Spring coil and spring assembly

Abstract: A spring coil (11) has an open-ended terminal convolution (11b, 11c) which is connected to the body (11a) of the coil through a gradient arm (20) which can be varied in length in manufacture to alter the spring compression and firmness. Offset portions (12, 13, 14) are formed on each terminal convolution with a major straight part (13a) which is outwardly spaced from minor straight parts (13c) for a three point engagement for the offset portion to a border wire (18). The offset portions (12, 14) have inside (25a) and outside (25b) shoulders adjacent their ends, with the pitch of joing cross-helicals (17) chosen so that a cross-helical simultaneously engages the outside shoulders of a pair of overlapped offset portions (12, 14). The spring rows are further arranged across the width of the mattress, with the columns extending along the length. Cross-helicals (28) can then be used across portions of the width for extra firmness for the entire mattress, or for selected areas, such as the middle third.

Description: Mattress innerspring units are generally formed of a plurality of spring coils arranged in side-by-side relation in parallel rows, with parallel columns also thereby being formed orthogonal to the rows. Border wires typically encircle both the upper and lower perimeters of the innerspring unit formed by the most outboard spring coils and are connected to terminal convolutions formed on the ends of the spring coils. It is a common practice to form the terminal convolution with an enlarged diameter with respect to that of the spirals which are axially inward from the coil ends. This facilitates interengagement of the springs and makes the spring coil more stable in compression. Terminal convolutions of adjacent spring coils in a row are overlapped, and helical spring coils, referred to as cross-helicals, are then wound along columns to encircle the overlapped convolution portions. These cross-helicals ordinarily have an internal diameter which is slightly larger than the combined diameters of the overlapped terminal convolution portions. Larger diameter helical springs are also often used to attach a border wire to the terminal convolutions. Examples of some of such springs can be found in GB-A-386251, US-A-1887058 and US-3533114 and US-A-4535978. GB-A-386251 discloses a mattress comprising a plurality of connected coil springs. Each spring has upper and lowermost coils which are provided with two intermediate straight sections and straight free end sections arranged parallel with and opposite to one of the intermediate straight sections and at rightangles to the other. In use the straight free end section is connected to the parallel intermediate section of a neighbouring coil by connecting transverse springs. There are some general considerations of manufacture and comfort which underlie the design of any mattress innerspring. For example, considerable effort has been devoted in the industry to the development of terminal convolutions which facilitate the interengagement of the spring coils as well as their connection to the border wire. For example, terminal convolutions have been developed having offset portions formed thereon which include a straight part. This enables the spring ends to be secured along a substantial length of the straight part which will "catch" more helical spirals, and thereby provide more stability for the individual coils. Improved stability is always being sought, however. These efforts have also been directed to find ways to prevent the spring coils from rotating relative to each other, and perhaps out of the upper or lower plane of the unit. A related problem in this area is that of hinging, where the overlapped portions of coils slip over one another and make noise. Hinging can further occur between coils overlapped with the border wire. Such hinging is obviously desired to be kept at a minimum in a mattress. US-A-3533114 disclosed a spring assembly composed of a peripheral row of springs. The terminal coils have straight sections interengaged by helical locking wires. No provision is made in this assembly to increase stability. US-A-1887058 discloses a spring assembly comprising a plurality of rows of spiral springs. The terminal coils of each spring have opposing inner and outer offset portions provided with angular portions forming shoulders for engaging coils of connecting helicals for preventing rotation of the spirals. However, the resulting structure of this assembly allows hinging and relative movement between the adjacent coils. US-A-4535978 tries to resolve this problem in one way by utilising two complexly shaped offset segments in each terminal coil comprising an apex and a pair of diverging legs which overlie each other exactly, laced around which is a cross helical spring. Another consideration in mattress design and manufacture is the ability to make innerspring units which have different firmness characteristics suited to an individual's personal preference. This may simply amount to providing several mattress lines having differing firmness, or, in more sophisticated mattresses, providing areas of different firmness in a particular mattress innerspring. As may be readily recognised, producing mattresses with different firmness characteristics may be accomplished through the use of springs of differing compression for each mattress firmness, ordinarily achieved by making the various springs out of different wire stock or in different configurations. The overall layout or construction of the innerspring until may also be changed from one mattress firmness to another, such as by changing the coil count and coil arrangement. Use of heavier wire stock, more springs, different springs or a different layout obviously adds expense to mattress production in terms of parts as well as labor. A primary consideration in making mattresses with different degrees of firmness is therefore to do so in the most efficient and economical manner