KR20170131476A - mattress - Google Patents

Abstract

The present invention is a mattress comprising a cushion pocket layer secured to a coil pocket layer. The first cushion pocket layer comprises first and second cushion pockets. Each of the first and second cushion pockets includes a pocket and a cushion member arranged in the pocket. The cushion pocket layer further comprises an attachment member including an upper surface and a lower surface. The first and second cushion pockets are connected to the upper surface of the attachment member. The coil pocket layer includes first and second coil pockets. Each of the first and second coil pockets includes a pocket and a coil spring arranged in the pocket. The lower surface of the attachment member is connected to the coil pocket layer so that the first and second cushion pockets act directly on the first and second coil pockets, respectively.

Description

mattress

1 and 2, a prior art mattress 50 generally has a layer of pocket coil spring 57 connected to the base 52 and optionally known as a marshall type spring. The mattress 50 further has a cushion layer 53, 54 and a mattress cover 51 arranged on the pocket coil spring 57. First, the marshall-type spring described in U.S. Patent No. 685,160 is a coil spring 56 housed within a material pocket 55. The pocket coil assembly is fabricated by inserting a coil spring 56 into each fabric coil pocket 55, which is generally suspended as a continuous pocket coil strip.

U.S. Patent No. 2,236,007 discloses a marshall type spring with a fiber filler added to the core of a pocket coil spring to help absorb the load by absorbing a portion of the load applied to the actual pocket coil spring in the fiber filler.

U.S. Patent No. 8,266,745 discloses a filling material comprising foaming agents or fibers arranged in a spring coil and pocket to reduce noise and to eliminate noise and prevent the fabric wrapping the springs from being sucked into the pocket when the user is on or off the bed A marshall type spring to be used is disclosed.

What most pocket coil mattresses have in common is that coil springs in individual cloth pockets provide initial loading softness and a softer feel to sleepers, reduce local high-voltage interface locations, and reduce the feeling of lying directly on the metal spring And are arranged below sheets or sheets of padded and cushioned material conforming to the body contour. This type of mattress often turns over at regular time intervals to mitigate or eliminate the problem of imprinting the body on one or more cushioning layers from a user who is repeatedly lying at similar locations every night.

3, according to another disadvantage of having a single or multiple sheets of cushioning material 53 on a layer of pocket coils 58, a compressive load ("water pressure compressive load" Is delivered to a plane of the cushioning material 53, generally perpendicular and perpendicular to the vertical plane of the pocket coil unit. As a result, the sleeping compaction load is transmitted transversely with respect to the adjacent pocket coil, even though no direct sleeping load acts on the same coils. This draws the sleeping person into the core of the mattress 50 to form a recess 60 that makes the mattress 50 inconvenient to sleep.

Another problem with the concave effect is that it occurs to another sleeping person using the same mattress at the same time as the original sleeping person. The other sleepers often have a concave effect of the original sleepers and have a load that draws the sleepers into the same sleeping space as the original sleepers. The opposite applies, and the original sleeper can be drawn into the recess effect created by the other sleepers. In both cases, sleepers have a disadvantage due to the manner in which the seat cushioning material behaves within the current mattress structure, creating a situation in which the sleeping person is not comfortable in the space of his own.

Another problem with the seat cushion located above the pocket springs is that the seat cushioning material has a trampoline effect when the load is applied from above. Rather than acting as a cushioning material only to provide initial loading softness, a smoother sleeping feel, reduce local high pressure interface locations and match body contours, seat cushioning often operates more like a trampoline, . The magnitude of the trampoline effect is generally closely related to the tensile strength of the cushioning material. The cushioning material is fixed in place on the uncompressed pocket coil spring and resists deflection in the area subjected to compressive loading by the transverse tensile strength of the material in the plane. Essentially, the sheet cushioning material essentially acts like a spring unit due to the tensile strength trampoline effect. This effect is often inconsistent with the purpose of the cushioning material in order to provide initial comfort to the sleeping person. Regarding comfortable and caring home mattresses, an important issue relates to patients with increased pressure on the mattress interface resulting in bedsore ulcers. The purpose of sheet cushioning on pocket coil cores in hospital mattresses is to reduce locally high patient interface pressures to reduce the incidence of bedsore ulcers. However, the trampoline effect generated by the sheet cushioning layers on the coil unit counteracts this purpose.

Additional deficiencies associated with seat cushioning on pocket coils are associated with the transmission of the mattress. In industry, mattresses are generally known to be carried in a flat structure along the horizontal or vertical direction. Often the bending of the mattress during the initial shipping and installation causes the mattress to break down and return. Often, the defective device within the mattress results in shearing, permanent deviation or deformation of the sheet cushioning material. In addition, the cost and logistics associated with the mattress transport are added to transport the mattress in a flat structure. Often, two workers and a truck are needed to carry the mattress to the consumer. It may be inherently advantageous to roll the mattress for transport and to eliminate the costs associated with compressing and transporting the flat mattress. In addition, storage costs associated with floor space can be significantly reduced for both manufacturers and retailers when the mattress is rolled and stored in compressed form.

According to the existing problems of sleeping on different types of foam, including but not limited to polyurethane, latex and memory foam, with different cushioning materials with the sheet, the material is unpleasantly damp when the sleeping person is lying on the mattress Or feels hot. This is partly because the cushioning material with the sheet has insulation properties that limit body cooling for the body part of the sleeping person in direct contact with the mattress. This feature combines with the very characteristics of the sheet of cushioning material that interfere with air flow around the cushioning material or through the cushioning material, further exacerbating the cooling problem. The fact that the sleeping person is unable to adequately control the temperature of the body part, together with the fact that the mechanism that awakens the sleeping person from the water surface is triggered by internal temperature control in part, so that the cushioning material with the seat in the pocket coil mattress is included, It can be a significant factor in poor sleep quality.

One of the major causes of mattress failure is the deterioration of the quality of the cushioning material with the sheet. This is a direct consequence of fatigue softening, particularly in the case of sheet foam cushioning materials with pure loads consistent with the water load acting on the mattress. Due to the passage of time and the continuous loading of the foam, the foam begins to lose the ability of the foam to resist compression. The deterioration of the quality of the seat cushioning material makes it advisable for the mattress manufacturer to flip the mattress to reduce and retard such quality deterioration.

The sheet cushioning also serves to trap dust, mites and potentially other microorganisms. Over the long term, this can seriously endanger health, especially to people with severe allergies or immunosuppression. In addition, hospitals and nursing homes alleviate this problem by covering mattresses with barrier fabrics.

It is an object of the present invention to provide a mattress which is not intended to form a recess.

Another object of the present invention is to provide a relatively cool mattress for sleeping and to develop a mattress that allows the circulation within the mattress core.

Another object of the present invention is to develop a mattress with a flexible spring or hardness of which the mattress can be selectively controlled and which has a pocket spring

It is a further object of the present invention to develop a mattress that can be easily manufactured as a mattress with single side or double side and potentially with a different comfort profile for each side.

It is another object of the present invention to develop a mattress that better isolates the movement of the sleeping person.

It is a further object of the present invention to develop a mattress that removes the sheet cushioning layer that forms shear stress from the compressive load of the sleeping person and consequently eliminates premature failure, thereby developing a relatively long-life mattress.

It is a further object of the present invention to develop a mattress that replaces seat cushioning with individually encased foam cushion pockets. The health hazard associated with the sheet cushioning material in prior art mattresses is substantially reduced because the cushion pockets are individually housed within the fabric and the cushion pockets are inherently insensitive to entrapping dust, dust mites and other microorganisms.

It is another object of the present invention to develop a mattress that reduces the amount of cushioning material from 20% to 25% compared to conventional pocket coil mattresses using sheet foam cushioning material to reduce the cost and weight associated with the additional sheet cushioning material . This is achieved by using an improved pocket coil spring with a cushioning material lying directly on the spring unit of the cushion pocket.

It is another object of the present invention to develop a mattress that removes the seat cushion layer that is associated with the occurrence of a pressure ulcer in a patient in a nursing home and a hospital.

It is a further object of the present invention to develop a machine and method for constructing a pocket spring comprising a coil pocket and a cushion pocket, respectively.

In a first embodiment, the invention is a mattress comprising a coil pocket layer comprising first and second coil pockets. Each of the first and second coil pockets includes a pocket and a coil spring arranged in the pocket. The mattress further comprises a first cushion pocket layer comprising first and second cushion pockets. Each of the first and second cushion pockets includes a pocket and a cushion member arranged in the pocket. The cushion pocket layer further comprises an attachment member including an upper surface and a lower surface. The first and second cushion pockets are connected to the upper surface of the attachment member. The lower surface of the attachment member is connected to the coil pocket layer so that the first and second cushion pockets act directly on the first and second coil pockets, respectively.

