Patent Publication Number: US-11033116-B2

Title: Dual-sided vented pocketed spring comfort layer

Description:
TECHNICAL FIELD OF THE INVENTION 
     This invention relates to a comfort layer for use in bedding and seating products and the method of manufacturing such a comfort layer. 
     BACKGROUND OF THE INVENTION 
     Comfort layers are commonly used in seating or bedding products above/below a core, which commonly is a pocketed spring assembly core. Such comfort layers may include foam, fiber and gel products. Conventional comfort layers are made of individually pocketed mini coil springs joined together with two pieces of spunbonded polypropylene fabric which results in comfort cores, which may be less desirable than the comfort layers of the present invention for the reasons below. 
     U.S. Pat. Nos. 9,943,173 and 9,968,202, each fully incorporated by reference herein, disclose comfort layers made with fabric material which is semi-impermeable to airflow through the fabric material. In such comfort layers, the fabric retards, but does not stop, airflow through the fabric, thereby giving the comfort layer a unique slow to compress, slow to recover feel. 
     Other comfort layers disclosed in U.S. Pat. Nos. 9,943,173 and 9,968,20 are made with layered fabric impermeable to airflow through the fabric. In such comfort layers, air flows between pockets only through gaps between seam segments, thereby giving the comfort layer a different slow to compress, slow to recover feel. 
     However, in all the comfort layers disclosed in U.S. Pat. Nos. 9,943,173 and 9,968,20, air does not freely flow through the fabric. Therefore, a bedding or seating product incorporating one or more of these comfort layers may have a warmer feel than desired due to the impedance of airflow through the comfort layer(s). 
     European Patent No. EP 1707081 discloses a pocketed spring mattress in which each pocket has a ventilation hole in order to improve the airflow into and out of the pocket. However, one drawback to such a product, depending upon the fabric used in the product, is that the fabric of the pocket may create “noise”, as the sound is named in the industry. Such noise may be created by the fabric expanding upon removal of the load due to the coil spring&#39;s upwardly directed force on the fabric. 
     It is therefore an objective of this invention to provide a pocketed spring comfort layer for a seating or bedding product, which has increased airflow through the comfort layer for cooling purposes. 
     Still another objective of this invention is to provide a pocketed spring comfort layer for a seating or bedding product having less noise than known pocketed spring comfort layers. 
     SUMMARY OF THE INVENTION 
     The invention, which accomplishes these objectives, comprises a comfort layer configured to overlay a spring core of a seating or bedding product. The comfort layer comprises an assembly or matrix of individually pocketed mini coil springs, each spring being contained within a fabric pocket. The fabric pocketing material within which the mini springs are contained, spunlaced aperture nonwoven fabric has an array or pattern of apertures that allows airflow through the fabric at a greater rate than conventional spunbond nonwoven polypropylene fabric. Due to the fabric of the comfort layers of the present invention, a bedding or seating product, such as a mattress, may have a cooler feel in areas of body contact with the product due to increased airflow through the comfort layers of the product. 
     The vented spunlaced aperture nonwoven fabric is permeable to airflow through the fabric material. As used herein, the term “permeable” means that the fabric material permits airflow through the material at a rate which does not retard or slow the rate at which a spring maintained in a pocket of the fabric may compress under load or return to its original height when a load is removed from the pocketed spring. In other words, air may pass through such a permeable material at a higher or increased rate compared to the rate at which air usually flows through a nonwoven polypropylene fabric commonly used in the bedding industry. 
     Each pocket has a weld seam around the pocket joining first and second pieces of fabric. The weld seams may be circular or rectangular. At least one of the pieces of fabric is made of a nonwoven spunlaced aperture fabric to increase the rate at which air escapes though the fabric when a load is placed on the pocket. At least one of the pieces of fabric may be made at least partially of polyester. Additionally, the rate of compression of the coil springs subjected to the load is increased by apertures in the fabric. The apertures are preferably oval-shaped, but may be any desired shape. Similarly, the size of the apertures may be as desired. 
     When a load is applied to a comfort layer made with permeable fabric, the rate of deflection of the comfort layer is enhanced by the rate at which air escapes through the permeable fabric within which the pocketed springs are contained and by the rate at which air travels between segments of seams separating individual pockets. Much more air escapes the pockets through the fabric than between the seam segments. 
     Any of the embodiments of comfort layer shown or described herein may be incorporated into a bedding product, such as a mattress, foundation or pillow. Further, any of the embodiments of comfort layer shown or described herein may be incorporated into a seating product, such as a vehicle seat and/or office or residential furniture, such as a recliner. Alternatively, any of the embodiments of comfort layer shown or described herein may be sold independently as a retail or wholesale item. In such an application, the comfort layer may be added to and/or removed from a bedding or seating product by a customer. 
     The comfort layer of the present invention, whether incorporated inside a bedding or seating product, or manufactured and sold as a separate product, provides an additional cooling effect to the product due to airflow through the comfort layer, including between adjacent pockets. The amount of airflow between pockets may be changed by changing the size of the teeth or slots on a welding tool, including an ultrasonic welding tool. An alternative way to adjust airflow inside a comfort layer and out of the comfort layer is to change the fabric material of the comfort layer. 
     According to another aspect of the invention, a comfort layer is configured to overlay a spring core of a seating or bedding product. The comfort layer comprises an assembly or matrix of mini coil springs. The comfort layer further comprises a first piece of nonwoven spunlaced aperture fabric permeable to airflow through the fabric on one side of the matrix of mini coil springs. The comfort layer further comprises a second piece of nonwoven spunlaced aperture fabric on another side of the matrix of mini coil springs. The first and second pieces of fabric are permeable to airflow through the fabric. Due to apertures in the fabric, air may pass through such a permeable fabric material at a higher or increased rate compared to the rate at which air flows through a nonwoven polypropylene material commonly used in the bedding industry. The apertures are preferably oval-shaped, but may be any desired shape. Similarly, the size of the apertures may be as desired. 
     The first and second pieces of fabric are joined together with weld seams to create individual pockets which contain the mini coil springs. The weld seams may be circular or rectangular. The weld seams may be solid or segmented. Segmented weld seams have gaps between weld segments through which air may flow. 
