mattress manufacturer's goals. Clip-type fittings can be utilized to make the cushion pocket layer removable, replaceable, and washable. It is then conceivable that the mattress retailer will change the comfort layer at the request of the customer, for example soft to hard. The retail store then re-mattes the mattress by just unclipping one pocket cushion layer by simply storing the different pocket cushion layers in the store and clipping another pocket cushion layer with different cushion properties. Can be configured. This allows retailers 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, multiple pocket cushion mounting layers can be placed on top of each other and each layer 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 over the layer of foam cushion pocket and clipped on it to create a completely different look and feel than a mattress. Coupling this with different heights, removable mattress covers, and levels of retail customization is endless. At the same time, by mixing and combining the components of different mattresses, the customer can create a purely custom bed in the retail store to his liking, greatly improving the customer's experience.

A disadvantage of manufacturing pocket coil springs with integral cushion pockets is that the cushion pockets need to be separated from each other after manufacture, as described in connection with FIGS. This requirement requires that the cushion pocket be smaller than the pocket coil pocket. This is because it is necessary to seal additional material between the cushion pockets and separate them from each other. This is a serious drawback, because the smaller the cushion pocket, the less area the sleeping person can support. 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 diameter of the pocket of the pocket coil. This increases the cross-sectional area of the pocket cushion, and can further support the sleeping person.

In a further embodiment, it is envisioned that rather than mounting all of the cushion pockets on a single mounting layer, individual mounting layer strips are utilized and a series of pocket coils are mounted on the mounting layer strip. The mounting strips are attached to the coil pocket strips such that the cushion pocket mounting strips are oriented at right angles to the direction of the pocket coil strips. In this way, the pocket coil core is provided with lateral stability support. It is also possible to apply a single strip around the outer row or rows of pocket coils to effectively create 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 comprises a cushion pocket 210 engaged with and directly acting on a plurality of microcoil pockets 220. In the illustrated embodiment, the cushion pocket is positioned and juxtaposed above the microcoil pocket 220. 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. The pocket 212 is sealed by heat welding 215. Cushion pocket 210 engages and acts directly on microcoil pocket 220 such that substantially all of the force from cushion pocket 210 is transferred to microcoil pocket 220. The pockets 224 of the microcoil pocket 220 may be connected to each other by thermal welding 226. As in other embodiments, the pockets 224 of the microcoil pocket 220 are made from non-woven fabric. 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 with any desired elasticity. The multi-rate pocket spring 200 is created by changing the spring characteristics of the micro springs 222 located in the pockets 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 that is identical to the pocket springs 90 previously described. The machine 300 generally comprises a base conveyor 302 that supports multiple layers of fabric and is adapted to move to various forming and cutting stations. The machine 300 further comprises a lower fabric roll 304 including a bottom fabric 305 and an upper fabric roll 306 including a top fabric 307. The lower fabric roll 304, together with the upper fabric roll 306, simultaneously supplies both the bottom fabric 305 and the top fabric 307 to the base conveyor 302, respectively. 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. be able to. Forming the side surface of the coil pocket 308 is a pocket coil drawing line 310 formed by the ultrasonic bonding horn 312. Forming the side surface of the cushion pocket 314 is a cushion pocket drawing line 316 formed by the ultrasonic bonding horn 319. In this embodiment, all delineation is done via ultrasonic welding and ultrasonic welding horns. 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, may be used. The cushion pocket 314 is directly above the coil pocket 308. However, there are twice as many cushion pocket lines 316 as there are pocket coil lines 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 independently compressed without affecting adjacent cushion pockets 314. Further, the ultrasonic bonding horn 318 forms a drawing line 320 between the coil pocket 308 and the corresponding cushion pocket 314. Initially, the uncompressed spring 322 is compressed by any one of known compression devices and techniques into a compression coil spring 324. A compression coil spring 324 is inserted between the upper and lower fabric portions into the previously formed coil pocket 308. Note that a compression coil spring 324 is loaded into each coil pocket 308 in a direction that is 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 has been sealed, the compression coil spring 324 is designed to reorient the compression coil spring 324 to the non-compression coil spring 322, some known techniques. By hitting with either of the means, it is reoriented to the correct plane. This reorientation is possible because the compression coil spring 324 has sufficient potential energy stored in the compressed state that it can orient itself in the coil pocket 308 with a small amount of stimulation. Is. At about the same time that the compression coil spring 324 is loaded into its 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 compressed foam cushion cylinder 326 is not sufficient to correct the orientation of the cushion cylinder, so the insertion of the foam cushion cylinder 326 will result in the correct orientation. To maintain. Another unique aspect of the invention is to cut individual foam cushion cylinders 326 from longer foam cylinders 328 with a cutting knife 330. It should be noted that the knife 330 may 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 major advantage of using the 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 figure after the initial coil pocket 308 and cushion pocket 314 formation. As the top and bottom fabric continues 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 forming a cushion pocket seal line 338. After the complete pocket spring 340 is formed, the ultrasonic cutting horn 342 is used to cut the fabric portion 344 between adjacent cushion pocket lines 316. This results in a finished pocket coil cushion pocket string of any length pre-programmed to be manufactured. By changing and/or adjusting the size of the ultrasonic bonding horn, it is possible to cut into different pocket lengths, which in turn allows cutting into various cushion pocket lengths. Facilitates customizing individual mattresses and creating more flexible manufacturing systems that allow different styles of foam cushions to be made for different customers.