while still achieving the desired results. FIELD OF THE INVENTION This invention relates to spring coils and spring coil assemblies, and particularly to those used in mattress innersprings. SUMMARY OF THE INVENTION The present invention provides a number of innovations and improvements to spring coils and spring coil assemblies, particularly as adapted for use in a mattress innerspring unit. The general considerations outlined above take form in the present invention as a spring coil having a firmness that is readily adjusted in manufacture. The invention further includes spring coil and spring assembly features that assure that the spring coils have little or no rotation relative to each other or to a border wire surrounding an innerspring unit. The invention also comprises various arrangements of spring coils and cross-helicals that yield innerspring assemblies of different firmness characteristics. According to the invention there is provided a spring assembly for a generally rectangular mattress innerspring unit comprising a plurality of spring coils having a spiral spring coil body with two ends, a terminal convolution at each end of said spring coil body, at least one of said terminal convolutions having a first and a second offset portion which are opposed to each other, and a third offset portion joining said first and second offset portions, all of said offset portions being approximately in the same plane, a border wire surrounding a perimeter formed by said spring coils, said third offset portion of each said spring coil having a stepped segment formed thereon, said stepped segment having a major part that is substantially straight and extending generally perpendicular to said first and second offset portions and spaced radially outwardly from said spring coil axis, short parts extending from the ends of said straight part, characterised in that said short parts join with remaining straight segments of said third offset portion which extend generally parallel to said straight part and which join with respective ends of said first and second offset portions, and the third offset portions being joined to said border wire with a border wire helical said a border wire helical coiling around and closely embracing said straight part and said straight segments of said third offset portion adjacent said border wire to hold said third offset portion against rotation about said border wire. In a preferred embodiment of the invention said first, second and third offset portions of said spring coils each have a stepped segment formed thereon. Preferably said first, second and third offset portions of said spring coils each have a stepped segment formed thereon, said stepped segment having a major part that is substantially straight and spaced radially outwardly from said spring coil axis, short parts extending from the ends of said straight part, said short parts joining with remaining straight segments of a respective offset portion which remaining straight segments extend generally parallel to said straight part, said border wire helical coiling around and closely embracing said straight part and said straight segments of perimeter offset portions to hold said perimeter offset portions against rotation about said border wire. The invention provides a spring coil for such an assembly, comprising a spring coil body with two ends, a terminal convolution at each end of said spring coil body, at least one of said terminal convolutions having an offset portion formed thereon, said offset portion having a stepped segment formed thereon, said stepped segment having an elongated major part that is substantially straight, an angled part extending away from said major part at each end of said major part, and minor elongated straight parts which are substantially in line and parallel to said major straight part extending outwardly from the angled parts, said offset portion thereby formed being adapted to be overlapped with a border wire surrounding a perimeter formed by a plurality of spring coils, such that a border wire helical can be coiled around said major and minor straight parts adjacent said border wire to hold said offset portion against rotation about said border wire. Thus there can be provided a unique arrangements of spring coil rows using cross-helicals to interengage the coils. In this respect, the innerspring unit has a length and a width, with the length being longer than the width. The spring coils are arranged in rows extending across the width, with the spring coil columns thereby formed extending along the length. The cross-helicals joining adjacent overlapped spring coils in a row thus extend along the columns. It will be noted that the arrangement of rows across the width of the innerspring unit permits rows to be spaced closer together in certain areas of the unit form more firmness. These areas of increased firmness would accordingly be constant across the entire width of the mattress. The foregoing features and advantages of the invention will be further understood upon consideration of the following detailed description of various embodiments of the invention taken in conjunction with the accompanying drawings, in which: BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a plan view of an end portion of a mattress innerspring unit incorporating the spring coil of Fig. 2; Fig. 2 is a perspective view of a spring coil embodying the gradient arm of this invention; Fig. 3 is an enlarged plan view of a pair of overlapped offset portions encircled by a cross-helical as shown in Fig. 1; Fig. 4 is a view similar to Fig. 1 illustrating three point engagement of the third offset portion with the border wire; Fig. 5 is a view similar to Fig. 4 wherein the terminal convolutions of the spring coils have stepped segments on each offset portion; Fig. 6 is a plan view of a portion of the middle third of a mattress innerspring unit showing orthogonally laced cross-helicals; Fig. 7 is a view similar to Fig. 1 showing