The following description of the invention will be better understood with reference to the accompanying drawings.
1 is a perspective view of a conventional pocket coil spring having a pocket and a coil spring disposed within the pocket.
2 is a perspective view of a prior art mattress having a plurality of pocket coil springs and a plurality of cushioning sheets or layers.
Figure 3 shows a conventional mattress with the formation of a recess.
FIG. 4 is a perspective view showing a mattress of a side portion according to the first embodiment of the present invention. FIG. 4 is a perspective view showing a plurality of pocket springs including a coil pocket and a cushion pocket, do.
Fig. 5 is a perspective view of a pocket spring according to a first embodiment of the present invention, showing a cushion pocket acting in unison with a coil pocket having a single speed spring coil with no load. Fig.
FIG. 6 is a perspective view of a pocket spring according to another embodiment of the present invention. FIG. 6 is a perspective view of a pocket spring according to another embodiment of the present invention, which includes a first cushion pocket having a non- Respectively.
FIG. 7 is a perspective view of a pocket spring according to another embodiment of the present invention, showing a first cushion pocket having a no-load state and acting in combination with a coil pocket, and a second cushion pocket operatively associated with the first cushion pocket.
FIG. 8 is a perspective view of a pocket spring according to another embodiment of the present invention, showing a plurality of pocket springs, each including a coil pocket and a cushion pocket that works in combination with the coil pocket, each having no load. Each coil pocket is connected to an adjacent coil pocket, and each cushion pocket is freely upright.
9 is an exploded view showing another embodiment of a pocket spring showing a coil pocket and a cushion pocket during the process of being attached to the coil pocket by an adhesive.
Figure 10 is a perspective view of the spring pocket of Figure 9 showing a cushion pocket attached to the coil pocket by adhesive.
FIG. 11 is a perspective view of a pocket spring according to a first embodiment of the present invention, showing a cushion pocket that is operatively engaged with a coil pocket having a multi-speed spring coil with no-load state.
Figure 12 is a perspective view of a mattress according to another embodiment of the present invention, wherein each of the plurality of pocket springs with no load condition includes a cushion pocket operatively associated with the coil pocket. Each coil pocket is connected to an adjacent coil pocket, and each cushion pocket is freely upright, allowing air circulation around the cushion pocket.
13 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 with no load. Each cushion pocket acts in conjunction with a corresponding coil pocket. In this embodiment, the cushion pockets are joined to the fabric sheet to form a layer of cushion pockets.
Fig. 14 is a perspective view of a pocket spring unit according to another embodiment of the present invention, showing a cushion pocket having a no-load state and acting in combination with a plurality of micro-coil pockets. Fig.
15 is a perspective view of a machine according to another embodiment of the present invention for manufacturing heat or strips of pocket springs, each comprising a coil pocket and a cushion pocket.
16 is a perspective view of a machine according to another embodiment of the present invention for manufacturing heat or strips of pocket springs, each comprising a coil pocket and a cushion pocket.
17 illustrates a mattress having a double side according to another embodiment of the present invention, which is a no-load state, having a first layer of cushion pockets disposed over a layer of coil pockets and a second layer of cushion pockets disposed below the layer of coil pockets And a second layer.
18 illustrates a mattress having a single side according to another embodiment of the present invention, showing a layer of a cushion pocket removably engaged with a layer of coil pocket with no load.
Figure 19 illustrates a mattress having a dual side according to another embodiment of the present invention, comprising a first layer of cushion pockets releasably engaged with the top of the layer of coil pockets with no load, And a second layer of cushion pockets removably coupled to the bottom.
Figure 20 shows a mattress with a single side according to another embodiment of the present invention, showing a plurality of strips of cushion pockets removably engaged with a layer of coil pocket with no load.
Figure 21 illustrates a mattress having a dual side according to another embodiment of the present invention, comprising a plurality of strips of cushion pockets removably coupled to the top of a layer of coil pockets, Lt; RTI ID = 0.0 > removably < / RTI >
22 illustrates a pocket spring according to another embodiment of the present invention and includes first and second micro-cushion pockets disposed and coupled on a single coil pocket.
23 is a view of a machine for producing a layer of cushion pockets.
24 is a view of a machine for manufacturing a cushion pocket.
Figure 25 illustrates a mattress with a single side according to another embodiment of the present invention, showing a layer of microcushion pocket removably associated with a layer of coil pocket with no load.
Figure 26 illustrates a mattress with a single side according to another embodiment of the present invention, comprising a first layer of microcushion pocket and a first layer of microcushion pocket removably coupled to the layer of coil pocket, Lt; RTI ID = 0.0 > micro-cushion < / RTI >
Figure 27 illustrates a mattress with a single side according to another embodiment of the present invention, showing a layer of cushioning material removably engaged with a layer of coil pocket with no load.

4, a mattress 10 according to a first embodiment of the present invention includes a plurality of pocket springs 90 arranged in rows and columns on a base 14. As shown in Fig. Each pocket spring 90 includes a cushion pocket 36 disposed thereabove and disposed side by side with the coil pocket 38. As described in more detail herein, the cushion pocket 36 is connected to the coil pocket 38 and acts directly thereon. The pocket springs 90 are covered over the top and sides of the pocket springs by the mattress fabric cover 12. [ In this embodiment, there are no layers of cushioning material between the mattress fabric cover 12 and the cushion pockets 36 except for the fibrous filler material that can form part of the quilted mattress fabric cover 12 . In the illustrated embodiment, the mattress 10 is a mattress with a single side or a mattress without a flip. However, as shown in a further embodiment, the mattress 10 is a mattress with a double side or a revrible mattress that does not require the base 14. The mattress 10 may have a size such as a single, queen or king size. In the case of a single size, the mattress 10 may have about 294 pocket springs 90.

5, the pocket springs 90 are shown having cushion pockets 36 arranged and aligned on the coil pockets 38. As shown in Fig. This particular embodiment of the pocket spring 90 is utilized in a flipless mattress with a single side. The cushion pocket 36 generates a load when pressed by the weight of the user. The cushion pockets 36 are connected to the coil pockets 38 and operate directly to transfer substantially all of the load generated from the cushion pockets 36 to the coil pockets 38. In this embodiment, the coil pocket 38 includes a pocket 39 and a spring 20 arranged in the pocket 39. [ In the illustrated embodiment, the spring 20 is a single ratio barrel spring. The spring 20 may have any other shape according to the prior art or having a coil spring shape developed in the future. For example, the spring 20 may be obtained from the Leggett & Plat Components Europe Limited, PO, under the trade name SOFT TOUCH®, located at 727 Double-U, Bowl, Box 681 (www.lpeurope.com/softtouch.asp) Speed multi-speed coil spring. The pockets 39 may be sealed at the sides by the ultrasonic coupling 31. [ However, the spring 20 may or may not be sealed within the pocket 39 by a stitched seal or adhesive pocket seal. In this embodiment, the pockets 39 are nonwoven polyester fabrics. However, many other fabrics, including woven fabrics including polyester, polypropylene, nylon, and fabric blends, along with nonwoven fabrics including polyester, polypropylene, nylon and fabric blends, It does not. The cushion pocket 36 includes a pocket 37 and an elastic member 32 arranged in the pocket 37. [ The pockets 37 are made from fabric pieces of the same continuous structure used to form the pockets 39 of the coil pockets 38. The elastic member 32 is an open cell portion of a cylindrical structure arranged in the pocket 37 of the cushion pocket 36 and the pocket 37 is a portion of the pocket 39 of the coil pocket 38 forming the pocket 39 of the coil pocket 38 Is formed by the same ultrasonic coupling (31). The open cell foam is available from a variety of sources, such as Foam Factory, Inc. (http://www.thefoamfactory.com/opencellfoam/supersoft.html) located at 2300 miles, Although a four-pound density open-cell viscoelastic foam per cubic foot is utilized as the resilient member 32, many other forms of foam and cushioning material may be included within the cushion pocket 36 individually or in some combination. These include, but are not limited to, viscoelastic foams of different density and thickness, latex foam, polyfoam, poly fibers, down fibers, wool fibers or some combination thereof. Further, in the above embodiment, the separation is formed between the pockets 37 of the cushion pockets 36 and the pockets 39 of the coil pockets 38 by the ultrasonic heat separating / coupling 34. However, it is possible to form the separation between the cushion pocket 36 and the coil pocket 38 by weaving separation or adhesive line separation, but is not limited thereto. In this particular embodiment, the coil pocket 38 is covered by a cushion pocket 36 having a length of three inches and has a length of seven inches. The width of the coil pocket 38 is about 2.75 inches, and the width of the cushion pocket 36 is about 2.5 inches. However, many different lengths and widths for the cushion pocket 36 and the coil pocket 38 are permissible and do not limit the scope of the present invention.

6, the pocket spring 90 includes a cushion pocket 36 that is located and aligned on one side of the coil pocket 38 and a cushion pocket 36 that is positioned and aligned on the other side of the coil pocket 38. In one embodiment, And includes a pocket 35. The cushion pocket (35) includes a pocket (41) and an elastic member (42) arranged in the pocket (41). This particular embodiment may have double sides or be used in reversible mattresses, but is not limited thereto. The elastic member 32 included in the cushion pocket 36 may be the same or different elastic member 42 included in the cushion pocket 35. In this embodiment and other embodiments, This effectively allows the end user to flip the mattress and have a completely different cushioning response from one side of the mattress to the other. By the same indication, the actual shape of the cushion pockets is different, and the cushion pocket 36 potentially has a different diameter and / or length than the diameter or length of the cushion pocket 35. This may result in different mattress cushioning profiles depending on the side of the mattress in direct contact with the sleeping person. The cushion pockets 36 and the cushion pockets 35 are made from a single piece of fabric and in the case of the cushion pockets 36 are formed by the ultrasonic thermal isolation coupling 34, Is formed by a similar ultrasonic heat-isolating coupling 33 (not explicitly shown in the figure) in the case of the pocket 35. [ It is contemplated, however, that both or both of the cushion pockets can be fabricated from individual pieces of material and coupled to the coil pocket 38 by a number of known engaging means. In addition, the separation between the coil pocket 38, the cushion pocket 36 and the cushion pocket 35 may be a weave separation or an adhesive line separation, but is not limited thereto. The embodiment is not limited to a single cushion pocket on either side of the coil pocket. In addition, more than one cushion pocket may be stacked on top of each other on the coil pocket or side by side to form a different cushioning profile for each side of the flipable mattress.

7, the pocket spring 90 includes a cushion pocket 36 at one side of the coil pocket 38 and a cushion pocket 46 at the top of the cushion pocket 36. In another embodiment, The cushion pocket 46 includes a resilient member 48 arranged within the pocket 47 and the pocket 47. This particular embodiment is used in a mattress without a flip with a single side. As shown in the above embodiment, more than one cushion pocket may be stacked on top of each other to form a different cushioning profile. Although the particular embodiment illustrates the two cushion pockets 46, 36 loaded on the coil pocket 38, the embodiment is not limiting and it is anticipated that many other cushion pockets could be additionally stacked below one another . The cushion pockets 46 may have a shorter length than the cushion pockets 36. As can be seen in the above embodiment, the actual shape of the cushion pockets may be different and the cushion pockets 36 potentially have different diameters or lengths from the cushion pockets 46. In addition to the above embodiments, the coil pocket 38, the cushion pocket 36 and the cushion pocket 46 are made of a single piece of fabric, and in the case of the cushion pocket 36 are formed by the ultrasonic heat- Is formed by a similar ultrasonic heat-isolating engagement (44) (not explicitly shown in the figure) in the case of the cushion pockets (36) and the separate cushion pockets (46). It is contemplated, however, that both or both of the cushion pockets may be fabricated from separate material pieces and joined to the coil pockets 38 and other cushion pockets by a number of known engaging means. In addition, the separation between the coil pocket 38, the cushion pocket 36 and the cushion pocket 46 can be a weave separation, a thermal bond separation or an adhesive line separation, but is not limited thereto. Multiple length and width combinations of coil pockets 38, cushion pockets 36 and cushion pockets 46 are permissible and do not limit the scope of the present invention.