Referring to FIG. 16, a machine 400 according to another embodiment of the present invention is shown for making a row or strip 440 of pocket springs. The machine 400 generally comprises a base conveyor 402 that supports multiple layers of fabric and is adapted to move to various forming and cutting stations. The machine 400 further includes a fabric roll 404, which 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 the 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 nonwovens composed of blends of polyester, polypropylene, nylon, and fabrics. obtain. Forming the side surface of the coil pocket 408 is a pocket coil drawing line 410 formed by the ultrasonic bonding horn 412. Forming the side surface of the cushion pocket 414 is a cushion pocket drawing line 416 formed by the ultrasonic bonding horn 419. In this embodiment, all delineation is done via ultrasonic welding and ultrasonic welding horns. 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, may also be used. The cushion pocket 414 is 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 the fabric must be cut between the cushion pockets 414, allowing each cushion pocket 414 to be independently compressed 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. Insertion of the foam cushion cylinder 426 maintains the correct orientation because the potential energy stored in the compressed foam cushion cylinder 426 is not sufficient to correct the orientation of the cushion cylinder unless the cushion cylinder is initially oriented correctly. To do. Another unique aspect of the invention is to cut individual foam cushion cylinders 426 from longer foam cylinders 428 with a cutting knife 430. It should be noted that the knife 430 may 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 major 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 drawing line 420 between the coil pocket 408 and its corresponding cushion pocket 414. The folded fabric 406 is then advanced to the coil spring loading station. The uncompressed spring 422 is compressed by any one of known compression devices and techniques into a compression coil spring 424. The compression coil spring 424 is inserted between the upper and lower folds of the folded fabric 406 and into the coil pocket 408 previously formed. Note that the compression coil springs 424 are loaded into each coil pocket 408 in an orientation 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 has been sealed, the compression coil spring 424 is designed to reorient the compression coil spring 424 relative to the uncompressed coil spring 422. By hitting any of the known means, it is reoriented to the correct plane. This reorientation is possible because the compression coil spring 424 has sufficient potential energy stored in the compressed state that it can orient itself in the coil pocket 408 with a small amount of stimulation. Is. For the purpose of illustrating this, and to better illustrate the overall process, after the formation of the initial coil pocket 408 and cushion pocket 414, the top portion of the folded fabric 406 is removed from this figure. As the folded fabric 406 continues to advance through the conveyor 402, the coil pocket 408 is sealed by the ultrasonic bonding horn 432 forming a coil pocket seal line 434. Note that the cushion pocket 414 need not be sealed. This is because the folds of fabric 406 provide a natural seal for cushion pocket 414. After the complete pocket spring 440 is formed, the ultrasonic cutting horn 442 is used to cut the fabric portion 444 between adjacent cushion pocket lines 416. This produces a pre-programmed finished pocket coil cushion pocket string of any length.

In another embodiment, the method uses a cylindrical tube of cushioning material (foam) to dispense into the cushioning pocket so that the cushioning material is always correctly oriented relative to the preformed pocket. Including the step of performing. The method further comprises slicing individual lengths of foam from the cylindrical tube of cushioning material prior to insertion into the pocket. The method further includes precompressing the foam using a compression set of jaws that is easily inserted into the pocket and maintains its final orientation during the insertion process. Alternatively, a compression set of jaws is used to precompress the ends of the foam cylinder, insert the foam cylinder into a prefabricated fabric pocket, and cut the foam after insertion to create individual foam cylinders in the fabric pocket.

In another embodiment, the method comprises folding an unbroken piece of fabric. The method further comprises the step of forming a line of the two pockets tangent to the movement of the fabric 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 on the top of the fabric. The method further includes sealing the fourth side of the first cushion pocket. The method further provides for creating a length of intermediate cushion pocket fabric that allows the first cushion pocket to be fully compressed without straining the uncompressed second cushion pocket. Including moving the fabric and the first cushion pocket a sufficient distance. The method further comprises the step of forming a delineation of the two pockets tangent to the movement of the fabric 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 top fold of the fabric. The method further includes sealing the fourth side of the second cushion pocket. Continue to form cushion pocket strips in a defined manner. The method further comprises gluing a continuous cushion pocket strip over the prefabricated 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 another embodiment, the method includes the step of folding onto an unbroken piece of fabric. The method further comprises forming two pocket stroke lines tangent to the movement of the fabric 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 on the top of the fabric. The method further includes sealing the fourth side of the first cushion pocket. The method further includes trimming individual cushion pockets. The method further comprises the step of joining the individual cushion pockets onto a prefabricated pocket coil strip in which each cushion pocket lies directly above or below the pocket coil spring. Continue to bond 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, mattress 500 includes a cushion pocket top layer 508 secured to the top of coil pocket layer 502 as described in the embodiment of FIG. The upper layer of cushion pocket 508 is separate and distinct from layer 502 of the coil pocket. In this embodiment, mattress 500 further comprises a bottom layer 518 of cushion pockets secured to the bottom of layer 502 of coil pockets. The bottom layer 518 of the cushion pocket is separate and distinct from the coil pocket layer 502. In this manner, the mattress 500 provides a two-sided mattress that can be turned inside out. Further, the top layer of the cushion pocket 508 can have a resilience R1 and/or softness that is different from the resilience and/or softness of the bottom layer 518 of the cushion pocket. 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 in the pocket 505. The upper layer of cushion pocket 508 includes a mounting member 510 having an upper surface 511 and a lower surface 513, respectively, and a plurality of cushion pockets 512 secured to the upper layer 511. Each of the cushion pockets 512 comprises a pocket 514 and a cushion member 516 disposed within each pocket 514. The lower layer 518 of the cushion pocket includes a mounting member 520 having an upper surface 521 and a lower surface 523, respectively, 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 mounting members 510 and 520, respectively, which in the illustrated embodiment are fabric sheets. The spacing and position of the cushion pockets 512 is such that each cushion pocket in the upper layer of the cushion pocket 508 is located directly above the coil pocket 505 on which it directly acts. Similarly, the spacing and location of the cushion pockets 522 is such that each cushion pocket in the lower layer 518 of the cushion pockets is located directly below the coil pocket 505 on which it directly acts. 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. Coil spring 506 can be any type of spring, such as a multi-rate coil spring.