     According to another aspect of the invention, a comfort layer is configured to overlay a spring core of a seating or bedding product. The comfort layer comprises mini coil springs and a first piece of nonwoven spunlaced aperture fabric permeable to airflow through the fabric on one side of the mini coil springs. The comfort layer further comprises a second piece of nonwoven spunlaced aperture fabric on another side of the mini coil springs. The first and second pieces of fabric are joined together with weld seams comprising spaced weld segments surrounding each of the mini coil springs to create gaps between weld segments and individual pockets which contain the mini coil springs. The first and second pieces of fabric are permeable to airflow through the fabric. The weld seams may be circular or rectangular. 
     When at least some of the pockets are subjected to a load, air moves out of the pockets through the apertures in the fabric and through the gaps between the segments of the seams, the rate of compression of the mini coil springs being increased by the size of the gaps between the weld segments of the weld seams and apertures in the fabric. The nonwoven spunlaced aperture fabric may be made of any fabric weldable to itself and is commonly made of at least some polyester fibers. 
     These and other objects and advantages of this invention will be more readily apparent from the following drawings, in which: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view, partially broken away, of a bedding product incorporating one of the comfort layers of this invention; 
         FIG. 2  is a perspective view of the comfort layer of  FIG. 1  being manufactured; 
         FIG. 2A  is a perspective view of a portion of the machine of  FIG. 2 , the mini coil springs being inserted into predetermined positions; 
         FIG. 3A  is a cross-sectional view of a beginning portion of the manufacturing process using the machine of  FIGS. 2 and 2A ; 
         FIG. 3B  is a cross-sectional view of the springs being compressed in the manufacturing process using the machine of  FIGS. 2 and 2A ; 
         FIG. 3C  is a cross-sectional view of the springs being laterally moved in the manufacturing process using the machine of  FIGS. 2 and 2A ; 
         FIG. 3D  is a cross-sectional view of the upper ply of fabric being moved in the manufacturing process using the machine of  FIGS. 2 and 2A ; 
         FIG. 3E  is a cross-sectional view of one of the springs being sealed in the manufacturing process using the machine of  FIGS. 2 and 2A ; 
         FIG. 4  is an enlarged perspective view of a portion of the comfort layer of  FIG. 1  partially disassembled and showing a portion of a welding tool; 
         FIG. 4A  is an enlarged perspective view of a portion of the comfort layer of  FIG. 1  partially disassembled and showing a portion of another welding tool; 
         FIG. 5  is a top plan view of a portion of the comfort layer of  FIG. 1 , the arrows showing airflow inside the comfort layer; 
         FIG. 5A  is a cross-sectional view taken along the line  5 A- 5 A of  FIG. 5 ; 
         FIG. 6  is a top plan view of a portion of another comfort layer, the arrows showing airflow inside the comfort layer; 
         FIG. 6A  is a cross-sectional view taken along the line  6 A- 6 A of  FIG. 6 ; 
         FIG. 7  is a perspective view, partially broken away, of a bedding product incorporating another embodiment of comfort layer in accordance with the present invention; 
         FIG. 8  is a perspective view of the comfort layer of  FIG. 7  being manufactured; 
         FIG. 9  is an enlarged perspective view of a portion of the comfort layer of  FIG. 7  partially disassembled and showing a portion of a welding tool; 
         FIG. 9A  is an enlarged perspective view of a portion of the comfort layer of  FIG. 7  partially disassembled and showing a portion of another welding tool; 
         FIG. 10  is a top plan view of a portion of the comfort layer of  FIG. 7 , the arrows showing airflow inside the comfort layer; 
         FIG. 10A  is a cross-sectional view taken along the line  10 A- 10 A of  FIG. 10 ; 
         FIG. 11  is a top plan view of a corner portion of the comfort layer of  FIG. 1 , the arrows showing airflow into and out of the comfort layer; 
         FIG. 11A  is a top plan view of a corner portion of the comfort layer of  FIG. 7 , the arrows showing airflow into and out of the comfort layer; 
         FIG. 12  is a top plan view of a corner portion of another embodiment of comfort layer; 
         FIG. 12A  is a top plan view of a corner portion of another embodiment of comfort layer; 
         FIG. 13A  is a perspective view of a posturized comfort layer; 
         FIG. 13B  is a perspective view of another posturized comfort layer; 
         FIG. 14  is a perspective view of a web of comfort layer according to another aspect of the invention; 
         FIG. 14A  is a perspective view of a web of comfort layer according to another aspect of the invention; 
         FIG. 15  is a top plan view of a portion of the comfort layer of  FIG. 14 , the arrows showing airflow inside the comfort layer; 
         FIG. 15A  is a cross-sectional view taken along the line  15 A- 15 A of  FIG. 15 ; 
         FIG. 16  is a top plan view of a portion of another comfort layer, the arrows showing airflow inside the comfort layer; 
         FIG. 16A  is a cross-sectional view taken along the line  16 A- 16 A of  FIG. 16 ; 
         FIG. 17A  is a perspective view of a posturized comfort layer; 
         FIG. 17B  is a perspective view of another posturized comfort layer; and 
         FIG. 18  is an enlarged view of one of the apertures of the nonwoven spunlaced aperture fabric used in the comfort layers of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     With reference to  FIG. 1 , there is illustrated a single-sided mattress  10  incorporating one embodiment of comfort layer in accordance with this invention. This mattress  10  comprises a spring core  12  over the top of which there is a conventional cushioning pad  14 , which may be partially or entirely made of foam or fiber or gel, etc. The cushioning pad  14  may be covered by a comfort layer  16  constructed in accordance with the present invention. A second conventional cushioning pad  14  may be located above the comfort layer  16 . In some applications, one or both of the cushioning pads  14  may be omitted. This complete assembly may be mounted upon a base  18  and is completely enclosed within an upholstered cover  20 . 
     As shown in  FIG. 1 , mattress  10  has a longitudinal dimension or length L, a transverse dimension or width W and a height H. Although the length L is shown as being greater than the width W, they may be identical. The length, width and height may be any desired distance and are not intended to be limited by the drawings. 