8, a string or unit 92 of a partially continuous structure is shown and includes a plurality of pocket springs 90 made of a continuous length fabric. The individual coil pockets 38 are separated from the next or previous coil pocket by an ultrasonic heat weld 31. The cushion pockets 36 are also made from fabric pieces of the same continuous structure, such as the coil pockets 38. It should be noted that, in the above embodiment, after the cushion pockets 36 are formed by the ultrasonic heat welding 31 and the pocket display welding 34, they are separated from the adjacent cushion pockets by cutting the fabric between respective heat welds do. The cushion pocket strips 36 may be formed from continuous individual fabric pieces and secured to the pocket coil strips by known means including, but not limited to, adhesive bonding, heat welding or stitching. In another embodiment, the cushion pockets can be kept connected to each other by the fabric between each cushion having sufficient flexibility to allow independent movement of each cushion pocket. It is also possible to form a cushion pocket from each fabric piece of cushion pocket 36 and secure the cushion pocket to the coil pocket 38 by one of said means. In this embodiment, the cushion pockets 36 are not connected to each other so that each cushion pocket acts directly on the respective coil pocket and allows air circulation within the mattress. The elastic member 32 of the cushion pocket 36 of the first pocket spring 90 includes elasticity R1. The elastic member 32 of the cushion pocket 36 of the second pocket spring 90 includes elasticity R2. In the above embodiment, the elasticity R1 is the same as the elasticity R2. In another embodiment, the elasticity R1 may be greater than the elasticity R2. The numerical values for elasticity (R1) and elasticity (R2) provide the ability to design different comforts.

9-10, in another embodiment, the pocket springs 90 are formed by hot melt adhesive bonding of the cushion pockets 36 to the coil pockets 38. As shown in Fig. A complete pocket spring 90 is shown in Fig. The adhesive applicator 144 is shown and dispenses the hot melt adhesive 146 to the top of the previously formed coil pockets 38. The previously formed cushion pocket 36 then descends into the coil pocket 38 to form the completed pocket spring 90.

Referring to FIG. 11, in another embodiment, the pocket spring 90 utilizes a multi-speed coil spring 132 as a spring element within the coil pocket 38. The multiple speed coil spring 132 may also be used in all of the above embodiments that utilize more than one cushioning pocket arranged on either or both sides of the coil pocket as described above.

12, in another embodiment, the mattress 10 includes a plurality of pocket units 92 (arranged) arranged in rows and / or columns. As shown, the pocket unit 92 provides improved air flow around the cushion pockets 36 of each pocket spring 90 and adjacent the coil pockets 38. As can be seen in the figure, air can infiltrate the quenched cover 12 and circulate freely between adjacent cushion pockets 36 and between adjacent coil pockets 38. This is because there is no cushioning sheet that blocks and restricts airflow from moving into and out of the mattress core. It may also have cushion pockets 36 joined together by an excess material that still allows the cushion pockets to act individually on each coil pocket and allow air flow to move into and out of the mattress core.

The present invention provides significant advantages over conventional mattresses. First, the use of the pocket spring 90 provides a new mattress with increased comfort and useful life over conventional mattresses by significantly reducing the formation of indentations. Second, the use of the pocket springs 90 provides better air circulation than conventional mattresses, and as a result, the sleeping pants cool more. Third, the use of the pocket springs 90 allows the softness or hardness of the cushion pockets on the individual coil pockets to be selectively controlled, thereby enabling a larger mattress fit selection to the desired consumer of a more complex cushion profile. This can be achieved by changing the contents, dimensions or the number of cushion pockets within the pocket spring string. Prior to the present invention, the coil spring parameters could be varied on a coil-by-coil basis, but the characteristics of the sheet foam cushion material on the coil in coil units could not be changed. Fourth, the use of the pocket springs 90 is advantageous because the cushioning material is embedded in the pocket spring 90 and does not require additional steps to insert and secure the seat cushioning material during the mattress manufacturing process, So that it is possible to easily manufacture the mattress having the mattress. Fifth, the use of the pocket spring 90 minimizes the transmission of the sleeping compaction force in a plane perpendicular to the plane of the pocket spring, thereby better isolating the sleeping movement. Sixth, the use of the pocket springs 90 increases the life of the mattress by removing the seat cushion layer which receives the shear force from the water pressure compressing load and the premature failure thereof. Seventh, the use of pocket springs 90 removes the seat cushion layer and replaces the seat cushion layer with a separately encased foam cushion pocket. Since the pockets with cushions are individually encased in fabric, the pockets are essentially insensitive to the trapping of dust, mites and other microorganisms and the health risks associated with the seat cushion material for prior art mattresses are substantially reduced. Eighthly, the use of pocket springs 90 eliminates the seat cushion layer and consequently reduces the amount of cushioning material from 20% to 25% compared to conventional pocket coil mattresses using seat cushioning material, Thereby reducing the corresponding cost and weight associated with the cushioning material. All sheet cushioning material between the pocket coils of the prior art mattress is removed by the use of a pocket spring 90. The pocket spring 90 also permits the manufacture of a mattress without a seat cushion layer that is associated with the occurrence of a pressure ulcer ulcer in patients in home and hospital care.

13, in another embodiment of the present invention, the mattress 150 includes a layer of cushion pockets (not shown) including a cushion pocket 36 that is clearly separated from a coil pocket layer 158 comprised of coil pockets 38 156). In this embodiment, the cushion pocket 36 is joined to the attachment member 152, which is a fabric sheet in this embodiment. In addition, the fabric sheet is ideally made of a material having quasi-isotropy in a single plane. The method of coupling the cushion pocket 36 to the attachment member 152 may be thermal bonding or adhesive bonding, but is not limited thereto. The spacing and position of the cushion pockets 36 are determined so that the cushion pockets are positioned just above the coil pockets 38 where each cushion pocket directly acts. In this embodiment, the attachment member 152 is used to position and secure the cushion pocket 36 over the coil pocket layer 158. [ However, other means of locating and securing the cushion pocket layer 156 over the layer 158 of coil pockets may be used. For example, it may be possible to arrange the attachment member 152 over the cushion pocket 36, or alternatively, between the cushion pockets. The attachment member 152 may also be constructed of a porous material that is air permeable or perforated to prevent airflow between the layer 158 of the coil pocket and the layer 156 of the cushion pocket, .

Many problems with the use of seat foams in mattresses, from concave effects to trampoline effects, are documented in the present application. However, one of the advantages of using a sheet foam in a mattress is to impart lateral stability to the mattress core. In the case of a pocket coil spring unit, the seat foam layer above the pocket coil spring unit restrains the spring core and resists lateral movement of the sleeping person. The same factors that make sleep less comfortable cause the mattress core to have transverse sleep load and movement and interfere with shifting. The main advantage of using an adhesive layer between the pocket coil layer and the cushion pocket layer is that the spring core will have lateral stability that is lost when the sheet foam is removed by the adhesive layer. This is because the fabric fibers exhibit in-plane shear strength as they are dispersed in the fabric plane and have quasi-isotropic properties that provide in-plane strength. The in-plane strength helps to stabilize the pocket coil device when a lateral load is applied.

Another advantage of a cushion pocket attached to a separate attachment layer is that it forms an independent pocket cushion layer. The layer can be independently fabricated and stored separately from the pocket coil layer. Thus, the manufacturer provides much greater flexibility during the manufacturing process, which matches different cushion layers and their associated properties to different pocket coil spring layers and properties. The number of now customizable combinations exponentially increases the number of base pocket coil spring units associated with the base cushion pocket layer. For example, three different pocket coil spring elements are combined with three different cushion elements to provide the manufacturer with nine possible combinations. Increasing the number of pocket coil spring units to five with five different cushion pocket element layers now has twenty-five custom units. With the addition of the second cushioning layer, the number of possible matching units increases to 125. Manufacturers therefore only require a limited number of base components, while offering tremendous custom manufacturing flexibility. Another advantage of using separate attachment layers is that the attachment layer can be arranged on the entire pocket coil core unit and has two attachment points for attachment points relative to all pocket coils. Also, the shape of the attachment point may vary depending on the mattress manufacturer's goals. A clip-shaped attachment can be used to remove the cushion pocket layer, interchangeable, and washable. Now, the mattress retailer can consider changing the comfort layer from a soft form to a hard form, for example, depending on the customer's requirements. Simply loading the other pocket cushion layer allows the retailer to remodel the mattress by simply removing one pocket cushion layer and clipping the other pocket cushion layers with different cushioning properties. As a result, retailers can show multiple beds in a single bed space and reduce floor space and overhead costs. Likewise, a retailer can reduce inventory by having only the base unit in stock while the last bed meets customer specifications. In addition, multiple pocket cushioning layers may be placed below one another to create a different cushion profile by clipping each layer to the previous layer. For example, the cushioning layer of the individual gel cushion pockets can be arranged on the foam cushion pocket layer and clipped to form a completely different shape and feel to the mattress. By combining it with a different height, removable mattress cover, there is no limit to the retail store alignment level. At the same time, the customer experience can be greatly improved because customers mix and match different mattress elements within the retail store to make the customer bed only according to their preference.

The disadvantage of manufacturing a pocket coil spring with integral cushion pockets is that after manufacture the cushion pockets must be separated from one another, as described with reference to Figures 15 and 16. [ This requirement requires that the cushion pockets be smaller than the pocket coil pockets because extra material is required between the cushion pockets so that the cushion pockets can be sealed and separated from one another. This is a significant drawback, as the cushion pocket is small and the area of support for the sleeping person is reduced. When bonding the cushion pockets to the attachment layer, the diameter of the cushion pockets may be the same as the diameter of the pocket coils and, in some cases, may be greater than the pocket coil pocket diameter. Thus, the pocket cushion cross-sectional area can be increased and the supporting area for the sleeping person can be increased.

In a further embodiment, it is contemplated that a separate adhesive layer strip is used rather than attaching all of the cushion pockets to a single adhesive layer so that the string of pocket coils is attached to the adhesive layer strip. The attachment strip may be attached to the coil pocket strip so that the orientation of the cushion pocket attachment strip is perpendicular to the orientation of the pocket coil strip. In this way, we provide lateral stability support to the pocket coil core. It is also possible to apply a single strip around one or two outer rows of pocket coils to effectively form a framing mechanism which further increases the lateral support of the pocket coil core unit.