Referring to FIG. 18, in another embodiment, mattress 600 has a cushion pocket attached to the top layer of coil pocket 602 by a mechanical clip 620 inserted through grommet 618 and through coil spring 606. Of the upper layer 608. As in FIG. 13, the cushion pocket 612 is joined to the mounting member 610, which in this embodiment is a fabric sheet made from a material that is quasi-isotropic. Further, as in FIG. 13, the spacing and position 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 cushion pocket top layer 608 is separate and distinct from the coil pocket layer 602. Although one type of clip and grommet combination is shown, one of ordinary skill in the art can clamp on the fabric attachment layer 610 and mechanically clamp the coil pocket 604 and the housed coil spring 606. It should be clear that a mechanical clip of is also feasible. Alternatively, the clips or fasteners can be attached directly to the typically used border wires or rods. Such a mechanical clamping device may eliminate the need to provide the mounting layer 610 with the grommet 618. All of the advantages described in the description of the embodiment of FIG. 13 are available in this embodiment. Additionally, the use of mechanical fasteners 620 allows a manufacturer, retail store, or end user to easily attach or remove cushion pocket layer 608 from coil pocket layer 602 by attachment member 610. The ability to add or remove the top layer 608 of the cushion pockets provides the manufacturer with considerable manufacturing flexibility in manufacturing the mattress. For example, a manufacturer may reduce the inventory of mattress parts, store several pocket coil units along with an assortment of cushion pocket layers, mix and match these two components during assembly, and Can produce mattress models. For retail stores, the cushion pocket layers can be replaced on a short-term basis, allowing the store to hold one demonstration unit with a layer 602 of coil springs inside the mattress cover 12, which is the mattress cover. Unzipping 12 with zipper 630 allows access, which allows the store to change cushioning layer 608 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 pocket layers 608 with pocket coil layers 602. At the same time, end users, who may decide to change the comfort of the mattress in the future, remove the cushion pocket layer 608 by releasing the mechanical clip 620, and the cushion pocket layer 608 is replaced with a different cushion member. It has the potential to be replaced with one having a elasticity of 616.

Referring to FIG. 19, in another embodiment of the invention, mattress 700 includes a cushion pocket top layer 708, which is inserted by a mechanical clip 732 inserted through grommets 730 and through coil springs 706. Secured to the top of layer 702 of coil pockets. The cushion pocket top layer 708 is separate and distinct from the coil pocket layer 702. In this embodiment, the mattress 700 further comprises a lower layer 718 of cushion pockets, which is secured to the bottom of layer 702 of coil pockets by a mechanical clip 736 inserted through grommets 734 and via coil springs 706. To be done. Although one type of clip and grommet combination is shown, it should be apparent to one of ordinary skill in the art that other forms of mechanical clips are possible. In such a mechanical clamping device, it is possible to eliminate the need to provide the mounting layer 710 with the grommet 730 and the mounting layer 720 with the grommet 734. The bottom layer 718 of the cushion pocket is separate and distinct from the coil pocket layer 702. In this manner, the mattress 700 provides a two-sided mattress that can be flipped over. Further, the upper layer 708 of the cushion pocket can have a resilience El and/or softness that is different from the resilience and/or softness of the lower layer 718 of the cushion pocket. 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, respectively, and a plurality of cushion pockets 712 secured to the upper surface 711. Each cushion pocket 712 includes a pocket 714 and a cushion member 716 disposed within each pocket 714. The lower layer 718 of the cushion pocket includes a mounting member 720 having an upper surface 721 and a lower surface 723, respectively, and a plurality of cushion pockets 722 fixed to the lower surface 723. Each cushion pocket 722 includes a pocket 724 and a cushion member 726 disposed within each pocket 724. As in the embodiment of FIG. 13, cushion pockets 712 and 722 are joined to mounting members 710 and 720, respectively, which in the illustrated embodiment are fabric sheets. The spacing and location of the cushion pockets 712 is such that each cushion pocket in the cushion pocket upper layer 708 is directly above the coil pockets 705 on which it directly acts. Similarly, the spacing and location of the cushion pockets 722 is such that each cushion pocket in the lower layer 718 of the cushion pockets is located directly below the coil pockets 705 with which it directly acts. As in the previous embodiments, 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. Coil spring 706 can be any type of spring, such as a multi-rate coil spring. As in FIG. 13, the cushion pocket 712 is joined to the mounting member 710, which in the present embodiment is a fabric sheet made of a quasi-isotropic material. The cushion pocket 722 is joined to the mounting member 720, which in this embodiment is a fabric sheet made from a material that is quasi-isotropic. Also, as in FIG. 13, the spacing and position of the cushion pockets 712 is such that each cushion pocket 712 is located directly above the coil pocket 705 on which it directly acts. The spacing and location of the cushion pockets 722 is such that each cushion pocket 722 is located directly below the coil pocket 705 on which it directly acts. 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, in this double-sided mattress embodiment, all of the benefits of using mechanical fasteners are available.