overlapped rows and orthogonally laced cross-helicals; Fig. 8 is a graph of spring compression related to the length of the gradient arm; Fig. 9 is a graph of various springs under load; Figs. 10a, 11a and 12a are plan views of terminal convolutions of three spring coils; and Figs. 10b, 11b and 12b are elevational views of the respective terminal convolutions of Figs. 10a, 11a and 12a. DETAILED DESCRIPTION OF PRESENTLY PREFERRED EMBODIMENTS OF THE INVENTION While the invention has found particular application for the innerspring unit of a mattress, and is so described in this environment hereafter, it will be understood that the invention is not limited to this application alone but may find utility in other employments. Referring now to the drawings, Fig. 1 shows an innerspring unit or assembly 10 comprised of spring coils 11 arranged in a rectangular pattern of parallel rows. The rows are shown here extending from right to left as viewed in this drawing, with adjacent rows being spaced apart. These rows extend across the width of the innerspring unit 10. Columns of spring coils 11 (simply referred to as coils hereafter) are thereby formed which extend along the length (longitudinally) of the innerspring unit 10 and are orthogonal to the rows. Extending the rows across the width of the unit permits making areas of increased firmness by simply moving rows closer together. The areas of increased firmness are thereby constant across the width of the unit. With reference now to Fig. 2, the coil 11 has a spiral coil body 11a with terminal convolutions 11b and 11c formed at each end. The spiral body 11a of the illustrated coil has a fairly constant diameter of about 46.8mm (1.843 in) in this embodiment. The terminal convolutions 11b, 11c are identical in form, and have a larger diameter than the spiral body 11a. The coil has an overall axial length of about 127mm (5.00 in) in this embodiment. The terminal convolutions 11b, 11c are each formed in an open end offset configuration comprised of three offset portions 12, 13 and 14 and an open end 15. The overall shape for the terminal convolution 11b, 11c is seen to be rectangular. The offset portions 12 and 14 have generally straight segments which are roughly parallel to each other and of approximately the same length. The third offset portion 13 extends between ends of the first and second offset portions 12, 14 and has a stepped segment which will be described in more detail hereafter. All portions of the terminal convolution are approximately in the same plane, which is perpendicular to the axis of the spring coil. These coils 11 are made from a single piece of wire stock, such as 15 gauge (1.8mm (0.072 in)) wire, which is first given a spiral body shape and then provided with the desired terminal convolutions. The coils 11 are positioned so that the offset portions 12 and 14 of adjacent coils in a row overlap. The overlapped offset pairs are then secured together by spirally rotating a first set of helical coil springs 17 across the rows, i.e. along the columns, so as to interlace the overlapped offset portions. The cross-helicals 17 have an internal diameter which is just slightly greater than the diameter of the overlapped offset portions so that the overlapped relationship is maintained in use. The terminal convolutions 11b and 11c on both the upper and lower sides of the innerspring unit 10 are thus laced together in this fashion. Providing such long relatively straight segments to the offset portions 12 and 14 enables a significant number of cross-helical turns to be made thereabout, which yields a secure engagement of overlapped offset pairs and greater stability for the coils 11. Offset portions 12-14 at the perimeter of the innerspring unit 10 are attached to a border wire 18 that extends around this perimeter. A border wire helical spring 19 is used to make this attachment and is spirally wound about the offset portions which are overlapped with the border wire. A border wire 18 is provided for both the upper and lower sides of the innerspring unit. Second offset portion 14 has a free end 14a which is inwardly turned to extend generally perpendicularly to the straight segment of the second offset portion. First offset portion 12 extends into a connecting segment 20 which connects the terminal convolutions 11b, 11c to the sprial body 11a at a shoulder. The integral connection of the connecting segment 20 and the sprial body 11a is at an angle i.e. not a smooth transition. This connecting segment 20 extends generally perpendicularly from the end of offset portion 12, and is in the same plane as the terminal convolution. The connecting segment 20 forms what will be referred to as a gradient arm for the coil 11. Figs. 10a and 10b, 11a and 11b and 12a and 12b illustrate three terminal convolutions with different gradient arm 20 lengths. The compression of the coil 11, and thus the firmness of the coil, can be adjusted within limits by varying the length of this gradient arm 20. This will be seen with reference to the graph of Fig. 8. As shown in this graph, a coil having a gradient arm of about 6.4mm (1/4 in) in length (measured from the end of the straight segment of the first offset portion 12 to the bend into the spiral body) had a spring gradient of 2.54 N/m (1.45 lbs/in). A like coil 11 with a gradient arm of 15.9mm (5/8 in) in length had a spring gradient of 3.24 N/m (1.85 lbs/in). From the foregoing it will thus be seen that the compression or firmness of the individual coils can be varied by adjusting the length of the gradient arm 20. This is readily accomplished in manufacture through a relatively uncomplicated adjustment in the coil forming machinery. Spring coils of varying firmness can therefore now be manufactured on the same machine from the same wire stock in an efficient and cost effective manner. A present estimate places the preferred range for the length of the gradient arm 20 at about 3 to 9% of the active material length of the spring coil. The active