     While several embodiments of comfort layer are illustrated and described as being embodied in a single-sided mattress, any of the comfort layers shown or described herein may be used in a single-sided mattress, double-sided mattress or seating cushion. In the event that any such comfort layer is utilized in connection with a double-sided product, then the bottom side of the product&#39;s core may have a comfort layer applied over the bottom side of the core and either comfort layer may be covered by one or more cushioning pads made of any conventional material. According to the practice of this invention, though, either the cushioning pad or pads, on top and/or bottom of the core, may be omitted. The novel features of the present invention reside in the comfort layer. 
     Although spring core  12  is illustrated being made of unpocketed coil springs held together with helical lacing wires, the core of any of the products, such as mattresses shown or described herein, may be made wholly or partially of pocketed coil springs (see  FIG. 7 ), one or more foam pieces (not shown) or any combination thereof. Any of the comfort layers described or shown herein may be used in any single or double-sided bedding or seating product having any conventional core. This document is not intended to limit in any way the core. The core may be any conventional core including, but not limited to, pocketed or unpocketed spring cores. 
       FIG. 4  illustrates the components of one embodiment of comfort layer  16  incorporated into the mattress  10  shown in  FIG. 1 . The comfort layer  16  comprises a first or upper piece of fabric  22  and a second or lower piece of fabric  24  with a plurality of mini coil springs  28  therebetween. Each of the first and second pieces of fabric  22 ,  24  is made of nonwoven spunlaced aperture fabric having a pattern of apertures  25  therethrough which allow air to flow quickly through the fabric. One of the apertures  25  is shown in detail in  FIG. 18 . 
     The fabric pieces  22 ,  24  are joined together with circular containments or weld seams  30 , each weld seam  30  surrounding a mini coil spring  28 . Each weld seam  30  comprises multiple arced or curved weld segments  26  with gaps  31  therebetween. The first and second pieces of fabric  22 ,  24  are joined together along each arced or curved weld segment  26  of each circular weld seam  30 . The first and second pieces of fabric  22 ,  24  are not joined together along each gap  31  between adjacent weld segments  26  of each circular weld seam  30 . The curved weld segments  26  are strategically placed around a mini coil spring  28  and create the circular weld seam  30 . The two pieces of fabric  22 ,  24 , in combination with one of the circular weld seams  30 , define a cylindrical-shaped pocket  44 , inside of which is at least one mini coil spring  28 . See  FIGS. 5 and 5A . 
     During the welding process, the mini coil springs  28  may be at least partially compressed before pocket  44  is closed and thereafter. If desired, resilient members other than mini coil springs, such as foam members, may be used. Alternatively, resilient members made of other resilient material(s), including those partially made of foam, which return to an original configuration after a load is removed from the material, may be used inside the pockets. 
     The size of the curved weld segments  26  of weld seams  30  are not intended to be limited by the illustrations; they may be any desired size depending upon the airflow desired inside the comfort layer. Similarly, the size, i.e., diameter of the illustrated weld seams  30 , is not intended to be limiting. The placement of the weld seams  30  shown in the drawings is not intended to be limiting either. For example, the weld seams  30  may be organized into aligned rows and columns, as shown in  FIGS. 5 and 5A  or organized with adjacent columns being offset from each other, as illustrated in  FIGS. 6 and 6A . Any desired arrangement of weld seams may be incorporated into any embodiment shown or described herein. 
     The weld segments may assume shapes other than the curved weld segments illustrated. For example, the welds or seams may be circular around mini coil springs, but the weld segments may assume other shapes, such as triangles or circles or ovals of the desired size and pattern to obtain the desired airflow between adjacent pockets inside the comfort layer and into or out of the perimeter of the comfort layer. 
     In any of the embodiments shown or described herein, each mini coil spring  28  in a relaxed condition may be between approximately 0.75 and 2.5 inches tall, have a diameter of approximately three inches and be made of seventeen and one-half gauge wire. While compressed inside one of the pockets  44 , each of the mini coil springs  28  may be approximately one and one-half inches tall. However, the mini coil springs  28  in a relaxed condition may be any desired height, have any desired shape, such as an hourglass or barrel shape, and be made of any desired wire thickness or gauge. 
     The focus of the present invention is on the fabric which makes up at least one of the first and second pieces of fabric  22 ,  24 . Although the drawings show the first and second pieces of fabric  22 ,  24  being identical, it is within the scope of the present invention that only one of the first and second pieces of fabric  22 ,  24  be the aperture fabric shown in the drawings. 
     As best shown in  FIG. 18 , each of the apertures  25  shown throughout each of the first and second pieces of fabric  22 ,  24  has an oval-shape comprising a length “L” and a width “W” in a relaxed condition. Some fabrics which have proven satisfactory are available from Hangzhou Nbond Nonwoven Company, Limited of China. These fabrics include a nonwoven spunlaced aperture fabric having four apertures per square centimeter in which the length dimension “L” is three (3) millimeters and the width dimension “W” is 2.5 millimeters. This fabric is known in the industry as a four-mesh fabric. 
     Another fabric from the same supplier is a nonwoven spunlaced aperture fabric having eight apertures per square centimeter in which the length dimension “L” is three millimeters and the width dimension “W” is one millimeter. This fabric is known in the industry as an eight-mesh fabric. 
     Another fabric from the same supplier is a nonwoven spunlaced aperture fabric having ten apertures per square centimeter in which the length dimension “L” is 1.8 millimeters and the width dimension “W” is one millimeter. This fabric is known in the industry as a ten-mesh fabric. 
     Another fabric from the same supplier is a nonwoven spunlaced aperture fabric having twenty apertures per square centimeter in which the length dimension “L” is 1.2 millimeters and the width dimension “W” is 0.7 millimeter. This fabric is known in the industry as a twenty-mesh fabric. 
     Another fabric from the same supplier is a nonwoven spunlaced aperture fabric having twenty-two apertures per square centimeter in which the length dimension “L” is 0.8 millimeters and the width dimension “W” is 0.4 millimeter. This fabric is known in the industry as a twenty-two mesh fabric. 