Referring to FIG. 20, in another embodiment, the mattress 800 comprises a top layer of compartmentalized cushion pockets, thereby imparting different pocket cushioning properties in different areas of the sleeping surface. In this particular embodiment, the cushion layer is made up of three alternating rows of cushion pockets. For the purposes of this discussion, each compartmented row of foam cushioning elements is varied in terms of foam resilience. Other compartmentalization possibilities may include, but are not limited to, different cushion pocket shapes, different cushioning materials, and different combinations and shapes of cushion attachment layers. Zone number 1 includes a row of cushion pockets 807 that are attached to the top layer 802 of coil pockets by mechanical clips 820 inserted through grommets 825 and through coil springs 806. As in FIG. 13, the cushion pocket 812 is joined to the upper surface 840 of the mounting member 810 and, in this embodiment, is a fabric sheet made from a material that is quasi-isotropic. Also, as in FIG. 13, the spacing and position of the cushion pockets 812 are such that each cushion pocket 812 is located directly above the coil pocket 805 that acts directly. In this embodiment, the cushion pocket 812 has a foam cushion member 816 that has resiliency R1. Note that the cushion pocket top layer 812 is separate and distinct from the coil pocket layer 802. Although one type of clip and grommet combination is shown, those of ordinary skill in the art will be able to clamp on fabric attachment layer 810 and mechanically clamp to coil pocket 804 and housed coil spring 806. It should be clear that a mechanical clip of is feasible. With such a mechanical clamping device, the need to provide the mounting layer 810 with the grommet 825 can be eliminated. Zone number 2 includes a row of cushion pockets 808 attached to the top layer 802 of coil pockets by mechanical clips 822 inserted through grommets 826 and through coil springs 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 of a quasi-isotropic material. Also, as in FIG. 13, the spacing and position of the cushion pockets 832 is such that each cushion pocket 832 is located directly above the coil pocket 805 that acts directly. In this embodiment, the cushion pocket 832 has a foam cushion member 836 with resilience R2. Note that the top layer of cushion pocket 832 is separate and distinct from coil pocket layer 802. Although one type of clip and grommet combination is shown, those of ordinary skill in the art will be able to clamp on the fabric attachment layer 811, mechanically clamp to the coil pocket 804 and the housed coil spring 806. It should be clear that a mechanical clip of is also feasible. Such a mechanical clamping device can eliminate the need to provide the mounting 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 coil pockets by mechanical clips 824 that are inserted through grommets 827 and through coil springs 806. As in FIG. 13, the cushion pocket 842 is joined to the upper surface 844 of the mounting member 813, which in this embodiment is a fabric sheet made from a material that is quasi-isotropic. Further, as in FIG. 13, the intervals and positions of the cushion pockets 842 are located directly above the coil pockets 805 on which the cushion pockets 842 directly act. In this embodiment, the cushion pocket 842 has a foam cushion member 846 with resilience R3. Note that the top layer of cushion pocket 842 is separate and distinct from coil pocket layer 802. Although one type of clip and grommet combination is shown, those of ordinary skill in the art will be able to clamp on the fabric attachment layer 813 and mechanically clamp on the coil pocket 804 and the housed coil spring 806. It should be clear that mechanical clips in form are also feasible. In such a mechanical clamping device, it is possible to eliminate the need to provide the mounting 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. In addition, the use of mechanical fasteners 820, 822 and 824 allows the manufacturer to easily attach or remove the compartmentalized layer of cushion pockets from layer 802 of coil pockets. 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 get an almost infinitely comfortable profile. 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 compartmentalized cushion pocket top and bottom layers, thereby imparting various pocket cushioning properties to different areas of a lying surface. Additionally, mattress 900 provides a double-sided mattress that can be flipped over. Furthermore, the upper layer of the cushion pocket may have a resilience E1 and/or flexibility that is different from the resilience 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 made up of three alternating rows of cushion pockets. For the purposes of this discussion, the elements of the foam cushion in each compartmentalized row are diverse in terms of foam resilience. Other compartmentalization possibilities may include, but are not limited to, different cushion pocket shapes, different cushioning materials, and different combinations and shapes of cushion attachment layers. Zone number 1 includes a row of cushion pockets 910 attached to the top layer of coil pockets 905 by mechanical clips 917 inserted through grommets 918 and through coil springs 906. As in FIG. 13, the cushion pocket 914 is joined to the upper surface 912 of the mounting member 911, which in this embodiment is a fabric sheet made from a material that is quasi-isotropic. Also, as in FIG. 13, the intervals and positions of the cushion pockets 914 are located directly above the coil pockets 905 on which the cushion pockets 914 directly act. In this embodiment, the cushion pocket 914 has a foam cushion member 916 that has resiliency R1. Note that the top layer of cushion pocket 914 is separate and distinct from coil pocket layer 902. Although one type of clip and grommet combination is shown, those skilled in the art will be able to clamp onto the fabric attachment layer 911 and mechanically clamp onto the coil pocket 904 and the housed coil spring 906. It should be clear that a mechanical clip of is also feasible. Such a mechanical clamping device may obviate the need to provide grommets 918 on attachment layer 911. Zone number 2 includes a row of cushion pockets 920 attached to the top layer of coil pockets 902 by mechanical clips 927 inserted through grommets 928 and through coil springs 906. As in FIG. 13, the cushion pocket 924 is joined to the upper surface 922 of the mounting member 921, which in this embodiment is a fabric sheet made from a material that is quasi-isotropic. 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 directly acts. In this embodiment, the cushion pocket 924 has a foam cushion member 926 with resiliency R2. Note that the top layer of cushion pocket 924 is separate and distinct from coil pocket layer 902. Although one type of clip and grommet combination is shown, those of ordinary skill in the art will be able to clamp on the fabric attachment layer 921 and mechanically on the coil pocket 904 and the housed coil spring 906. It should be clear that mechanical clips in the form of are also feasible. Such a mechanical clamping device may obviate the need for grommet 928 on attachment layer 921. Zone number 3 includes a row of cushion pockets 930 attached to the top layer of coil pockets 902 by mechanical clips 937 inserted through grommets 938 and through coil springs 906. As in FIG. 13, the cushion pocket 934 is joined to the upper surface 932 of the mounting member 931 which in this embodiment is a fabric sheet made from a material that is quasi-isotropic. In addition, as in FIG. 13, the spacing and position of the cushion pockets 934 are located directly above the coil pockets 905 on which each cushion pocket 934 directly acts. In this embodiment, the cushion pocket 934 has a foam cushion member 936 with resiliency R3. Note that the top layer of the cushion pocket 934 is separate and distinct from the coil pocket layer 902. Although one type of clip and grommet combination is shown, one of ordinary skill in the art can clamp on the fabric attachment layer 931 and mechanically clamp the coil pocket 904 and the housed coil spring 906. It should be clear that a mechanical clip of is also feasible. With such a mechanical clamping device, it is possible to eliminate the need to provide the mounting 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. In addition, the use of mechanical fasteners 917, 927 and 937 allows the manufacturer to easily attach or remove the compartmented layer of the cushion pocket from the layer 902 of the coil pocket. Completely changing the mattress comfort configuration by varying the cushion pocket compartmentalized layers 910, 920 and 930 and the corresponding resilient compartmentalized regions R1, R2 and R3. , Which gives the manufacturer an almost infinitely comfortable profile. At the same time, the manufacturer need only store a few different layers of cushion pockets to achieve this flexibility. Furthermore, this mattress is double-sided and is likewise compartmentalized on the side of the other mattress having zone 4, zone 5 and zone 6. Zone number 4 includes a row of cushion pockets 940 attached to the bottom layer 902 of coil pockets by mechanical clips 947 inserted through grommets 948 and through coil springs 906. The cushion pocket 940 is adhered to the bottom surface 941 of the mounting member 943, which in this embodiment is a fabric sheet made from a material that is quasi-isotropic. As in FIG. 13, the spacing and position of the cushion pockets 940 should be directly below the coil pockets 905 on which each cushion pocket 940 acts directly. In this embodiment, the cushion pocket 944 has a foam cushion member 946 with resiliency R4. Zone number 5 includes a row of cushion pockets 950 that are attached to the bottom layer 902 of coil pockets by mechanical clips 957 inserted through grommets 958 and through coil springs 906. The cushion pocket 950 is joined to the bottom surface 951 of the mounting member 953, which in this embodiment is a fabric sheet made of a quasi-isotropic material. As in FIG. 13, the spacing and position of the cushion pockets 950 should be directly below the coil pockets 905 on which each cushion pocket 950 acts directly. In this embodiment, the cushion pocket 954 has a foam cushion member 956 with resilience R5. Zone number 6 includes a row of cushion pockets 960 attached to the bottom layer 902 of coil pockets by mechanical clips 967 inserted through grommets 968 and through coil springs 906. The cushion pocket 960 is joined to the bottom surface 961 of the mounting member 963, which in this embodiment is a fabric sheet made of a quasi-isotropic material. As in FIG. 13, the spacing and position of the cushion pockets 960 are such that each cushion pocket 960 is located directly below the coil pocket 905 on which it directly acts. In this embodiment, the cushion pocket 964 has a foam cushion member 966 that has resiliency 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.