14, in another embodiment, a pocket spring unit 200 according to the present invention generally includes a cushion pocket 210 coupled to and directly acting upon a plurality of micro-coil pockets 220. As shown in FIG. In the illustrated embodiment, the cushion pockets are arranged and aligned on each microcoiled pocket 220. Each micro-coil pocket 220 includes a pocket 224 and a micro-coil spring 222. The cushion pocket 210 includes a pocket 212 and an elastic member 214 disposed within the pocket 212. The pocket 212 is sealed by a heat weld 215. The cushion pocket 210 is directly engaged with the micro-coil pocket 220 so that substantially all of the load of the cushion pocket 210 is transferred to the micro-coil pocket 220. [ The pockets 224 of the micro-coil pockets 220 may be connected together by a heat weld 226. As in other embodiments, the pockets 224 of the microcoil pockets 220 are made of nonwoven fabrics. The micro-coil spring 222 may be a conventional micro-coil, such as a single-speed micro-coil spring. As in other embodiments, the pockets 212 of the cushion pockets 210 may be made of nonwoven fabrics and may be connected to the microcoil pockets 220 with an adhesive. As in other embodiments, the resilient member 214 may be a foam cushion having any desired resiliency. The multi-speed pocket springs 200 are formed by changing the spring characteristics of the micro springs 222 disposed in the pockets.

Referring to FIG. 15, a machine 300 according to another embodiment of the present invention is shown for producing heat or strips of pocket springs 340 that are the same as the pocket springs 90. The machine 300 generally includes a base conveyor 302 configured to support a plurality of fabric layers and to move to various molding and cutting stations. The machine 300 further includes a top fabric roll 306 that includes a bottom fabric roll 304 and a top fabric 307 that includes a bottom fabric 305. The lower fabric roll 304 with the upper fabric roll 306 feeds the lower fabric 305 and the upper fabric 307 to the base conveyor 302 simultaneously. Many fabrics, including woven fabrics such as cotton, polyester, polypropylene, nylon and fabric blends, as well as nonwoven fabrics, including polyester, polypropylene, nylon and fabric blends, Do not. Forming the side of the coil pocket 308 of the pocket coil contour 310 is formed by the ultrasonic coupling horn 312. It is the cushion pocket contour 316 formed by the ultrasonic coupling horn 319 to form the side of the cushion pocket 314. In this embodiment, all contours are performed through ultrasonic welding and ultrasonic welding horns. However, it is contemplated that other types of bonding devices and bonding horns may be utilized, such as, for example, thermal bonding horns and thermally bondable fabrics and thermal bonding. The cushion pockets 314 are located just above the coil pockets 308. However, if there is a double cushion pocket contour 316, there are pocket coil contours 310. This is because the fabric is cut between the cushion pockets 314 so that each cushion pocket 314 can be independently compressed without affecting the adjacent cushion pockets 314. [ Ultrasonic coupling horn 318 also forms contour 320 between coil pockets 308 and corresponding cushion pockets 314. Initially, the uncompressed spring 322 is compressed with a coil spring 324 compressed by a known compression device and technique. A compressed coil spring 324 is inserted into the previously formed coil pockets 308 between the upper and lower pieces of fabric. The compressed coil spring 324 is inserted into each coil pocket 308 along a direction in contact with the vertical direction of the final cushion pocket 314 '. After the second half of the assembly process and the fourth side of the coil pocket 308 are sealed, the compressed coil spring 324 is urged against the coil spring 322, which is designed to rearrange the coil spring 324 against the uncompressed coil spring 322 And then re-directed to the correct plane by striking the coil spring. Since the reorientation has a sufficient potential energy that the compressed coil spring 324 is stored in the compressed state so that the coil spring may slightly stagger and have the correct orientation within the coil pocket 308. [ Approximately at the same time as the compressed coil spring 324 is inserted into the coil pocket 308, the cushion foam cylinder 326 is inserted into the cushion pocket 314. Unlike the coil spring 324, the foam cushion cylinder 326, which is compressed by a number of known means, is inserted into the cushion pocket 314 along the correct final direction. If the foam cushion cylinder does not have the correct orientation for starting, the potential energy stored in the compressed foam cushion cylinder 326 will not be sufficient and the cushion cylinder will not be able to correct the orientation, Lt; / RTI > Another unique aspect of the present invention is cutting the individual foam cushion cylinder 326 from a longer foam cylinder 328 by a cutting knife 330. It should be noted that knife 330 may be, but is not limited to, a shearing knife, a hot knife, or an ultrasonic cutting knife or other cutting device or method. It is advantageous to use a long foam cylinder 328 when assembled to ensure that the foam cushion cylinder 326 always has the correct orientation relative to the cushion pocket 314.

For illustrative purposes and to better illustrate the overall process, the upper fabric layer is removed after the initial coil pockets 308 and the cushion pockets 314 are formed. As the upper and lower fabrics continue to move on the conveyor 302, the coil pockets 308 are sealed by the ultrasonic coupling horn 332 forming the coil pocket sealing contour 334. At the same time, the cushion pocket 314 is sealed by the ultrasonic coupling horn 336 forming the cushion pocket sealing contour 338. After the completed pocket springs 340 have been formed, the ultrasonic cutting horn 342 is used to cut the fabric portion 344 between adjacent cushion pocket contours 316. Thus forming a finished pocket coil cushion pocket string with a length pre-programmed for assembly. Various pocket lengths may be cut and / or trimmed to resize and / or trim the ultrasonic bonded horns to provide different mattress alignment by cutting different cushion pocket lengths on a fly or to produce foam cushions of various styles for different customers A more flexible manufacturing system can be formed.

Referring to FIG. 16, there is shown a machine 400 for manufacturing heat or strips of pocket springs 440 in accordance with another embodiment of the present invention. The machine 400 generally includes a base conveyor 402 for supporting multi-layer fabrics and moving them to various forming and cutting stations. The machine 400 further includes a fabric roll 404 that includes an unfolded fabric 405 that passes through a known fabric folding mechanism and into a folded fabric 406. The fabric roll 404 feeds the fabric 405 to a known folding mechanism and base conveyor 402. In the present invention, woven fabrics such as cotton, polyester, polypropylene, nylon and fabric blends may be used with non-woven fabrics including polyester, polypropylene, nylon and fabric blends, but are not limited thereto. Forming the side of the coil pocket 408 of the pocket coil contour 410 is formed by the ultrasonic engaging horn 412. Forming the side surface of the cushion pocket 414 is the cushion pocket contour 416 formed by the ultrasonic coupling horn 419. [ In this embodiment, all contours are performed by ultrasonic welding and ultrasonic welding horns. However, it is contemplated that other types of coupling devices and coupling horns may be used, such as, for example, thermally coupling thermally bonded horns and thermally bondable fabrics. The cushion pocket 414 is located just above the coil pocket 408. [ However, if there is a double cushion pocket contour 416, there is a pocket coil contour 410. This is because the fabric is cut between the cushion pockets 414 so that each cushion pocket 414 can be independently compressed without affecting the adjacent cushion pockets 414. [ The foam cushion cylinder 426, which is compressed by a number of known means, is inserted into the cushion pocket 414 along the correct final direction. If the foam cushion cylinder does not have the correct orientation for starting, the potential energy stored in the compressed foam cushion cylinder 426 will not be sufficient and the cushion cylinder will not be able to correct the orientation, Lt; / RTI > Another unique aspect of the present invention is cutting the individual foam cushion cylinder 426 from the longer foam cylinder 428 by the cutting knife 430. [ It should be noted that knife 430 may be, but is not limited to, a shearing knife, hot knife, or ultrasonic cutting knife or other cutting device or method. Use of a long foam cylinder 428 during assembly is advantageous because it is ensured that the foam cushion cylinder 426 always has the correct orientation relative to the cushion pocket 414. After the foam cushion cylinder 426 is arranged in the cushion pocket 414, the ultrasonic coupling horn 418 forms a contour 420 between the coil pocket 408 and the corresponding cushion pocket 414. The folded fabric 406 now moves to the coil spring insertion station. The uncompressed spring 422 is compressed with a coil spring 424 compressed by a known compression device and technique. Between the upper and lower pieces of the folded fabric 406, a compressed coil spring 424 is inserted into the previously formed coil pocket 408. The compressed coil spring 424 is inserted into each coil pocket 408 along the direction of contact with the vertical direction of the final cushion pocket 414 '. After the second half of the assembly process and the fourth side of the coil pocket 408 are sealed, the compressed coil spring 424 is urged against the unsprung coil spring 422, And then re-directed to the correct plane by striking the coil spring. Since the reorientation has a sufficient potential energy that the compressed coil spring 424 is stored in the compressed state so that the coil spring may slightly stagger and have the correct orientation within the coil pocket 408. [ For illustrative purposes and to better illustrate the overall process, the upper piece of folded fabric 406 is removed after the initial coil pocket 408 and cushion pocket 414 are formed. As the folded fabric 406 continues to move on the conveyor 402, the coil pocket 408 is sealed by an ultrasonic coupling horn 432 that forms a coil pocket sealing contour 434. It should be noted that it is not necessary to seal the cushion pockets 414 because the folded fabric 406 provides a natural container for the cushion pockets 414. After the completed pocket springs 440 are formed, the ultrasonic cutting horn 442 is used to cut the fabric portion 444 between adjacent cushion pocket contour lines 416. Thus, a finished pocket coil cushion pocket string with a length pre-programmed for assembly is formed.

In yet another embodiment, the method includes using a cylindrical tube of cushioning material (foam) to be fed into the cushion pocket so that the cushioning material always has the correct orientation relative to the preformed pocket. The method further comprises slicing the individual length of the foam from the cylindrical tube of cushioning material prior to insertion into the pocket. The method further comprises pre-compressing the foam so that the foam is easily inserted into the pocket and using a compressed set of jaws to maintain the final orientation in the insertion process. Optionally, a compression set of jaws is used to pre-compress the end of the foam cylinder and the foam cylinder is inserted into the preformed fabric pocket and the foam is cut after insertion to form an individual foam cylinder in the fabric pocket.

In yet another embodiment, the method comprises folding over a continuous piece of fabric. The method further includes forming two pocket contours that contact the movement of the fabric and form the sides of the first cushion pocket. The method inserts the foam from the open side of the fabric into the pocket and arranges or coils up the foam against the upper fold of the fabric. The method further includes sealing the fourth side of the first cushion pocket. The method can move the fabric and the first cushion pockets by a sufficient distance to form the length of the inter-cushion pocket fabric so that the first cushion pockets can be fully compressed without creating any torsion in the uncompressed second cushion pockets . The method further includes forming two pocket contours that contact the movement of the fabric and form the sides of the second cushion pocket. The method further comprises inserting the foam from the open side of the fabric into the pocket and arranging or coil-up the foam against the upper fold of the fabric. The method further includes sealing the fourth side of the second cushion pocket. Continuous cushion pocket strips are subsequently formed according to the above method. The method comprises the steps of: placing each cushion pocket above or below the pocket coil spring and over a pre-formed pocket coil strip, each cushion pocket being compressible by an excess fabric between the cushion pockets without affecting adjacent cushion pockets; And combining the continuous cushion pocket strips.