material length is considered to be that length of material which is free to deflect when a load is applied to the spring. The spiral portion of the coil, exclusive of the gradient arms and terminal convolutions, would thus constitute the active material length for the coils illustrated herein. Also, while this firmness adjustment feature of the invention has been described in relation to an embodiment having particular offset portions, it is considered to have applications to other terminal convolution configurations. The spring coil of this invention further provides a firmness that varies under load, i.e. as the coil is deflected. With reference to the graph of Fig. 9, an innerspring units formed with springs of a Bonnell type exhibited a fairly linear deflection in response to an increasing load (line B). An innerspring unit formed of springs of the type shown in Karpen, U.S. Patent No. 3,533,114 likewise exhibited a fairly linear response to load (line A). An innerspring unit comprised of spring coils 11 of this invention exhibited a marked non-linear response to load (line C) in contrast to the foregoing innerspring units. The result is that in the initial stage of deflection, the innerspring assembly of this invention offers a first firmness that provides "surface comfort" to an individual. As increased load is imposed on the innerspring unit, the firmness increases to provide "depth" or "supportive" firmness. A more comfortable mattress is thereby produced. Referring now to Fig. 3, another feature of this invention resides in matching the pitch of the cross-helicals 17 to the length of the offset portions 12, 14 to lock the coils 11 against rotation relative to one another. To this end, each of the offset portions 12, 14 has a shoulder 25 formed at each end thereof. An inside shoulder 25a and an outside shoulder 25b are thereby presented at each shoulder 25. The pitch (as indicated in Fig. 3) of the helical 17 is selected so that the cross-helical simultaneously engages the outside shoulders 25b of one of a pair of overlapped offset portions, such as the outside shoulders of offset portion 14 in Fig. 3. The offset portion 14, and thus its coil 11, is thereby firmly held against rotation by the cross-helical 17. The pitch of the cross-helical 17 is also advantageously selected so that the cross-helical 17 catches the inside shoulders 25a of the other of the pair of overlapped offset portions. As shown in Fig. 3, the overlapped offset portions 12, 14 are coterminus, and the cross-helical 17 catches the inside shoulders 25a of offset portion 12. The coil 11 having the offset portion 12 is thereby further secured against rotation (it being understood that this same coil 11 will have its offset portion 14 held by the next adjacent cross-helical in the manner previously described). Another feature of the invention relates to the three point attachment achieved between perimeter coils 11 and the border wire 18. Referring to Figs. 2 and 4 in particular, third offset portion 13 has a stepped segment formed thereon comprised of a major straight part 13a, angled parts 13b extending from the ends of the major straight part 13a, and minor straight parts 13c extending from the angled parts 13b. The major straight part 13a is spaced radially outwardly from the coil body 11a and is generally tangential thereto. The minor parts 13c are approximately in line with each other and generally parallel to the major straight part 13a. A border wire helical 19 is wrapped around the overlapped border wire 18 and third offset portion 13 to catch the inboard sides of the minor straight parts 13c and the outboard sides of the major straight part 13a. This yields a three point attachment of the offset portion 13 with the border wire which is very secure, and which substantially prevents any hinging of the offset portion with the border wire. As shown in Fig. 5, the terminal convolution of a coil 11 could be provided with such stepped segments on all three of its offset portions 12-14. Three point attachments of the perimeter coils would thus be effected around the entire border wire (although for full effect the last row of coils may have to be reversed so that the third offset portions thereof are adjacent the border wire). Another feature of the invention is the ability to adjust the firmness of the innerspring unit 10 through the addition of a second set of cross-helicals 28 which are orthogonal to the first set 17 to further interlace the coils. As seen in Fig. 6, the cross-helicals 28 extend along the coil rows, that is, they are across the width of the mattress. The cross-helicals 28 are substantially identical to the cross-helicals 17 and are wrapped about the short segments 14a and gradient arms 20 of the terminal convolutions. It will be noted that the cross-helicals 28 could alternatively be wrapped around the third offset portions 13 in a row to the same effect. The second set of cross-helicals 28 provide extra firmness, and can extend along the entire length of one or both sides of the innerspring unit 10, or can be located in selected segments of the innerspring unit 10 to "posturize" the unit, such as the middle third of the innerspring. Such posturizing is readily accomplished due to arranging the springs so that the primary cross-helicals 17 run along the length of the mattress. Fig. 7 illustrates yet another aspect of the invention whereby a very firm innerspring unit is produced. Adjacent rows of coils 11 are overlapped so that the third offset portions 13 of one row extend into the open ends 15 of the coils 11 of an adjacent row. A second set of cross-helicals 28 are then wrapped about the "overlapped" major straight portions 13a of one row and the short segments 14a and gradient arms 20 of the other row. A very dense pattern of coils 11 is thereby produced with virtually no gaps existing between coils 11. Reference is made to European Application No. 87903650.7, and applicants co-pending divisional application of same date.