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. In addition, the second cushion pocket 1014 engages and acts directly on the coil pocket 1002. In the illustrated embodiment, each cushion pocket is located 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 arranged in the pocket 1010. The cushion pocket 1014 includes a pocket 1016 and an elastic member 1018 arranged in the pocket 1016. The cushion pocket 1008 is engaged with and acts directly on the coil pocket 1002, transferring substantially all of the force from the cushion pocket 1008 to the coil pocket 1002. The cushion pocket 1014 engages and acts directly on the coil pocket 1002 so that substantially all of the force from the cushion pocket 1014 is transferred to the coil pocket 1002. As in other embodiments, the pocket 1004 of the coil pocket 1002 is made from non-woven fabric. 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 non-woven fabric and connected to the coil pocket 1002 by adhesive or other conventional means. As in other embodiments, the pocket 1014 of the cushion pocket 1016 may be made from 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 elastic modulus R2. Elasticity R1 may be the same as elasticity R2, or may be designed to have different elasticity to create a multi-rate cushion assembly. It is also possible that the first cushion pocket 1008 has a different shape than the second cushion pocket 1014. Due to the different shapes of the two cushion pockets, R1 of cushion pocket 1008 differs from R2 of cushion pocket 1014, thereby creating a multi-rate cushion assembly. Furthermore, the 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 invention for making individual pocket cushions 1130 and attaching them to a mounting layer 1134 supplied from a mounting roll 1132. The machine 1100 generally includes a base conveyor 1108 adapted to support and move multiple layers of fabric to various forming and cutting stations, and a mount layer conveyor 1138 adapted to move a mount layer fabric 1134. Equipped with. The machine 1100 further includes a fabric roll 1110 that includes unfolded fabric 1112 that passes through any of the known fabric folding mechanisms into a folded fabric 1113. The fabric roll 1110 feeds the fabric 1112 to the known folding mechanism and on the base conveyor 1108. Many fabrics can be used in the present invention and include 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, It is not limited to them. Forming the side surface of the cushion pocket 1126 is a cushion pocket drawing line 1128 formed by the ultrasonic bonding horn 1116. In this embodiment, all delineation is done by ultrasonic welding and ultrasonic welding horns. However, it is envisioned that other types of bonding devices and bonding horns, such as thermal bonding horns or thermal bonding with thermally bondable fabrics, may 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. Insertion of the foam cushion cylinder 1122 is not possible because the potential energy stored in the compressed foam cushion cylinder 1122 is not sufficient to correct the orientation of the cushion cylinder unless the cushion cylinder is initially oriented correctly. Maintain the right orientation. Another unique aspect of the invention is to cut individual foam cushion cylinders 1122 from longer foam cylinders 1120 with a cutting knife 1121. The method further comprises slicing individual lengths of foam from the cylindrical tube 1120 of cushioning material prior to insertion into the pocket. This allows the size of each cushion foam cylinder to be pre-programmed and changed. In doing this, various areas of the cushion pocket wearing layer having different sized foam cushion pockets 1130 can be compartmentalized. 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 mounting layer. Note that the knife 1121 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 major 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 comprises the step of using a compression set of jaws to pre-compress the foam so that it is easily inserted into the pocket and maintains its final orientation during the insertion process. Alternatively, a compression set of jaws is used to pre-compress the ends of the foam cylinder, insert the foam cylinder into a prefabricated fabric pocket, and then cut the foam 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 drawing line that seals the cushion pocket 1126. The folded fabric 1113 then proceeds to the pocket cushion spring cutoff station. For purposes of illustrating this and to better illustrate the overall process, the top portion of folded fabric 1113 is removed from this figure after the initial cushion pocket 1126 is formed. As the folded fabric 1113 continues to advance through the conveyor 1108, the cushion pocket 1126 is separated from the advancing 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 mounting layer conveyor 1138. In this embodiment, an adhesive applicator 1136 lays down the 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 entire mounting layer 1134 and mounting layer conveyor 1138 are movable in two axes in the material plane of the mounting layer 1134, allowing the pocket cushion 1130 to be mounted in any predetermined position on the mounting layer 1134.