In another embodiment, the method comprises folding over successive fabric pieces. The method further includes forming two pocket contours that contact the movement of the fabric and form the sides of the first cushion pocket. The foam is inserted into the pocket from the open side of the fabric and the foam is arranged or coiled up against the upper fold of the fabric. The method further includes sealing the fourth side of the first cushion pocket. The method further includes cutting the individual cushion pockets. The method further comprises joining the individual cushion pockets onto a preformed pocket coil strip, each cushion pocket being arranged above or below the pocket coil spring. Continue joining the individual cushion pockets into the pocket until the completed pocket coil cushion core is completed.

17, in another embodiment of the present invention, the mattress 500 includes an upper layer 508 of a cushion pocket secured to the top of the coil pocket layer 502, as described in the embodiment of FIG. 13 . The top layer 508 of the cushion pocket is separated and separated from the coil pocket layer 502. In this embodiment, the mattress 500 further comprises a lower layer 518 of a cushion pocket secured to the bottom of the coil pocket layer 502. The lower layer 518 of the cushion pocket is separated and separated from the coil pocket layer 502. In this manner, the mattress 500 provides a double-sided mattress that can be flipped. In addition, the top layer 508 of the cushion pocket may have elasticity and / or elasticity (R1) that is different from the elasticity and / or flexibility of the bottom layer 518 of the cushion pocket. The coil pocket layer 502 includes a plurality of coil pockets 505. Each coil pocket 505 includes a pocket 504 and a coil spring 506 arranged in the pocket 505. The upper layer 508 of the cushion pocket includes an attachment member 510 having upper and lower surfaces 511 and 513 respectively and a plurality of cushion pockets 512 secured to the upper surface 511. Each cushion pocket 512 includes a pocket 514 and a cushion member 516 arranged in each pocket 514. The lower layer 518 of the cushion pocket includes an attachment member 520 having upper and lower surfaces 521 and 523 and a plurality of cushion pockets 522 secured to the lower surface 523. Each cushion pocket 522 includes a pocket 524 and a cushion member 526 disposed within each pocket 524. As in the embodiment of FIG. 13, the cushion pockets 512, 522 are each joined to attachment members 510, 520, which are textile sheets in the illustrated embodiment. Each cushion pocket of the upper layer 508 of the cushion pocket is formed with an interval and position of the cushion pocket 512 so as to be located directly above the coil pocket 505 that directly acts on the upper layer of the cushion pocket. Similarly, each cushion pocket of the lower layer 518 of the cushion pocket is formed with a spacing and position of the cushion pocket 522 so as to be located directly below the coil pocket 505, which acts directly on the lower layer of the cushion pocket. As in this embodiment, each of the pockets 504, 514 and 524 is a fabric material and each of the cushion members 516 and 526 is a foam piece. The coil spring 506 may be any type of spring, such as a multi-speed coil spring.

18, in another embodiment, the mattress 600 includes a cushion pocket 608 attached to the top layer 602 of the coil pocket by a mechanical clip 620 that is inserted through the grommet 618 and the coil spring 606. In one embodiment, Gt; 608 < / RTI > 13, the cushion pockets 612 are joined to the attachment member 610, which is a fabric sheet made of a material having quasi-isotropy in this embodiment. 13, the spacing and position of the cushion pockets 612 are determined such that the cushion pockets are positioned just above the coil pockets 604 on which the respective cushion pockets 612 directly act. It should be noted that the top layer 608 of the cushion pocket is separate and distinct from the coil pocket layer 602. Although one type of clip and grommet combination is shown, those skilled in the art will appreciate that other types of mechanical clips that may be secured to the fabric attachment layer 610 and mechanically secured to the coil pocket 604 and the enclosed coil spring 606 You need to know that it is possible. Optionally, the clip or fastener may be attached directly to the boundary wire or rod typically used. Due to this mechanical clamping device, the need to provide a grommet 618 on the adhesive layer 610 can be eliminated. All of the advantages described in the description of the embodiment of Fig. 13 are available in this embodiment. The use of the mechanical fastener 620 also allows the manufacturer, retailer or end user to easily attach or remove the top layer 608 of the cushion pocket from the coil pocket layer 602 by the attachment member 610. Adding or removing the top layer 608 of the cushion pocket provides the manufacturer with significantly greater manufacturing flexibility when manufacturing the mattress. For example, a manufacturer may reduce inventory of mattress components and load a few pocket coil units with a categorization of cushion pocket layers, and mix and match the two components during the manufacturing process to create multiple mattress models. The ability to change the cushion pocket layer in short order for the retailer is achieved by one retailer having a coil spring layer 602 inside the mattress cover 12 accessible by opening the zipper 630 of the mattress cover, And the retailer may change the cushioning layer 608 to indicate different levels of comfort. The retailer can also match the mattress to the exact comfort preference of the customer by mixing the different cushion pocket layer 608 with the pocket coil layer 602. At the same time, the end user, who decides to change the mattress comfort level in the future, can potentially remove the cushion pocket layer 608 by releasing the mechanical clip 620 and move the cushion pocket layer 608 to another cushioning member 616 ) Elasticity.

19, the mattress 700 is fixed to the top of the coil pocket layer 702 through a mechanical clip 732 and a coil spring 706 that are inserted through the grommet 730. In this embodiment, Gt; 708 < / RTI > The upper layer 708 of the cushion pocket is separated and separated from the coil pocket layer 702. The mattress 700 includes a mechanical clip 736 inserted through the grommet 734 and a lower layer 718 of a cushion pocket secured to the bottom of the coiled pocket layer 702 through a coil spring 706. In this embodiment, . One type of clip and grommet combination is shown, but it should be understood by those skilled in the art that other types of mechanical clips are also possible. With this mechanical clamping device, the need to provide a grommet 730 on the adherent layer 710 and a grommet 734 on the adherent layer 720 can be eliminated. The lower layer 718 of the cushion pocket is separated and separated from the coil pocket layer 702. The mattress 700 is a mattress that can be flipped with double sides. The upper layer 708 of the cushion pocket may also have elasticity El and / or softness different from the elasticity and / or softness of the lower layer 718 of the cushion pocket. The coil pocket layer 702 includes a plurality of coil pockets 705. Each coil pocket 705 includes a pocket 704 and a coil spring 706 arranged in a pocket 705. The top layer 708 of the cushion pocket includes an attachment member 710 having a top surface 711 and a bottom surface 713 and a plurality of cushion pockets 712 secured to the top 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 an attachment member 720 having upper and lower surfaces 721 and 723 respectively and a plurality of cushion pockets 722 secured 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 shown in FIG. 13, the cushion pockets 712 and 722 are respectively engaged with attachment members 710 and 720, which are textile sheets in the illustrated embodiment. Each cushion pocket of the upper layer 708 of the cushion pocket is spaced and positioned between the cushion pockets 712 such that the cushion pocket is positioned directly above the coil pocket 705 to which the cushion pocket directly acts. Similarly, each cushion pocket of the lower layer 718 of the cushion pocket is spaced and positioned within the cushion pocket 722 such that the cushion pocket is positioned directly beneath the coil pocket 705 to which the cushion pocket directly acts. As in the previous embodiment, each of the pockets 704,714, 724 is a fabric material and each of the cushioning members 716,726 is a foam piece. The coil spring 706 may be any type of spring, such as a multi-speed coil spring. 13, the cushion pockets 712 are joined with an attachment member 710, which in this embodiment is a fabric sheet made of a material having quasi-isotropic properties. The cushion pockets 722 are joined to the attachment member 720, which in this embodiment is a fabric sheet made of a material having quasi-isotropy. 13, each cushion pocket 712 is spaced and positioned within the cushion pocket 712 such that the cushion pocket 712 is positioned directly above the coil pocket 705 to which the cushion pocket directly acts. Each cushion pocket 722 is spaced and positioned by the cushion pockets 722 such that the cushion pockets are directly underneath the coil pockets 705 to which they are directly applied. All of the advantages described in the description of the embodiment of Fig. 13 are available in this embodiment. As explained in the embodiment of Fig. 18, all the advantages of using mechanical fasteners are available in the embodiment of the double side mattress.

Referring to FIG. 20, in another embodiment, the mattress 800 provides different pocket cushioning characteristics in different areas of the surface of the water surface, including the upper layer of the zoned cushion pockets. In this particular embodiment, the cushion layer consists of three rows of repeating and alternating cushion pockets. For purposes of illustration, the foam cushion elements in each zoned row are different in respect of foam elasticity. Other zoning possibilities may include, but are not limited to, different combinations and geometries of different cushion pocket geometry, different cushioning materials, and cushioning layers. Zone 1 includes the row of cushion pockets 807 attached to the upper layer 802 of coil pockets by a mechanical clip 820 inserted through the grommet 825 and inserted through the coil spring 806. 13, the cushion pocket 812 is bonded to the upper surface 840 of the attachment member 810, which in this embodiment is a fabric sheet made of a material having semi-isotropy. 13, each cushion pocket 812 is spaced and positioned within the cushion pocket 812 such that the cushion pocket 812 is positioned directly above the coil pocket 805 to which the cushion pocket directly acts. In this embodiment, the cushion pocket 812 has a foam cushion member 816 having elasticity R1. It should be noted that the upper layer 812 of the cushion pocket is separate and distinct from the layers of the coil pocket 802. One type of clip and grommet combination is shown, but one skilled in the art will appreciate that other forms that can be clamped on the fabric attachment layer 810 and mechanically clamped on the coil pocket 804 and the enclosed coil spring 806 It should be noted that the mechanical clips of Fig. With this mechanical clamping device, it may be unnecessary to provide the grommet 825 on the attachment layer 810. Zone 2 includes the row of cushion pockets 808 attached to the top layer of coil pockets 802 by a mechanical clip 822 that is inserted through the grommet 826 and through the coil spring 806. 13, the cushion pocket 832 is bonded to the upper surface 847 of the attachment member 811, which in this embodiment is a fabric sheet made of a material having quasi-isotropy. 13, each cushion pocket 832 is spaced and positioned in the cushion pocket 832 such that it is positioned directly above the coil pocket 805 to which the cushion pocket directly acts. In this embodiment, the cushion pocket 832 has a foam cushion member 836 having an elasticity R2. It should be noted that the upper layer of the cushion pocket 832 is separated from the layer of the coil pocket 802. [ While one type of clip and grommet combination is shown, those skilled in the art will appreciate that other forms of clamping that can be clamped onto the fabric attachment layer 811 and mechanically clamped on the coil pocket 804 and the containment coil spring 806 It should be noted that mechanical clips are also feasible. With this mechanical clamping device, it may be unnecessary to provide a grommet 826 on the attachment layer 811. Zone 3 includes the row of cushion pockets 809 attached to the top layer of coil pockets 802 by a mechanical clip 824 that is inserted through the grommet 827 and through the coil spring 806. 13, the cushion pockets 842 are bonded to the upper surface 844 of the attachment member 813, which in this embodiment is a fabric sheet made of a material having semi-isotropy. 13, each cushion pocket 842 is spaced and positioned in the cushion pocket 842 such that it is positioned directly above the coil pocket 805 to which the cushion pocket directly acts. The cushion pocket 842 has a foam cushion member 846 having elasticity R3 in this embodiment. It should be noted that the upper layer of the cushion pocket 842 is separate and distinct from the layers of the coil pocket 802. One type of clip and grommet combination is shown, but other types of mechanical clips, which can be secured to the fabric attachment layer 813 and mechanically clamped on the coil pocket 804 and the enclosed coil spring 806, You need to know what is possible. With this mechanical clamping device, it may be unnecessary to provide a grommet 827 on the attachment layer 813. 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, 824 allows the manufacturer to easily attach or remove the zoned layers of the cushion pockets from the coil pocket layer 802. The ability of the mattress to completely change the comfort structure of the mattress by altering the corresponding elasticity of the zoned layer and the zoned areas R1, R2, R3 of the cushion pockets 807, 808, 809 provides the manufacturer with a virtually infinite comfort profile . At the same time, the manufacturer only needs to stock several layers of cushion pockets to achieve this flexibility.