     Each of the first and second pieces of fabric  22 ,  24  preferably has a fabric weight of between 45 grams per square meter and 150 grams per square meter, but may have any desired fabric weight. Any of these nonwoven spunlaced aperture fabrics is said to be vented and allows air to flow freely though the material while still providing enough surface area to glue one piece of the nonwoven spunlaced aperture fabric to another surface, such as a surface of a foam piece of a surface of a pocketed spring assembly. 
     In order to be weldable to itself, the nonwoven spunlaced aperture fabric must be made of at least 50 percent synthetic fibers, such as polyester fibers, including polyethylene terephthalate (PET) fibers. The other fibers in the fabric may be made of viscose fibers, bamboo, Tencel, cotton, nylon, bio-component fiber, polylactic acid (“PLA”) fiber, rayon or wood pulp or any combination thereof. 
     With reference to  FIG. 4 , there is illustrated a portion of a mobile ultrasonic welding horn  32  and anvil  42 . The movable ultrasonic welding horn  32  has a plurality of spaced cut-outs or slots  34  along its lower edge  36 . The remaining portions  38  of the ultrasonic welding horn&#39;s bottom  36  between the slots  34  are the portions which weld the two pieces of fabric  22 ,  24  together and create the curved weld segments  26 . Along the ultrasonic welding horn&#39;s bottom edge  36 , the ultrasonic welding horn  32  can be milled to make the slots a desired length to allow a desired airflow between the curved weld segments  26  as illustrated by the arrows  40  of  FIG. 5 . The airflows affect the feel/compression of the individually pocketed mini coil springs  28  when a user lays on the mattress  10 . 
     As shown in  FIG. 4 , underneath the second piece of fabric  24  is an anvil  42  comprising a steel plate of ⅜ th  inch thickness. However, the anvil may be any desired thickness. During the manufacturing process, the ultrasonic welding horn  32  contacts the anvil  42 , the two pieces of fabric  22 ,  24  therebetween, to create the circular weld seams  30  and, hence, cylindrical-shaped pockets  44 , at least one mini coil spring being in each pocket  44 . 
     These curved weld segments  26  are created by the welding horn  32  of a machine (not shown) having multiple spaced protrusions  38  on the ultrasonic welding horn  32 . As a result of these circular weld seams  30  joining pieces  22 ,  24 , the pieces  22 ,  24  define a plurality of spring-containing pockets  44  of the comfort layer  16 . One or more mini coil springs  28  may be contained within an individual pocket  44 . 
       FIG. 4A  illustrates another apparatus for forming the circular weld seams  30  comprising multiple curved weld segments  26  having gaps  31  therebetween for airflow. In this apparatus, the ultrasonic welding horn  32   a  has no protrusions on its bottom surface  39 . Instead, the bottom surface  39  of ultrasonic welding horn  32   a  is smooth. As shown in  FIG. 4A , the anvil  42   a  has a plurality of curved projections  41 , which together form a projection circle  43 . A plurality of projection circles  43  extend upwardly from the generally planar upper surface  45  of anvil  42   a . When the ultrasonic welding horn  32   a  moves downwardly and sandwiches the plies  22 ,  24  of fabric between one of the projection circles  43  and the smooth bottom surface  39  of ultrasonic welding horn  32   a , a circular weld seam  30  is created, as described above. Thus, a plurality of pockets  44  are created by the circular weld seams  30 , each pocket  44  containing at least one mini coil spring  28 . 
     Upon being subjected to a load, a pocket  44  containing at least one mini coil spring  28  is compressed by compressing the mini coil spring(s)  28  and air contained within the pocket  44 . Air exits the pocket  44  through apertures  25  in the fabric and gaps  31  between the curved weld segments  26  of the circular weld seams  30 . Similarly, when a load is removed from the pocket  44 , the mini coil spring  28  separates the fabric layers  22 ,  24 , and air reenters the pocket  44  though apertures  25  in the fabric and through the gaps  31  between the curved weld segments  26  of the circular weld seams  30 . As shown in  FIG. 5 , the size of the gaps  31  between the segments  26  of circular seams  30  of perimeter pockets  44  may affect how quickly air may enter or exit the comfort layer  16 . 
     In the present invention the fabric material is permeable to airflow, so the rate at which the mini coil springs  28  compress when a load is applied to a pocketed spring core comfort layer  16  is not slowed or retarded by the air entrapped within the individual pockets as the pocketed spring comfort layer  16  is compressed. Similarly, the rate of return of the compressed coil spring comfort layer to its original height after compression is not retarded or slowed by the rate at which air may pass through the permeable fabric material into the interior of the individual pockets  44  of the pocketed spring comfort layer  16 . Air passes through the apertures in the first and second pieces of fabric  22 ,  24  when the pocket  44  is compressed and when the pocket  44  is unloaded, enlarging or expanding due to the inherent characteristics of the mini springs  28 . In addition, air passes through the gaps  31  between the curved weld segments  26  of the circular weld seams  30 , as described above. 
     As best illustrated in  FIG. 5 , the individual pockets  44  of comfort layer  16  may be arranged in longitudinally extending columns  46  extending from head-to-foot of the bedding product and transversely extending rows  48  extending from side-to-side of the bedding product. As shown in  FIGS. 5 and 5A , the individual pockets  44  of one column  46  are aligned with the pockets  44  of adjacent columns  46 . 
       FIGS. 6 and 6A  illustrate another comfort layer  50  having the same pockets  44  and same springs  28  as does the embodiment of comfort layer  16  of  FIGS. 1-5A . As best illustrated in  FIG. 6 , the individual pockets  44  of comfort layer  50  are arranged in longitudinally extending columns  52  extending from head-to-foot of the bedding product and transversely extending rows  54  extending from side-to-side of the bedding product. As shown in  FIGS. 6 and 6A , the individual pockets  44  of one column  52  are offset from, rather than aligned with, the pockets  44  of the adjacent columns  52 . 