Referring to FIG. 24, a machine 1200 according to another embodiment of the invention for manufacturing 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, which includes an unfolded fabric 1212 that passes through any one of the known fabric folding mechanisms into a folded fabric 1213. The fabric roll 1210 feeds the fabric 1212 into the known folding mechanism and onto the base conveyor 1208. Many fabrics can be used in the present invention and include 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, It is not limited to them. Forming the side surface of the cushion pocket 1226 is a cushion pocket drawing line 1228 formed by the ultrasonic bonding horn 1214. In this embodiment, all delineation is done by ultrasonic welding and ultrasonic welding horns. However, it is envisioned that other types of bonding devices and bonding horns, such as thermal bonding with a fabric that can be thermally bonded with a thermal bonding horn, may be used. 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. Insertion of the foam cushion cylinder 1222 is not possible because the potential energy stored in the compressed foam cushion cylinder 1222 is not sufficient to correct the orientation of the cushion cylinder unless the cushion cylinder is initially oriented correctly. , Maintain the right orientation. Another unique aspect of the invention is to cut individual foam cushion cylinders 1222 from longer foam cylinders 1220 with a cutting knife 1221. The method further comprises slicing individual lengths of foam from the cylindrical tube 1220 of cushioning material prior to insertion into the pocket. It should be noted 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 major advantage of using a long foam cylinder 1220 within 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 comprises the step of pre-compressing the foam using a compression set of jaws so that it is easily inserted into the pocket and maintains its final orientation during the insertion process. Alternatively, a compression set of jaws is used to pre-compress the ends of the foam cylinder, insert the foam cylinder into a prefabricated fabric pocket, and then cut the foam 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 line that seals the cushion pocket 1226. The folded fabric 1213 then proceeds to the pocket cushion spring cutoff station. For purposes of illustrating this, and to better illustrate the overall process, the top portion of folded fabric 1213 is removed from this figure after the initial cushion pocket 1226 is formed. As the folded fabric 1213 continues to advance on the conveyor 1208, the cushion pocket 1226 is separated from the advancing folded fabric 1213 by the ultrasonic cutting horn 1218. After the complete pocket cushion 1230 is formed, it can be deposited in a hopper (not shown) and later used in an assembly machine to create the pocket cushion attachment layer.