21, in another embodiment, the mattress 900 provides different pocket cushioning properties in different areas of the surface of the water surface, including the upper and lower layers of the zoned cushion pockets. In addition, the mattress 900 provides a flipped dual side mattress. In addition, the upper layer of the cushion pocket may have elasticity (El) and / or flexibility that is different from the elasticity 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 comprised of three alternating and repeating rows of cushion pockets. For purposes of illustration, each zoned column of foam cushioning elements is different in respect of foam elasticity. Other zoning possibilities may include, but are not limited to, different cushion pocket geometry, different cushioning materials, and different combinations and geometries of cushioning layers. Zone 1 includes the row of cushion pockets 910 attached to the top layer 905 of the coil pocket by a mechanical clip 917 inserted through the grommet 918 and inserted through the coil spring 906. 13, the cushion pockets 914 are bonded to the upper surface 912 of the attachment member 911, which in this embodiment is a fabric sheet made of a material having quasi-isotropy. 13, each cushion pocket 914 is spaced and positioned in the cushion pocket 914 such that it is positioned directly above the coil pocket 905 to which the cushion pocket directly acts. In this embodiment, the cushion pocket 914 has a foam cushion member 916 having elasticity R1. It should be noted that the upper layer 914 of the cushion pocket is separate and distinct from the coil pocket layer 902. One type of clip and grommet combination is shown, but one of ordinary skill in the art will appreciate that other forms of clamping on the fabric attachment layer 911 and mechanical clamping on the coil pocket 904 and the enclosed coil spring 906 It should be noted that the mechanical clips of Fig. With this mechanical clamping device, it may be unnecessary to provide the grommet 918 on the attachment layer 911. Zone 2 includes the row of cushion pockets 920 attached to the upper layer of coil pockets 902 by a mechanical clip 927 that is inserted through the grommet 928 and through the coil spring 906. As shown in Figure 13, the cushion pockets 924 are bonded to the upper surface 922 of the attachment member 921, which in this embodiment is a fabric sheet made of semi-isotropic material. 13, each cushion pocket 924 is spaced and positioned in the cushion pocket 924 such that it is positioned directly above the coil pocket 905 to which the cushion pocket directly acts. In this embodiment, the cushion pocket 924 has a foam cushion member 926 having an elasticity R2. It should be noted that the upper layer of the cushion pockets 924 is separated from the layers of the coil pockets 902. Although one type of clip and grommet combination is shown, those skilled in the art will appreciate that other forms of clamping that can be clamped onto the fabric attachment layer 921 and mechanically clamped on the coil pocket 904 and the containment coil spring 906 It should be noted that mechanical clips are also feasible. This mechanical clamping device may eliminate the need to provide a grommet 928 on the attachment layer 921. Zone 3 includes the row of cushion pockets 930 attached to the upper layer of coil pockets 902 by a mechanical clip 937 inserted through the grommet 938 and through the coil spring 906. 13, the cushion pockets 934 are bonded to the upper surface 932 of the attachment member 931, which in this embodiment is a fabric sheet made of semi-isotropic material. 13, each cushion pocket 934 is spaced and positioned in the cushion pocket 934 such that it is positioned directly above the coil pocket 905 to which the cushion pocket directly acts. The cushion pocket 934 has a foam cushion member 936 having elasticity R3 in this embodiment. It should be noted that the upper layer of the cushion pockets 934 is separate and distinct from the layers of the coil pockets 902. One type of clip and grommet combination is shown, but other types of mechanical clips that can be secured to the fabric attachment layer 931 and mechanically clamped on the coil pocket 904 and the enclosed coil spring 906 You need to know what is possible. With this mechanical clamping device, it may be unnecessary to provide a grommet 938 on the attachment layer 931. All of the advantages described in the description of the embodiment of Fig. 13 are available in this embodiment. The use of mechanical fasteners 917,927,937 also allows the manufacturer to easily attach or remove the zoned layers of the cushion pockets from the coil pocket layer 902. [ The ability to completely change the comfort structure of the mattress by altering the corresponding elasticity of the zoned layers and the zoned regions R1, R2, R3 of the cushion pockets 910,920,930 provides the manufacturer with an almost infinite comfort profile. At the same time, the manufacturer only needs to stock several layers of cushion pockets to achieve this flexibility. The mattress is similarly similarly sectioned and has double sides on the other mattress sides with area 4, area 5 and area 6. Zone 4 includes the rows of cushion pockets 940 attached to the lower layer of coil pockets 902 by mechanical clips 947 inserted through grommet 948 and inserted through coil springs 906. The cushion pockets 940 are bonded to the lower surface 941 of the attachment member 943, which in this embodiment is a fabric sheet made of semi-isotropic material. 13, each cushion pocket 940 is spaced and positioned in the cushion pocket 940 such that it is positioned directly beneath the coil pocket 905 to which the cushion pocket directly acts. In this embodiment, the cushion pocket 944 has a foam cushion member 946 having elasticity R4. Zone 5 includes the row of cushion pockets 950 attached to the lower layer of coil pockets 902 by a mechanical clip 957 inserted through the grommet 958 and through the coil spring 906. The cushion pockets 950 are joined to the lower surface 951 of the attachment member 953, which in this embodiment is a fabric sheet made of semi-isotropic material. 13, each cushion pocket 950 is spaced and positioned in the cushion pocket 950 such that it is positioned directly beneath the coil pocket 905 to which the cushion pocket directly acts. In this embodiment, the cushion pocket 954 has a foam cushion member 956 having elasticity R5. Zone 6 includes the row of cushion pockets 960 attached to the lower layer of coil pockets 902 by a mechanical clip 967 inserted through the grommet 968 and through the coil spring 906. The cushion pockets 960 are bonded to the lower surface 961 of the attachment member 963, which in this embodiment is a fabric sheet made of semi-isotropic material. 13, each cushion pocket 960 is spaced and positioned in the cushion pocket 960 such that it is positioned directly beneath the coil pocket 905 to which the cushion pocket directly acts. The cushion pocket 964 has a foam cushion member 966 having elasticity R6 in this embodiment. Given the zoning level, the mattress 900 can be fabricated in a number of different configurations from a small number of cushioning layers and pocket coil springs.

Referring to Figure 22, in another embodiment, a pocket spring unit 1000 according to the present invention includes a first cushion pocket 1008 that is generally associated with coil pocket 1002 and acts directly on the coil pocket. Also provided is a second cushion pocket 1014 that is connected to the coil pocket and acts directly on the coil pocket 1002. [ In the illustrated embodiment, each of the cushion pockets is arranged and aligned on 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 connected to the coil pocket 1002 and acts directly so that all of the force from the cushion pocket 1008 is transferred to the coil pocket 1002. [ The cushion pocket 1014 is connected to the coil pocket 1002 and acts directly so that all of the force from the cushion pocket 1014 is transmitted to the coil pocket 1002. [ As in other embodiments, the pockets 1004 of the coil pockets 1002 are made of nonwoven fabrics. The coil spring 1006 can be any conventional coil, such as a single speed coil spring. As in other embodiments, the pockets 1010 of the cushion pockets 1008 are made of nonwoven fabrics and are connected to the coil pockets 1002 by adhesive or other prior art means. As in other embodiments, the pockets 1014 of the cushion pockets 1016 are made of nonwoven fabrics and are connected to the coil pockets 1002 by an adhesive. As in other embodiments, the resilient member 1012 can be a foam cushion having any desired resilience R1. As in other embodiments, the elastic member 1018 may be a foam cushion having any desired elasticity R2. The elasticity R1 may be equal to elasticity R2 and may be designed to have different elasticity to form a multi-speed cushion assembly. The first cushion pocket 1008 may have a structure different from that of the second cushion pocket 1014. Based on the different geometry of the two cushion pockets, R1 in the cushion pocket 1008 is different from R2 in the cushion pocket 1014 to form a multiple speed cushion assembly. In addition, the present invention is not limited to the two microcushions of the above embodiment, but may include more than two microcushions such as three microcushions.