       FIG. 7  illustrates an alternative embodiment of comfort layer  56  incorporated into a single-sided mattress  60 . Single-sided mattress  60  comprises a pocketed spring core  62 , a cushioning pad  14  on top of the pocketed spring core  62 , a base  18 , another cushioning pad  14  above comfort layer  56 , and an upholstered covering material  20 . Pocketed spring core  62  may be incorporated into any bedding or seating product, including a double-sided mattress, and is not intended to be limited to single-sided mattresses. As described above, comfort layer  56  may be used in any conventional core, including a spring core made with non-pocketed conventional springs, such as coil springs. 
     As shown in  FIG. 7 , mattress  60  has a longitudinal dimension or length L, a transverse dimension or width W and a height H. Although the length L is shown as being greater than the width W, they may be identical. The length, width and height may be any desired distance and are not intended to be limited by the drawings. 
       FIG. 9  illustrates the components of the comfort layer  56  incorporated into the mattress  60  shown in  FIG. 7 . The comfort layer  56  comprises a first piece of fabric  64  and a second piece of fabric  66  joined together with multiple linear weld segments  68 . The first and second pieces of fabric  64 ,  66  are made of the same nonwoven spunlaced aperture fabric described herein with respect to first and second pieces of fabric  22 ,  24 . Each of the first and second pieces of fabric  64 ,  68  is made of nonwoven spunlaced aperture fabric having a pattern of apertures  25  therethrough which allow air to flow quickly through the fabric. One of the apertures  25  is shown in detail in  FIG. 18 . 
     The weld segments  68  are strategically placed around a mini coil spring  28  and create a rectangular containment or seam  70 . During the welding process, the mini coil springs  28  may be compressed. The length and/or width of the linear weld segments  68  of seams  70  is not intended to be limited to those illustrated; they may be any desired size depending upon the airflow desired through the comfort layer. Similarly, the size of the illustrated seams  70  is not intended to be limiting. Shapes other than linear weld segments may be used to create rectangular seams. Such shapes may include, but are not limited to, triangles or circles or ovals of any desired size and pattern to obtain the desired airflow between adjacent pockets and into or out of the perimeter of the comfort layer. 
     With reference to  FIG. 9 , there is illustrated a portion of an ultrasonic welding horn  72  and anvil  74 . The mobile or movable ultrasonic welding horn  72  has a plurality of spaced cut-outs or slots  76  between projections  80 . The projections  80  of the ultrasonic welding horn  72  are the portions which weld the two pieces of fabric  64 ,  66  together and create the linear weld segments  68  in rectangular weld seams  70 . Along the ultrasonic welding horn&#39;s lower portion  78 , the ultrasonic welding horn  72  can be milled to allow a desired airflow between the linear weld segments  68  as illustrated by the arrows  82  of  FIG. 7 . The airflows affect the feel/compression of the individually pocketed mini coil springs  28  when a user lays on the mattress  60 . 
     As shown in  FIG. 9 , underneath the second piece of fabric  66  is an anvil  74  comprising a steel plate of ⅜ th  inch thickness. However, the anvil may be any desired thickness. During the manufacturing process, the ultrasonic welding horn  72  contacts the anvil  74 , the two pieces of fabric  64 ,  66  being therebetween, to create the rectangular weld seams  70  and, hence, pockets  84 , at least one mini coil spring  28  being in each pocket  84 . See  FIGS. 10 and 10A . 
     These linear weld segments  68  may be created by the welding horn  72  of a machine (shown in  FIG. 8  and described below) having multiple spaced protrusions  80  on the ultrasonic welding horn  72 . As a result of these rectangular weld seams  70  defining the spring-containing pockets  84  of the comfort layer  56 , each mini coil spring  28  is contained within its own individual pocket  84 . Air exits the pocket  84  through gaps  77  between the weld segments  68  of the rectangular weld seams  30 . Similarly, when a load is removed from the pocket  84 , the mini coil spring  28  separates the fabric layers  64 ,  66 , and air reenters the pocket  84  though the gaps  77  between the weld segments  68  of the rectangular weld seams  70 . As shown in  FIG. 10 , the size of the gaps  77  between the segments  68  of rectangular weld seams  70  of the pockets  84  may assist how quickly air may enter or exit the comfort layer  56 . 
       FIG. 9A  illustrates another apparatus for forming the rectangular weld seams  70  comprising multiple linear weld segments  68  having gaps  77  therebetween for airflow. In this apparatus, the ultrasonic welding horn  72   a  has no protrusions on its bottom surface  79 . Instead, the bottom surface  79  of ultrasonic welding horn  72   a  is smooth. The anvil  74   a  has a plurality of linear projections  71 , which together form a projection pattern  73 , shown in  FIG. 9A . A plurality of spaced projections  71  in pattern  73  extend upwardly from the generally planar upper surface  75  of anvil  74   a . When the ultrasonic welding horn  72   a  moves downwardly and sandwiches the pieces  64 ,  66  of fabric between the projections  71  and the smooth bottom surface  79  of ultrasonic welding horn  72   a , rectangular weld seams  70  are created. Thus, a plurality of pockets  84  are created by the rectangle weld seams  70 , each pocket  84  containing at least one mini coil spring  28 . 
     In accordance with the practice of this invention, one fabric material permeable to airflow, which may be used in either of the two pieces of the pocketed spring comfort layers disclosed or shown herein, may be a nonwoven spunlaced aperture fabric with apertures  25 . 
     In an air permeability test known in the industry as the ASTM Standard D737, 2004 (2012), “Standard Test Method for Air Permeability of Textile Fabrics,” ASTM International, West Conshohocken, Pa. 2010, airflow through the permeable ten-mesh nonwoven spunlaced aperture fabric available from Hangzhou Nbond Nonwoven Company, Limited of China described above was measured. The average result was approximately 477 cubic feet per minute (“CFM”). Using the same test with semi-impermeable fabric available from Hanes Industries of Conover, N.C. disclosed in U.S. Pat. No. 9,943,173 resulted in a range of between 0.029 and 0.144 CFM. Using the same test with conventional nonwoven spunbond polypropylene bedding fabric resulted in an average of 146 CFM. 