Referring to FIG. 25, in another embodiment, a mattress 1300 has a microcushion attached to the top layer 1302 of a coil pocket by a mechanical clip 1320 inserted through a grommet 1318 and through a coil spring 1306. It comprises an upper layer 1308 of the pocket. As in FIG. 13, the microcushion pocket array 1311 is bonded to the upper layer 1318 of the attachment member 1310, which in this embodiment is a fabric sheet made from a material that is quasi-isotropic. Note that the top layer 1308 of the microcushion pocket is separate and distinct from the layer of coil pocket 1302. Also, as in FIG. 13, the spacing and position of the microcushion pocket array 1311 is such that each microcushion pocket array 1311 is located 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 in the microcushion array 1311 has a fabric pocket 1312 that houses a resilient R1 foam element 1313. The second microcushion of the microcushion array 1311 has a fabric pocket 1314 that houses a resilient R2 foam element 1315. The third microcushion of the microcushion array 1311 has a fabric pocket 1316 that houses a resilient R3 foam element 1317. These three different foam element resiliences R1, R2, R3, which make up the cushion elements of the microcushion array 1311, achieve variable speed cushioning with different flexibility depending on how strongly and quickly the cushion elements are pushed. can do. The fabric pocket 1312 can also 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 pockets, R1 of the cushion pocket 1312 can have different cushion pocket 1314 R2 than R3 of 1316, thereby creating a multi-rate micro cushion assembly. Although one type of clip and grommet combination is shown, those skilled in the art will appreciate 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. With such a mechanical clamping device, the need to provide grommets 1318 on attachment layer 1310 can be eliminated. 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 1320 allows a manufacturer, retail store, or end user to 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 pockets provides the manufacturer with considerable manufacturing flexibility in manufacturing the mattress. For example, a manufacturer could reduce the inventory of mattress parts, store a few pocket coil units together with an assortment of cushion pocket layers, mix and match these two components during assembly, and Mattress models can be created. For retail stores, the cushion pocket layers can be replaced on a short-term basis, allowing the store to hold one demonstration unit with a layer 1302 of coil springs inside the mattress cover 12, which is the mattress cover. Unzipping 12 with a zipper 1330 allows access, which allows the store to alter the microcushion layer 1308 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 microcushion pocket layers 1308 with pocket coil layers 1302. At the same time, the end user, who may decide to change the comfort of the mattress to a future date, potentially removes the cushion pocket layer 1308 and releases the cushion pocket layer 1308 by releasing the mechanical clip 1320. It can be replaced by one having a different cushion member comfort level.

Referring to FIG. 26, in another embodiment, the mattress 1400 includes a cushion pocket attached to the upper layer 1402 of the coil pocket by a mechanical clip 1420 inserted through the grommet 1418 and through the coil spring 1406. Includes top layer 1408. As in FIG. 13, the cushion pocket 1412 is joined to a mounting member 1410, which in this embodiment is a fabric sheet made from a material that is quasi-isotropic. Also, as in FIG. 13, the spacing and location of the cushion pockets 1412 is such that each cushion pocket 1412 is located directly above the coil pocket 1405 on which it directly acts. The cushion cushion top layer 1408 is separate and distinct from the coil pocket layer 1402. The upper layer of cushion pockets 1408 includes attachment members 1410, each having a bottom surface 1413 and a top surface 1411 and a plurality of cushion pockets 1412 secured to the top surface 1411. Although one type of clip and grommet combination is shown, one of ordinary skill in the art could clamp on fabric attachment layer 1410 to mechanically clamp on coil pocket 1404 and housed coil spring 1406. It should be clear that a mechanical clip of is also feasible. Such a mechanical clamping device may eliminate the need to provide the mounting layer 1410 with the grommet 1418. All of the advantages described in the description of the embodiment of FIG. 13 are available in this embodiment. In addition, the use of mechanical fasteners 1420 allows a manufacturer, retail store, or end user to easily attach or remove cushion pocket layer 1408 from coil pocket layer 1402 by attachment member 1410. In addition, the second cushion pocket layer 1422 is made up of cushion pockets 1424, which are joined to the attachment layer 1423, which is directly above the cushion layer 1408, so that all cushion pockets 1424 are in the cushion layer 1408. It 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 also envisioned that other joining means such as non-limiting mechanical joining may be used. The ability to add or remove the top layers 1408 and 1422 of the cushion pockets gives the manufacturer considerable flexibility in manufacturing the mattress. For example, a manufacturer could reduce the inventory of mattress parts, store a few pocket coil units together with an assortment of cushion pocket layers, mix and match these two components during assembly, and Mattress models can be created. For retail stores, the cushion pocket layers can be replaced on a short-term basis, allowing the store to hold one demonstration unit with a layer 1402 of coil springs inside the mattress cover 12, which is the mattress cover. Unzipping 12 with a zipper 1430 allows access, which allows the store to change 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 preference by mixing different matching cushion pocket layers 1408 and 1422 with the pocket coil layer 1402. The potential mixing of different layers of different pocket spring coils allows the manufacturer to increase product flexibility while requiring only minimal raw material ingredients.