Referring to Figure 23, a machine 1100 according to another embodiment of the present invention is shown fabricating individual pocket cushions 1130 and attaching them to an adhesive layer 1134 supplied from an adhesive roll 1132. The machine 1100 generally includes a base conveyor 1108 configured to support and move the multi-layer fabric to various forming and cutting stations, and an attachment layer conveyor 1138 configured to move the attachment layer fabric 1134 . The machine 1100 includes a fabric roll 1110 that includes an unfolded fabric 1112 that passes through a known folding mechanism and discharges the folded fabric 1113. The fabric roll 1210 feeds the fabric 1112 into the known folding mechanism and onto the base conveyor 1108. Many other fabrics, including woven fabrics, including cotton, polyester, polypropylene, nylon and fabric blends, along with nonwoven fabrics including polyester, polypropylene, nylon and fabric blends, It does not. The formation of the side of the cushion pocket 1126 of the cushion pocket contour 1128 is formed by the ultrasonic coupling horn 1116. In this embodiment, all contours are performed through ultrasonic welding and ultrasonic welding horns. However, it is contemplated that other types of coupling devices and coupling horns may be utilized, such as, for example, thermal bonding horns and thermally bondable fabrics and thermal bonding. The foam cushion cylinder 1122 is compressed by a number of known means and inserted into the cushion pocket 1126 along the correct final direction. If the cushion cylinder does not have the correct direction for starting operation, the potential energy stored in the compressed foam cushion cylinder 1122 is insufficient and the cushion cylinder can not correct the direction, so that the correct direction of the foam cushion cylinder 1122 . Another unique aspect of the present invention is cutting the individual foam cushion cylinder 1122 from a longer foam cylinder 1120 by a cutting knife 1121. The method further comprises slicing the individual length of foam from the cylindrical tube (1120) of the cushioning material prior to insertion into the pocket. Therefore, the size of each cushion foam cylinder can be programmed and changed in advance. In this way, various areas of the cushion pocket attachment layer with different sized foam cushion pockets 1130 can be zoned. It is contemplated that different elastic foam cylinders 1120 may be used to form a single cushioned pocket attachment layer to form a zoned cushioned pocket attachment layer. It should be noted that the knife 1121 may be, but is not limited to, a shearing knife, a hot knife, or an ultrasonic cutting knife or other cutting device or method. Use of a long foam cylinder 1120 during assembly is highly advantageous because it is ensured that the foam cushion cylinder 1122 always has the correct orientation relative to the cushion pocket 1126. The method further includes using a set of compression jaws to pre-compress the foam so that the foam is easily inserted into the pocket and retains its final orientation during the insertion process. Optionally, a compression set is used to pre-compress the end of the foam cylinder, a foam cylinder is inserted into a pre-formed fabric pocket, and the foam is cut after insertion to form an individual foam cylinder in the fabric pocket. After the foam cushion cylinder 1122 is arranged in the cushion pocket 1126, the ultrasonic coupling horn 1114 forms an outline that seals the cushion pocket 1126. The folded fabric 1113 now advances to the pocket cushion spring cutting station. For illustrative purposes and to better illustrate the overall process, the upper piece of folded fabric 1113 is removed in this example after the initial cushion pocket 1126 is formed. As the folded fabric 1113 continues to move over the conveyor 1108 the cushion pockets 1126 are separated from the folded fabric 1113 advanced by the ultrasonic cutting horn 1118. After the completed pocket cushion 1130 is formed, the cushion pockets are pressed towards the attachment layer 1134 and the attachment layer conveyor 1138. In this embodiment, the adhesive applicator 1136 arranges the adhesive between the pocket cushion 1130 and the adhesive layer 1134. It is apparent to those skilled in the art that other means of attaching the cushion pocket 1130 to the adhesive layer 1134 is possible. This may include, but is not limited to, ultrasonic welding and hot melt adhesives. The entire attachment layer 1134 and the attachment layer conveyor 1138 are movable in both axes of the attachment plane 1134 material plane so that the pocket cushion 1130 can be attached at any desired location on the attachment layer 1134. [

Referring to FIG. 24, a machine 1200 according to another embodiment of the present invention is shown fabricating an individual pocket cushion 1230. The machine 1200 generally includes a base conveyor 1208 configured to support and move the multi-layer fabric to various forming and cutting stations. The machine 1200 further includes a fabric roll 1210 that includes an unfolded fabric 1212 that passes through a known fabric folding mechanism and discharges the folded fabric 1213. [ The fabric roll 1210 feeds the fabric 1212 into a known folding mechanism and onto the base conveyor 1208. Many other fabrics, including woven fabrics, including cotton, polyester, polypropylene, nylon and fabric blends, along with nonwoven fabrics including polyester, polypropylene, nylon and fabric blends, It does not. The formation of the side of the cushion pocket 1226 of the cushion pocket contour 1228 is formed by the ultrasonic coupling horn 1214. In this embodiment, all contours are performed through ultrasonic welding and ultrasonic welding horns. However, it is contemplated that other types of coupling devices and coupling horns may be utilized, such as, for example, thermal bonding horns and thermally bondable fabrics and thermal bonding. The foam cushion cylinder 1222 is compressed by a number of known means and inserted into the cushion pocket 1226 along the correct final direction. If the cushion cylinder does not have the correct direction for starting operation, the potential energy stored in the compressed foam cushion cylinder 1222 is insufficient and the cushion cylinder can not correct the direction, so that we can not correct the direction of the foam cushion cylinder 1222 . Another unique aspect of the present invention is cutting the individual foam cushion cylinder 1222 from the longer foam cylinder 1220 by a cutting knife 1221. [ The method further includes slicing the individual length of foam from the cylindrical tube 1220 of the cushioning material prior to insertion into the pocket. It should be noted that knife 1221 may be, but is not limited to, a shearing knife, a hot knife, or an ultrasonic cutting knife or other cutting device or method. Use of a long foam cylinder 1220 during assembly is very advantageous because it is ensured that the foam cushion cylinder 1222 always has the correct orientation relative to the cushion pocket 1226. The method further includes using a set of compression jaws to pre-compress the foam so that the foam is easily inserted into the pocket and retains its final orientation during the insertion process. Optionally, a compression set is used to pre-compress the end of the foam cylinder, a foam cylinder is inserted into a pre-formed fabric pocket, and the foam is cut after insertion to form an individual foam cylinder in the fabric pocket. After the foam cushion cylinder 1222 is arranged in the cushion pocket 1226, the ultrasonic coupling horn 1216 forms an outline that seals the cushion pocket 1226. The folded fabric 1213 now advances to the pocket cushion spring cutting station. For illustrative purposes and to better illustrate the overall process, the upper piece of folded fabric 1213 is removed in this example after the initial cushion pockets 1226 are formed. As the folded fabric 1213 continues to move over the conveyor 1208 the cushion pockets 1226 are separated from the folded fabric 1213 advanced by the ultrasonic cutting horn 1218. After the completed pocket cushion 1230 is formed, the pocket cushion is arranged in a hopper (not shown) and later utilized within the assembly machine to form a pocket cushioning layer.

25, the mattress 1300 is fixed to the top of the coil pocket layer 1302 by a mechanical clip 1320 inserted through the grommet 1318 and inserted through the coil spring 1306. In other embodiments, And an upper layer 1308 of the microcushion pocket. 13, the microcushion pocket arrangement 1311 is bonded to the upper layer 1318 of the attachment member 1310, which in this embodiment is a fabric sheet made of a material having quasi-isotropy. It should be noted that the top layer 1308 of the microcushion pocket is separate and distinct from the coil pocket layer 1302. 13, the micro-cushion pocket arrangement 1311 is spaced and positioned so that the micro-cushion pocket arrangement is positioned just above the coil pocket 1305 on which each micro-cushion pocket arrangement 1311 directly acts All. In this embodiment, the micro cushion pocket arrangement 1311 is made up of three different micro cushions each having the same or different elasticity (R). One of the microcushions of the microcushion pocket arrangement 1311 has a fabric pocket 1312 surrounding a foam element 1313 having elasticity R1. The second microcushion of the microcushion pocket arrangement 1311 has a fabric pocket 1314 surrounding the foam element 1315 with elasticity R2. The third microcushion of the microcushion pocket arrangement 1311 has a fabric pocket 1316 surrounding the foam element 1317 with elasticity R3. When the three different foam element elasticities R1, R2, R3 form the cushioning elements of the micro-cushion pocket arrangement 1311, we can vary the strength of the cushioning elements Speed cushioning can be formed. In addition, the fabric pockets 1312 may be different from the fabric cushion pockets 1314 or the fabric cushion pockets 1316 and may have a unique geometry. Based on the different geometry of the cushion pockets, R1 of the cushion pocket 1312 may be different from R3 of the cushion pocket 1316 and R2 of the other cushion pocket 1314 to form a multi-speed microcushion assembly. Although one type of clip and grommet combination is shown, those skilled in the art will appreciate that other forms of mechanical, such as those that can be secured to the fabric attachment layer 1310 and mechanically secured to the coil pocket 1304 and the encased coil spring 1306 You should know that clips are also possible. This mechanical clamping device may eliminate the need to provide a grommet 1318 on the attachment layer 1310. All of the advantages described in the description of the embodiment of Fig. 13 are available in this embodiment. The use of the mechanical fastener 1320 also allows the manufacturer, retailer or end user to easily attach or remove the microcushion pocket 1308 layer from the coil pocket layer 1302 by the attachment member 1310. The ability to add or remove the top layer of microcushion pocket 1308 significantly improves the manufacturer ' s manufacturing flexibility when manufacturing the mattress. For example, a manufacturer can reduce the inventory of mattress components and load them with only a small number of cushion pocket layers of the pocket coil unit, and mix and match the two components during the assembly process to create multiple mattress models . The ability to change the cushion pocket layer in a short order for a retailer is one that has a coil spring layer 1302 within the mattress cover 12 that the retailer can access by opening the zipper 1330 of the mattress cover 12 The retailer may change the microcushion layer 1308 to indicate different levels of comfort. The retailer can also match the mattress to the exact comfort preference of the customer by mixing the different microcushion pocket layer 1308 with the pocket coil layer 1302. At the same time, the end user, who decides to change the mattress comfort level in the future, can potentially remove the cushion pocket layer 1308 by releasing the mechanical clip 1320 and release the cushion pocket layer 1308 to another cushioning member comfort level . ≪ / RTI >

