Patent Publication Number: US-9414692-B2

Title: Pocketed spring assembly comprising strings of springs having Y-shaped seams and inserts

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 13/921,499 filed Jun. 19, 2013 entitled “Pocketed Spring Assembly Comprising Strings of Springs Having Y-Shaped Seams Separating Adjacent Pockets”, which is fully incorporated by reference herein. 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     This invention relates to bedding and seating products and, more particularly, to pocketed spring assemblies used in bedding and seating products, including mattresses and the method of manufacturing such pocketed spring assemblies. 
     BACKGROUND OF THE INVENTION 
     Pocketed spring cores or assemblies are commonly used in seating or bedding products. Such pocketed spring assemblies are commonly made of multiple strings or rows of individually pocketed springs. Adjacent strings of individually pocketed springs are joined together by gluing or otherwise attaching the fabric of the strings of springs to each other. 
     Pocketed coil springs are often referred to as a Marshall construction in which each coil spring is encased within its own fabric sack or pocket. The sack or pocket is typically defined between two plies of a fabric strip connected together at intervals along transverse lines of attachment spaced along the strip. The two-ply fabric strip is generally formed by folding a strip of double width fabric upon itself along a longitudinal centerline, leaving the overlapped plies along the unjoined opposite edges of the strip to be connected to each other along a longitudinal seam. After the springs are inserted between the plies, opposed plies are joined along transverse lines of attachment to close the pockets and separate adjacent springs. 
     A variety of techniques have evolved for the manufacture of pocketed springs, some contemplating the creation of the pockets within the fabric plies prior to insertion of the wire spring and others contemplating the insertion of compressed wire springs between the plies of the strip and the subsequent creation of the pockets by joining the two plies to each other along transverse lines of attachment between adjacent springs. In recent times, heat sensitive fabric and ultrasonic welding techniques have been utilized to join the fabric plies together along the seams or lines of attachment. 
     Most seams separating adjacent individually pocketed springs are linear, such as those disclosed in U.S. Pat. No. 6,826,796. In theory, a load placed upon the pocketed spring moves straight up and down along a vertical axis. However, in reality, the load placed upon a pocketed spring is often angled relative to the axis of the spring. Such an angled load may cause the pocketed spring to try to buckle and create stress on the fabric of the pocket. Over time, the fabric may wear and eventually break, causing the pocketed spring to move outside the pocket. 
     It is therefore an objective of this invention to provide a seating or bedding product which has a pocketed spring assembly which allows the springs inside the pockets to buckle without stressing the fabric of the pockets. 
     Still another objective of this invention is to provide a seating or bedding product which has a pocketed spring assembly having increased comfort due to ability of the springs inside the pockets to buckle. 
     SUMMARY OF THE INVENTION 
     The invention of this application which accomplishes these objectives comprises a seating or bedding product made from an assembly of pocketed springs, each spring of which is contained within a fabric pocket. The pocketed spring assembly comprises a plurality of strings of springs which may extend longitudinally or transversely in the product. 
     One primary advantage of pocketed spring assemblies utilizing the present invention is that the construction of the strings of springs allows individually pocketed springs placed under load to buckle without damaging the fabric of the strings of springs and return to their original position in the fabric pocket quickly and easily. 
     According to one aspect of the invention, the bedding or seating product comprises a pocketed spring assembly comprising a plurality of parallel strings of springs which may be joined to each other. In some embodiments the strings of springs may be joined to one or more scrim sheet(s) in addition to each other. In other embodiments the strings of springs may be joined to one or more scrim sheet(s) without being secured to each other. Each of the strings of springs comprises a plurality of interconnected pockets, each of the pockets containing at least one spring encased in fabric. The individually pocketed springs may be barrel-shaped springs, hourglass-shaped springs or springs having a uniform diameter. The fabric is joined to itself along a longitudinal seam which may be located along one side of the string of springs. Adjacent individually pocketed springs are separated from each other by a separating seam joining opposed first and second plies. Each of the separating seams may comprise a pair of V-shaped end portions joined together by a linear portion. Cushioning materials may be on at least one side of the product. An upholstered covering may encase the pocketed spring assembly and cushioning materials. 