Referring to FIG. 27, in another embodiment, the mattress 1500 is of a cushion attached to the top layer 1502 of the coil pocket by mechanical clips 1520 inserted through grommets 1518 and through coil springs 1506. Includes upper layer 1508. As in FIG. 13, the cushion 1512 is joined to the mounting member 1510, which in this embodiment is a fabric sheet made from a material that is quasi-isotropic. Also, as in FIG. 13, the spacing and position of the cushions 1512 is such that each cushion is located directly above the coil pocket 1505 on which it directly acts. In this embodiment, the foam cushion element 1516 is not housed in the pocket fabric, but instead is directly bonded to the upper surface 1511 of the attachment layer 1510. Note that the cushion top layer 1508 is separate and distinct from the coil pocket layer 1502. Although one type of clip and grommet combination is shown, one of ordinary skill in the art will appreciate that other forms of clamping on the fabric attachment layer 1510 and mechanical clamping to the coil pocket 1504 and the contained coil spring 1506 are possible. It should be clear that mechanical clips are also feasible. With such a mechanical clamping device, the need to provide grommets 1518 on attachment layer 1510 can be eliminated. 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 1520 allows a manufacturer, retail store, or end user to easily attach or remove cushion layer 1508 from layer 1502 of the coil pocket by attachment member 1510. The ability to add or remove the top layer 1508 of the cushion pocket provides the manufacturer with considerable manufacturing flexibility when manufacturing the mattress. For example, manufacturers can reduce the inventory of mattress parts, store only a few pocket coil units, along with an assortment of cushion layers, and mix and match these two components during assembly to create a large number of Mattress models can be created. For retail stores, the cushion layers can be replaced on a short-term basis, so that the store can hold one demonstration unit with a layer 1502 of coil springs inside the mattress cover 12, which is the mattress cover 12. It can be accessed by unzipping it with a zipper 1530, which allows the store to change the cushioning layer 1508 to present a number of different comfort levels. Additionally, the retailer can customize the mattress to the customer's exact comfort preference by mixing different matching cushion layers 1508 with the pocket coil layers 1502. At the same time, the end user, who may decide to change future mattress comfort, potentially removes the cushion layer 1508 by releasing the mechanical clip 1520, replacing 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 shown and described, it will be obvious to those skilled in the art that changes and modifications can be made without departing from the scope of the invention as claimed.

Claims (11)

A mattress,
A layer of coil pockets including first and second coil pockets, each of the first and second coil pockets including a pocket and a coil spring disposed within the pocket. Layers of
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 within the pocket. The first layer of the cushion pocket further comprises a mounting member including an upper surface and a lower surface, the first and second cushion pockets engaging the upper surface of the mounting member, and the first and second cushion pockets. The first layer of cushion pockets, wherein the lower surface of the mounting member is engaged with a layer of the coil pockets such that the cushion pockets each directly act only on the first and second coil pockets;
The mattress. The mattress of claim 1, wherein the first layer of cushion pockets is located above the layer of coil pockets. The mattress of claim 2, wherein the attachment member is a fabric sheet. The mattress of claim 3, wherein each of the cushion pockets is connected to an upper surface of the mounting member by an adhesive, and a lower surface of the mounting member is securely attached to a layer of the coil pocket by an adhesive. Wherein said pocket of each of said pocket and front Chrysanthemum Tsu Deployment pockets each coil pocket is made from a single fabric of claim 4 mattress. The mattress of claim 1, wherein the cushion member is a foam. The mattress of claim 1, wherein the attachment member is removably engaged with a layer of the coil pocket. Further comprising a second layer of cushion pockets disposed below the layer of coil pockets,
The second layer of cushion pockets includes 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 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 lower surface of the mounting member,
The upper surface of the mounting member is a layer of the coil pocket so that the first and second cushion pockets of the second layer of the cushion pocket act directly on only the first and second coil pockets, respectively. Engaged,
The mattress according to claim 1. A pocket spring unit,
A layer of coil pockets including first and second coil pockets;
A first layer of cushion pockets including 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 first layer of the cushion pocket further comprises a mounting 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 pocket spring, wherein the lower surface of the mounting member is engaged with a layer of the coil pockets such that the first and second cushion pockets act directly on only the first and second coil pockets, respectively. unit. The pocket spring unit according to claim 9, wherein the attachment member is a fabric sheet. The pocket spring unit according to claim 10, wherein the cushion members of the first and second cushion pockets are one foam.

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