Referring to Figure 26, in another embodiment, the mattress 1400 is attached to the top of the coil pocket layer 1402 by a mechanical clip 1420 inserted through the grommet 1418 and inserted through the coil spring 1406 Gt; 1408 < / RTI > 13, the cushion pocket 1412 is coupled to the attachment member 1410 which is a fabric sheet made of a material having quasi-isotropy in this embodiment. 13, the spacing and position of the cushion pockets 1412 are determined such that the cushion pockets are positioned just above the coil pockets 1405 on which the respective cushion pockets 1412 directly act. It should be noted that the upper layer 1408 of the cushion pocket is separated and separated from the coil pocket layer 1402. The upper layer of the cushion pockets 1408 includes an attachment member 1410 having a lower surface 1413 and an upper surface 1411 and a plurality of cushion pockets 1412 secured to the upper surface 1411. Although one type of clip and grommet combination is shown, those skilled in the art will appreciate that other forms of mechanical, such as those that can be secured to the fabric attachment layer 1410 and mechanically secured to the coil pocket 1404 and the enclosed coil spring 1406 You should know that clips are also possible. This mechanical clamping device may eliminate the need to provide a grommet 1418 on the attachment layer 1410. All of the advantages described in the description of the embodiment of Fig. 13 are available in this embodiment. The use of mechanical fastener 1420 also allows a manufacturer, retailer or end user to easily attach or remove a layer of cushion pockets 1408 from coil pocket layer 1402 by attachment member 1410. [ The second cushion pocket layer 1422 also includes a cushion pocket 1424 that engages an attachment layer 1423 disposed just above the cushion layer 1408 such that all of the cushion pockets 1424 extend from the cushion layer 1408 Is directly connected to the cushion pocket 1412 and acts directly. In this embodiment, the cushion layer 1422 via its attachment layer 1423 is bonded directly to the coil layer 1408 by an adhesive. However, it is also expected that other coupling means, such as mechanical coupling, may be used and are not limited thereto. The ability to add or remove the top layer of the cushion pockets 1408,1422 significantly improves the manufacturer ' s manufacturing flexibility when manufacturing the mattress. For example, a manufacturer can reduce the inventory of mattress components and load them with only a small number of cushion pocket layers of the pocket coil unit, and mix and match the two components during the assembly process to create multiple mattress models . The ability to change the cushion pocket layer in a short order for a retailer is one that has a coil spring layer 1402 inside the mattress cover 12 that the retailer can access by opening the zipper 1430 of the mattress cover 12 And the retailer may change the cushioning layers 1408,1422 to indicate different levels of comfort. The retailer can also match the mattress to the exact comfort preference of the customer by mixing the different microcushion pocket layers 1408,1422 with the pocket coil layer 1402. By the ability to load multiple cushion layers and to mix and match potentially different cushion layers with different pocket spring coils, manufacturers have greater product flexibility and require only minimal material components.

Referring to Figure 27, in another embodiment, the mattress 1500 is attached to the upper layer of the coil pocket layer 1502 by a mechanical clip 1520 that is inserted through the grommet 1518 and inserted through the coil spring 1506 And an upper layer 1508 of the cushion to which it is attached. 13, the cushion 1512 is joined to the attachment member 1510, which is a fabric sheet made of a material having quasi-isotropy in this embodiment. 13, the spacing and position of the cushion 1512 are determined such that the cushion pockets are positioned just above the coil pockets 1505 on which the respective cushions 1512 directly act. In this embodiment, the foam cushioning element 1516 is not enveloped within the pocket fabric but is directly bonded to the top surface 1511 of the attachment layer 1510. [ It should be noted that the upper layer 1508 of the cushion is separated and separated from the coil pocket layer 1502. [ Although one type of clip and grommet combination is shown, those skilled in the art will appreciate that other forms of mechanical, such as those that can be secured to the fabric attachment layer 1510 and mechanically secured to the coil pocket 1504 and the enclosed coil spring 1506 You should know that clips are also possible. With this mechanical clamping device, it may be unnecessary to provide a grommet 1518 on the attachment layer 1510. [ All of the advantages described in the description of the embodiment of Fig. 13 are available in this embodiment. The use of the mechanical fastener 1520 also allows the manufacturer, retail store or end user to easily attach or remove the layer of cushion pockets 1508 from the coil pocket layer 1502 by means of the attachment member 1510. The ability to add or remove the top layer of the cushion pockets 1508 significantly improves the manufacturer ' s manufacturing flexibility when manufacturing the mattress. For example, a manufacturer can reduce the inventory of mattress components and load them with only a small number of cushion pocket layers of the pocket coil unit, and mix and match the two components during the assembly process to create multiple mattress models . The ability to change the cushion pocket layer in a short order for a retailer is one that has a coil spring layer 1502 inside the mattress cover 12 that the retailer can access by opening the zipper 1530 of the mattress cover 12 And the retailer may change the cushion layer 1508 to indicate different levels of comfort. The retailer can also match the mattress to the exact comfort preference of the customer by mixing the different microcushion pocket layer 1508 with the pocket coil layer 1502. An end user who decides to change the mattress comfort level at a later time can potentially remove the cushioning layer 1508 by releasing the mechanical clip 1520 and release the cushioning layer 1508 against the elasticity of another cushioning member 1516 .

Although specific embodiments of the invention have been shown and described, those skilled in the art will recognize that changes and modifications may be practiced within the scope of the invention.

Claims (36)

As a mattress:
Wherein each of said first and second coil pockets comprises a pocket and a coil spring arranged in said pocket, said coil pocket layer comprising a first and a second coil pocket,
A first cushion pocket layer comprising first and second cushion pockets, each said first and second cushion pockets comprising a pocket and a cushion member arranged in said pocket, said cushion pocket layer comprising a top surface and Wherein said first and second cushion pockets engage with an upper surface of said attachment member and said sewage surface of said attachment member engages said coil pocket layer to engage said first and second cushion pockets, The second cushion pockets acting directly on the respective first and second coil pockets.
A mattress according to claim 1, wherein the cushion pocket layer is arranged on the coil pocket.
3. A mattress according to claim 2, wherein said attachment member is made of a semi-isotropic material.
The mattress according to claim 3, wherein the attachment member is a fabric sheet.
5. A mattress according to claim 4, wherein each said cushion pocket is connected to said surface of said attachment member by means of an adhesive.
6. The mattress of claim 5, wherein the lower surface of the attachment member is securely attached to the coil pocket layer by an adhesive.
7. A mattress according to claim 6, wherein said pocket of each said coil pocket and said pocket of each said second cushion pocket are fabricated from fabric pieces.
8. A mattress according to claim 7, wherein said coil springs in each of said coil pockets are multi-speed coil springs.
The mattress according to claim 8, wherein the cushion member is a foam piece.
The mattress of claim 1 wherein said attachment member is detachably connected to said coil pocket layer.
11. A mattress according to claim 10, further comprising a fastener for releasably connecting said attachment member with said coil pocket layer.
12. The mattress of claim 11, wherein the fastener comprises a female connector connected to the attachment member and a male connector connected to the coil pocket.
The mattress of claim 12, wherein the female connector is a grommet.
14. A mattress according to claim 13, wherein said male connector is a clip.
The method of claim 1, further comprising: providing a second cushion pocket layer disposed below the coil pocket layer; The second cushion pocket layer comprising first and second cushion pockets; Each of said first and second cushion pockets comprising a pocket and a cushion member arranged in said pocket; The second cushion pocket layer further comprising an attachment member including an upper surface and a lower surface; Said first and second cushion pockets of said second cushion pocket layer being connected to said upper surface of said attachment member; Wherein the lower surface of the attachment member is connected to the coil pocket layer so that the first and second cushion pockets of the second cushion pocket layer act directly on the respective first and second coil pockets.
As a pocket spring:
A first micro-coil pocket including a pocket and a coil spring within the pocket;
A second micro-coil pocket including a pocket and a coil spring within the pocket;
A cushion pocket comprising a pocket and a cushion member within the pocket; Said cushion pockets being arranged and acting on said first and second micro-coil pockets.
17. The pocket spring of claim 16, wherein the first cushion pockets are secured directly to the first and second microcoil pockets.
18. The pocket spring of claim 17, wherein the pocket of the first and second micro-coil pockets and the pocket of the cushion pocket are made of fabric pieces.
19. The pocket spring of claim 18, wherein the coil springs of the first and second micro-coil pockets are multi-speed coil springs.
20. The pocket spring of claim 19, wherein the cushion member is a foam piece.
As a pocket spring:
A coil pocket including a pocket and a coil spring within the pocket;
A first micro-cushion pocket comprising a pocket and a cushion member within the pocket;
The first cushion pockets being arranged and acting on the coil cokes;
A second micro-cushion pocket comprising a pocket and a cushion member within the pocket;
Said second cushion pockets being arranged and acting on said coil cokes.
22. The pocket spring of claim 21, wherein the first and second micro-cushion pockets are secured directly to the coil pockets.
23. The pocket spring of claim 22, wherein the pocket of the first and second micro-cushion pockets and the pocket of the coil pocket are made of fabric pieces.
24. The pocket spring of claim 23, wherein the coil spring is a multi-speed coil spring.
25. The pocket spring of claim 24 wherein said cushioning member of said first and second micro-cushion pockets is a foam piece.
A method of forming a cushion spring comprising:
a) providing at least one piece of fabric;
b) forming a first cushion pocket from the fabric;
c) supplying a continuous piece of cushion material;
d) cutting the cushion member from the continuous piece of cushion material;
e) inserting the cushion material into the first cushion pocket;
f) sealing said first cushion pockets.
27. The method of claim 26, further comprising attaching the cushion pocket to the attachment member.
A first cushion pocket layer comprising first and second cushion pockets, each said first and second cushion pockets comprising a pocket and a cushion member arranged in said pocket, said cushion pocket layer comprising a top surface and Wherein said first and second cushion pockets engage with an upper surface of said attachment member and said sewage surface of said attachment member engages said coil pocket layer to engage said first and second cushion pockets, And the second cushion pockets act directly on the respective first and second coil pockets.
29. The pocket spring unit of claim 28, wherein the attachment member is a fabric sheet.
30. A pocket spring unit according to claim 29, wherein said cushion members of said first and second cushion pockets are foam pieces.
As multi-speed pocket springs;
A coil pocket including a pocket and a coil spring within the pocket;
A first micro-cushion pocket comprising a pocket and a cushion member within the pocket;
The first cushion pockets being arranged and acting on the coil cokes; The cushion member comprises elasticity R1;
A second micro-cushion pocket comprising a pocket and a cushion member within the pocket;
The second cushion pockets being arranged and acting on the coil cokes; Characterized in that the cushion member of the second micro-cushion pocket comprises a resilience (R2) different from the resilience (R1).
32. The multi-speed pocket spring of claim 31, wherein the pocket of the first and second micro-cushion pockets and the pocket of the coil pocket are made of fabric pieces.
33. The multi-speed pocket spring of claim 32, wherein the coil spring is a multi-speed coil spring.
34. The multi-speed pocket spring of claim 33, wherein the cushion members of the first and second micro-cushion pockets are foam pieces.
35. A method according to claim 34, wherein said cushion member of said first micro-cushion pocket comprises a first geometric shape forming said elasticity R1 and said cushion member of said second micro- Wherein the second geometric shape comprises a second geometric shape to form a second geometric shape.
34. The device of claim 33, wherein the cushion member of the first micro-cushion pocket comprises a foam piece forming the elasticity R1, and the cushion member of the second micro- Characterized in that it comprises a foam piece.

Images