     As these test results show, air flows much quicker and easier through the nonwoven spunlaced aperture fabric of the present invention compared to the semi-impermeable fabric available from Hanes Industries of Conover, N.C. disclosed in U.S. Pat. No. 9,943,173. Using such test data, air flows through the ten-mesh nonwoven spunlaced aperture fabric over one thousand times quicker than the semi-impermeable fabric described available from Hanes Industries of Conover, N.C. disclosed in U.S. Pat. No. 9,943,173. Using the same test data, air flows through the ten-mesh nonwoven spunlaced aperture fabric over four times quicker than conventional nonwoven spunbond polypropylene bedding fabric. 
     As best illustrated in  FIG. 10 , the individual pockets  84  of comfort layer  56  may be arranged in longitudinally extending columns  86  extending from head-to-foot of the bedding product and transversely extending rows  88  extending from side-to-side of the bedding product. As shown in  FIGS. 10 and 10A , the individual pockets  84  of one column  86  are aligned with the pockets  84  of the adjacent columns  86 . Air may flow between pockets  84  and into and out of the comfort layer  56  between the linear segments  68  of seams  70 . 
       FIG. 11  illustrates one corner of comfort layer  16  of mattress  10  showing airflow between the curved weld segments  26  of the peripheral pockets  44 , as illustrated by the arrows  40 . Although  FIG. 11  illustrates the arrows  40  only on one corner pocket  44 , each of the pockets  44  around the periphery of the comfort layer  16  allows airflow through the gaps  31  between the weld segments  26  of circular seams  30 . This airflow affects the amount of air entering the comfort layer  16  when a user changes position or gets off the bedding or seating product, thus allowing the springs  28  in the pockets  44  to expand and air to flow into the comfort layer  16 . Similarly, when a user gets onto a bedding or seating product, the springs  28  compress and cause air to exit the pockets  44  around the periphery of the comfort layer  16  and exit the comfort layer. The amount of air exiting the comfort layer  16  affects the feel/compression of the individually pocketed mini coil springs  28  when a user lays on the mattress  10 . 
       FIG. 11A  illustrates one corner of comfort layer  56  of mattress  60  of  FIG. 7  showing airflow between the weld segments  68  of the peripheral pockets  84 , as illustrated by the arrows  82 . Although  FIG. 11A  illustrates the arrows  82  only on one corner pocket  84 , each of the pockets  84  around the periphery of the comfort layer  56  allows airflow through the gaps  77  between the weld segments  68  of rectangular seams  70 . This airflow affects the amount of air entering the comfort layer  56  when a user changes position or gets off the bedding or seating product, thus allowing the springs  28  in the pockets  84  to expand and air to flow into the comfort layer  56 . Similarly, when a user changes position or gets onto a bedding or seating product, the springs  28  compress and cause air to exit the pockets  84  around the periphery of the comfort layer  16  and exit the comfort layer. The amount of air exiting the comfort layer  56  affects the feel/compression of the individually pocketed mini coil springs  28  when a load is applied to the mattress  10 . 
       FIG. 12  illustrates one corner of an alternative embodiment of comfort layer  16   a , which may be used in any bedding or seating product. The comfort layer  16   a  comprises aligned rows  48  and columns  46  of pockets  44   a , each pocket  44   a  comprising a circular seam  30   a  joining upper and lower plies of fabric, as described above. However, each of the circular seams  30   a  is a continuous seam, as opposed to a seam having curved weld segments with gaps therebetween to allow airflow through the circular seam. These circular seams  30   a  of pockets  44   a  allow no airflow through the seams  30   a . Therefore, the fabric material of the first and second plies of pockets  44   a  of comfort layer  16   a  must be made of permeable material to allow airflow into and out of the pockets  44   a  of comfort layer  16   a . The type of material used for comfort layer  16   a  solely controls the amount of air entering the comfort layer  16   a  when a user gets off the bedding or seating product, thus allowing the springs  28  in the pockets  44   a  to expand and air to flow into the comfort layer  16   a . Similarly, when a user gets onto a bedding or seating product, the springs  28  compress and cause air to exit the pockets  44   a  of the comfort layer  16   a  and exit the comfort layer. The amount of air exiting the comfort layer  16   a  affects the feel/compression of the individually pocketed mini coil springs  28  when a user lays on the product incorporating the comfort layer  16   a.    
       FIG. 12A  illustrates one corner of an alternative embodiment of comfort layer  56   a , which may be used in any bedding or seating product. The comfort layer  56   a  comprises aligned rows  88  and columns  86  of pockets  84   a , each pocket  84   a  comprising a rectangular seam  70   a  joining upper and lower plies of fabric as described above. However, each of the rectangular seams  70   a  is a continuous seam, as opposed to a seam having weld segments with gaps therebetween to allow airflow through the seam. These rectangular seams  70   a  of pockets  84   a  allow no airflow through the seams  70   a . Therefore, the fabric material of the first and second plies of pockets  84   a  of comfort layer  56   a  must be made of permeable material to allow airflow into and out of the pockets  84   a  of comfort layer  56   a . The type of material used for comfort layer  56   a  solely controls the amount of air entering the comfort layer  56   a  when a user gets off the bedding or seating product, thus allowing the springs  28  in the pockets  84   a  to expand and air to flow into the comfort layer  56   a . Similarly, when a user gets onto a bedding or seating product, the springs  28  compress and cause air to exit the pockets  84   a  of the comfort layer  56   a  and exit the comfort layer. The amount of air exiting the comfort layer  56   a  affects the feel/compression of the individually pocketed mini coil springs  28  when a user lays on the product incorporating the comfort layer  56   a.    
       FIG. 2  illustrates a machine  90  used to make several of the comfort layers shown and disclosed herein, including comfort layer  16  shown in  FIG. 1 . Some parts of the machine  90  may be changed to make other comfort layers shown or described herein, such as comfort layer  56  shown in  FIG. 7 . Machine  90  comprises a pair of ultrasonic welding horns  32 , and at least one stationary anvil  42 , as shown in  FIG. 4 . Alternatively, ultrasonic welding horns  32   a  and anvil  42   a  of  FIG. 4A  may be used in the machine. 