Claims: A spring assembly (10) for a generally rectangular mattress innerspring unit comprising a plurality of spring coils (11) having a spiral spring coil body (11a) with two ends, a terminal convolution (11b, 11c) at each end of said spring coil body, at least one of said terminal convolutions having a first and a second offset portion (12, 14) which are opposed to each other, and a third offset portion (13) joining said first and second offset portions (12, 14), all of said offset portions (12-14) being approximately in the same plane, a border wire (18) surrounding a perimeter formed by said spring coils (11), said third offset portion (13) of each said spring coil (11) having a stepped segment formed thereon, said stepped segment having a major part (13a) that is substantially straight and extending generally perpendicular to said first and second offset portions (12, 14) and spaced radially outwardly from said spring coil axis, short parts (13b) extending from the ends of said straight part (13a), characterised in that said short parts (13b) join with remaining straight segments (13c) of said third offset portion (13) which extend generally parallel to said straight part (13a) and which join with respective ends of said first and second offset portions (12, 14), and the third offset portions (13) being joined to said border wire (18) with a border wire helical (19) said a border wire helical (19) coiling around and closely embracing said straight part (13a) and said straight segments (13c) of said third offset portion (13) adjacent said border wire (18) to hold said third offset portion (13) against rotation about said border wire (18). A spring assembly (10) as claimed in claim 1 wherein said first, second and third offset portions (12, 14, 13) of said spring coils (11) each have a stepped segment formed thereon. A spring assembly (10) as claimed in claim 1 or claim 2 wherein said first, second and third offset portions (12, 13, 14) of said spring coils (11) each have a stepped segment formed thereon, said stepped segment having a major part that is substantially straight and spaced radially outwardly from said spring coil axis, short parts (13b) extending from the ends of said straight part (13a), said short parts (13b) joining with remaining straigth segments (13c) of a respective offset portion (13) which remaining straight segments (13c) extend generally parallel to said straight part (13a), said border wire helical (19) coiling around and closely embracing said straight part (13a) and said straight segments (13c) of perimeter offset portions (13) to hold said perimeter offset portions (13) against rotation about said border wire (18). A spring coil (11) in the spring assembly as claimed in any one of claims 1, 2 or 3 for a mattress innerspring unit comprising a spring coil body (11a) with two ends, a terminal convolution (11b, 11c) at each end of said spring coil body, at least one of said terminal convolutions having an offset portion (13) formed thereon, said offset portion having a stepped segment formed thereon, said stepped segment having an elongated major part (13a) that is substantially straight, an angled part (13b) extending away from said major part (13a) at each end of said major part (13a), and minor elongated straight parts (13c) which are substantially in line and parallel to said major straight part (13a) extending outwardly from the angled parts (13b), said offset portion (13) thereby formed being adapted to be overlapped with a border wire (18) surrounding a perimeter formed by a plurality of spring coils (11), such that a border wire helical (19) can be coiled around said major (13a) and minor straight parts (13c) adjacent said border wire (18) to hold said offset portion (13) against rotation about said border wire (18).

Inventors: FLESHER KEITH A, WAGNER ROBERT F, FLESHER, KEITH A., WAGNER, ROBERT F.
Applicants: OHIO MATTRESS CO, THE OHIO MATTRESS COMPANY LICENSING AND COMPONENTS GROUP
Application year: 1989
Main classification: A47C27
IPC codes: A47C27