     Machine  90  discloses a conveyor  92  on which are loaded multiple mini coil springs  28 . The conveyor  92  moves the mini coil springs  28  in the direction of arrow  94  (to the right as shown in  FIG. 2 ) until the mini coil springs  28  are located in predetermined locations, at which time the conveyor  92  stops moving. Machine  90  further discloses several actuators  96 , which move a pusher assembly  97 , including a pusher plate  98  in the direction of arrow  100 . Although two actuators  96  are illustrated in  FIGS. 2 and 2A , any number of actuators  96  of any desired configuration may be used to move the pusher assembly  97 . The pusher plate  98  has a plurality of spaced spring pushers  102  secured to the pusher plate  98  underneath the pusher plate  98 . The spring pushers  102  push the mini coil springs  28  between stationary guides  104  from a first position shown in  FIG. 2  to a second position shown in  FIG. 4  in which the mini coil springs  28  are located above the stationary anvil  42  (or above the alternative anvil  42   a  shown in  FIG. 4A ).  FIG. 2A  illustrates the mini coil springs  28  being transported from the first position to the second position, each mini coil spring  28  being transported between adjacent stationary guides  104 . The stationary guides  104  are secured to a stationary mounting plate  106 . 
     The machine  90  further comprises a compression plate  108 , which is movable between raised and lowered positions by lifters  110 . Although two lifters  110  are illustrated in  FIGS. 2 and 2A , any numbers of lifters  110  of any desired configuration may be used to move the compression plate  108 . 
     As best shown in  FIG. 2 , machine  90  further comprises three pressers  112  movable between raised and lowered positions via actuators  116 .  FIGS. 3B  and  3 C show one of the pressers  112  in a raised position, while  FIGS. 3A, 3D and 3E  show the presser in a lowered position. Each presser has a blade  114  at the bottom thereof for bringing the plies  22 ,  24  of fabric together when the presser is lowered, as shown in  FIGS. 3A, 3D and 3E . 
     As best shown in  FIG. 3A , machine  90  further comprises rollers  120 ,  122  around which the plies,  22 ,  24  respectively pass before they come together. After the circular seams  30  are created by the ultrasonic welding horn  32  and anvil  42 , thereby creating the pockets  44 , a main roller  116  and secondary roller  118  pull the continuous spring blanket  124  downwardly. Once a desired amount of continuous spring blanket  124  is made, a blade  126  cuts the continuous spring blanket  120  to create comfort layer  16  of the desired size. Of course, the machine  90  may be programmed to create the desired length and width of comfort layer. This machine  90  is adapted to make any of the comfort layers shown or disclosed herein having circular weld seams. 
       FIG. 3A  illustrates the ultrasonic welding horn  32  in a lowered position contacting the stationary anvil  42  with at least one of the pressers  112  in a lowered position pressing the upper ply  22  into contact with the lower ply  24 . A new row of mini coil springs  28  has been moved into a loading position with the compression plate  108  in its raised position. 
       FIG. 3B  illustrates the ultrasonic welding horn  32  in a raised position spaced from the anvil  42  with at least one of the pressers  112  in a raised position. The compression plate  108  is moved to its lowered position by lifters  110 , thereby compressing the row of mini coil springs  28  located on the conveyor  92 . 
       FIG. 3C  illustrates the row of compressed mini coil springs  28  located on the conveyor  92  being pushed downstream towards the ultrasonic welding horn  32  and stationary anvil  42  by the pusher assembly  97 . More particularly, the pushers  102  secured to the pusher plate  98  contact the compressed mini coil springs  28  and move them downstream between the stationary guides  104  and past the raised pressers  112 . 
       FIG. 3D  illustrates the pusher assembly  97  being withdrawn in the direction of arrow  128 . Additionally, the pressers  112  are moved to a lowered position pressing the upper ply  22  into contact with the lower ply  24 . Also, the compression plate  108  is moved to its raised position by lifters  110 . 
       FIG. 3E  illustrates the ultrasonic welding horn  32  in a lowered position contacting the stationary anvil  42  with at least one of the pressers  112  in a lowered position pressing the upper ply  22  into contact with the lower ply  24 . A new row of mini coil springs  28  has been moved by the conveyor  92  into a position in which they may be compressed with the compression plate  108  during the next cycle. 
       FIG. 8  illustrates a machine  130 , like the machine  90  shown in  FIGS. 2 and 2A . However, instead of having two ultrasonic welding horns  32 , machine  130  has four ultrasonic welding horns  72  along with anvil  74 . Alternatively, ultrasonic welding horns  72   a  and anvil  74   a  of  FIG. 9A  may be used in machine  130 . This machine  130  is adapted to make any of the comfort layers shown or disclosed herein having rectangular weld seams, as opposed to circular weld seams. 
       FIG. 13A  illustrates a posturized comfort layer  132  having three different areas or regions of firmness depending upon the airflow within each of the areas or regions. The comfort layer  132  has a head section  134 , a foot section  136  and a lumbar or middle section  138  therebetween. The size and number of segments in the seams, along with the type of material used to construct the posturized comfort layer  132 , may be selected so at least two of the sections may have a different firmness due to different airflows within different sections. Although three sections are illustrated in  FIG. 13A , any number of sections may be incorporated into a posturized comfort layer. Although each of the sections is illustrated being a certain size, they may be other sizes. The drawings are not intended to be limiting. Although  FIG. 13A  shows each of the segmented seams of comfort layer  132  being circular, a posturized comfort layer, such as the one shown in  FIG. 13A , may have rectangular or square segmented seams. 
       FIG. 13B  illustrates a posturized comfort layer  140  having two different areas or regions of firmness depending upon the airflow within each of the areas or regions. The comfort layer  140  has a first section  142  and a second section  144 . The size and number of segments in the seams, along with the type of material used to construct the posturized comfort layer  140 , may be selected so at least two of the sections may have a different firmness due to different airflows within different sections. Although two sections are illustrated in  FIG. 13B , any number of sections may be incorporated into a posturized comfort layer. Although each of the sections is illustrated being a certain size, they may be other sizes. The drawings are not intended to be limiting. Although  FIG. 13B  shows each of the segmented seams of comfort layer  140  being circular, a posturized comfort layer, such as the one shown in  FIG. 13B , may have rectangular or square segmented seams. 
       FIG. 14  illustrates a web or blanket  150  of comfort layer like the blanket  124  described above and shown in  FIGS. 2 and 2A  moving in the direction of arrow  152 . The blanket  150  has a lesser density of individually pocketed mini coil springs than blanket used to make the comfort layers shown in the other drawings. In blanket  150 , spaced rows  154  of pocketed mini coil springs  156  extend in a direction perpendicular to the direction of travel of the blanket  150  during manufacture. The spaced rows  154  are spaced between spaced areas  158  which contain no pocketed mini coil springs. In some applications, the spaced areas  158  may be the same size as the rows  154  so every other row of pocketed mini coil springs is missing or omitted. However, the spaced areas  158  may be any desired size. Due to the spacing between rows  154  extending from side-to-side, the pocketed mini coil springs  156  form columns  155  extending parallel the direction of travel of the blanket  150  during manufacture. Each column  155  comprises pocketed mini coil springs  156  spaced from each other a distance equal to or greater than the diameter of one circular weld seam  170 . The circular weld seams  170  may be segments or solid. 
       FIG. 14A  illustrates another web or blanket  160  of comfort layer moving in the direction of arrow  162 . The blanket  160  has a lesser density of individually pocketed mini coil springs than blanket used to make the comfort layers shown in the drawings other than  FIG. 14 . In blanket  160 , spaced columns  164  of pocketed mini coil springs  156  extend in a direction parallel the direction of travel of the blanket  160  during manufacture. The spaced columns  164  are spaced between spaced areas  168  which contain no pocketed mini coil springs. In some applications, the spaced areas  168  may be the same size as the columns  164 . However, the spaced areas  168  may be any desired size. Due to the spacing between columns  164  extending in the direction of travel of the blanket  160 , the pocketed mini coil springs  156  form rows  165  extending perpendicular to the direction of travel of the blanket  160  during manufacture. Each row  165  comprises pocketed mini coil springs  156  spaced from each other a distance equal to or greater than the diameter of one circular weld seam  170 . 
     Although  FIGS. 14 and 14A  illustrate pocketed mini coil springs  156  having circular weld seams  170 , rectangular weld seams as described herein may be incorporated into the pocketed mini coil springs of  FIGS. 14 and 14A . Although the drawings show the blankets  150 ,  160  made with nonwoven spunlaced aperture fabric, any fabric described or shown herein may be used to form blankets  150 ,  160 . 
       FIGS. 15 and 15A  illustrate enlarged views of a portion of the blanket  160 . The circular weld seams  170  are segmented having gaps  31  between curved weld segments  26 , like the circular weld seams  30 .  FIGS. 15 and 15A  show at least one mini coil spring  28  being in each pocket  171  formed by one of the circular weld seams  170 . Arrows  40  illustrate airflow between the curved weld segments  26  into and out of the pockets  171 . 
       FIGS. 16 and 16A  illustrate enlarged views of a portion of another blanket  160   a  having rectangular weld seams  172  rather than circular weld seams. The rectangular weld seams  172  are segmented having gaps  174  between straight weld segments  176 , like the rectangular weld seams  70 .  FIGS. 16 and 16A  show at least one mini coil spring  28  being in each pocket  175  formed by one of the rectangular weld seams  172 . Arrows  82  illustrate airflow between the straight weld segments  176  into and out of the pockets  175 . 
       FIG. 17A  illustrates a posturized comfort layer  180  having three areas or regions of differing firmness depending upon the density of pockets within each of the areas or regions. The comfort layer  180  has a head section  182 , a foot section  184  and a lumbar or middle section  186  therebetween. The number of pockets in the sections may be selected so at least two of the sections may have a different firmness. Although three sections are illustrated in  FIG. 17A , any number of sections may be incorporated into a posturized comfort layer. Although each of the sections is illustrated being a certain size, they may be other sizes. The drawings are not intended to be limiting. Head and foot sections  182 ,  184  may have the same firmness due to having the same density of individually pocketed mini coil springs  192 . 
     Although  FIG. 17A  shows each of the number of individually pocketed mini coil springs  190  in the middle section  186  being greater than the number of individually pocketed mini coil springs  192  in the head and foot sections  182 ,  184 , the opposite may be true. Any comfort layer may be posturized by having more or less individually pocketed mini coil springs in one section when compared to another section. Although  FIG. 17A  shows solid circular weld seams and associated pockets, the circular weld seams may be segmented. Although not shown, a posturized comfort layer, such as the one shown in  FIG. 17A , may have rectangular or square weld seams with either segmented or solid weld seams. 
       FIG. 17B  illustrates a posturized comfort layer  200  having two different areas or regions of firmness depending upon the density of individually pocketed mini coil springs  194  within each of the areas or regions. The comfort layer  200  has a first section  202  and a second section  204 . The number of individually pocketed mini coil springs  194  may have different firmness due to different pocketed densities within different sections. Although two sections are illustrated in  FIG. 17B , any number of sections may be incorporated into a posturized comfort layer. Although each of the sections is illustrated being a certain size, they may be other sizes. The drawings are not intended to be limiting. Although  FIG. 17B  shows solid circular weld seams and associated pockets, the circular weld seams may be segmented. Although not shown, a posturized comfort layer, such as the one shown in  FIG. 17B , may have rectangular or square weld seams with either segmented or solid weld seams. 
     Although  FIGS. 17A and 17B  show the first and second pieces of fabric being nonwoven spun laced aperture fabric, any known fabric may be used in accordance with the posturized comfort layers having sections of different firmness due to the density of the individually pocketed mini coil springs. 
     While we have described several preferred embodiments of this invention, persons skilled in this art will appreciate that other permeable fabric materials may be utilized in the practice of this invention. Similarly, such persons will appreciate that each pocket may contain any number of coil springs or other type of spring, made of any desired material. Persons skilled in the art may further appreciate that the segments of the weld seams may be stitched, glued or otherwise adhered or bonded. Therefore, we do not intend to be limited except by the scope of the following appended claims.