     According to another aspect of the invention, a pocketed spring assembly for use in a bedding or seating product comprises a plurality of strings of springs. Each of the strings of springs comprises a piece of fabric joined to itself along a longitudinal seam and multiple spaced separating seams to define a plurality of pockets. Each pocket contains at least one spring. Each of the springs has end turns and central convolutions between the end turns. Opposed plies of the fabric are joined together by the separating seams. The separating seams are shaped such that the end turns of each pocketed spring are closer to the separating seams than the central convolutions of the pocketed spring, such that upon compression of at least a portion of the spring in the pocket, the central convolutions of the spring may expand in the pocket without being inhibited by the separating seams. 
     According to another aspect of the invention, a pocketed spring assembly for use in a bedding or seating product comprises a plurality of strings of springs. Each of the strings of springs comprises a piece of fabric joined to itself along a longitudinal seam and multiple spaced separating seams to define a plurality of pockets. Each pocket contains at least one spring, each spring having upper and lower end turns and central convolutions between the end turns. Each of the separating seams comprises a linear portion and a pair of branch portions. Each branch portion extends outwardly from the linear portion of the separating seam. The spring assembly is characterized, when a load is placed upon the spring assembly, by the ability of at least some of the central convolutions of the spring to move laterally in the pocket of fabric. 
     According to another aspect of the invention, a pocketed spring assembly for use in a bedding or seating product comprises a plurality of strings of springs. Each of said strings of springs comprises a plurality of interconnected pocketed springs, each spring of which is contained within a pocket of fabric. Each spring has upper and lower end turns and central convolutions between the end turns. Adjacent individually pocketed springs are separated from each other by at least one separating seam joining first and second plies on opposed sides of the string of springs, each of the separating seams comprising a Y-shaped or U-shaped seam. The pocketed spring assembly is characterized, when a load is placed upon the pocketed spring assembly, by the ability of some of the central convolutions of the spring to move laterally in the pocket of fabric within which the spring is contained and return to their original position upon removal of the load. 
     According to another aspect of the invention, a pocketed spring assembly constructed in accordance with the present invention may be posturized or have different regions of different firmness. Some of the strings of springs may have separating seams which are different than the separating seams of other strings of springs, thus imparting different firmnesses to the different strings of springs. 
     According to another aspect of the invention, a bedding or seating product incorporating a pocketed spring assembly constructed in accordance with the present invention may impart an improved “feel” or comfort level to a user due to the construction of the strings of springs. The fabric of the strings of springs may be folded in a manner between the individually pocketed springs in bridging portions of the strings of springs so that the fabric is generally co-planar with the fabric of the pockets inside which the springs reside. Such construction provides a generally smoother surface or surfaces of the pocketed spring assembly and avoids bunched up fabric between the pockets of the strings of springs. 
     According to another aspect of the invention, any embodiment of bedding or seating product described or shown herein may have a plurality of inserts between adjacent strings of springs. The inserts may be made partially or entirely of foam and/or fiber. The foam may be latex foam, polyurethane foam or “viscoelastic” polyurethane memory foam or any other known foam. Each of the inserts may comprise a unitary piece of foam or multiple pieces or sections of different materials joined together, such as by lamination, for example. 
     In some embodiments, each insert has a generally rectangular cross-sectional shape. However, the inserts may be cylindrical or any other desired shape. 
     In some embodiments, perimeter or outermost rows and columns of inserts may be higher than the remainder of the inserts inside the product to provide edge support to the product. Alternatively or additionally, to achieve edge support, the inserts may be different materials, the inserts around the perimeter being firmer than the remainder of the inserts. In other embodiments, all the inserts may be the same height, which may be approximately the same, or a different height as the unloaded or unstressed pocketed springs in the strings of springs. 
     In order to impart a particular feel or firmness to a particular section of a product, inserts of different materials or heights may be strategically located in order to posturize a product (impart different sections of different firmness). For example, a mattress may have two sections, a firmer section for a male and a softer section for a female, the inserts of the firmer section being firmer than the inserts of the softer section. This is known in the industry as a his/hers mattress. Alternatively, one or more sections may lack inserts while other sections have inserts. 
     Another advantage of the use of inserts in accordance with the present invention is that a manufacturer may be able to achieve the same “feel” or firmness in a bedding or seating product while using thinner wire for the springs inside the pockets of the strings of springs. The use of thinner wire may save costs and/or ease of manufacture. 
     These and other objects and advantages of this invention will be more readily apparent from the following description of the drawings, in which: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view, partially broken away, of a bedding product incorporating one embodiment of pocketed spring assembly; 
         FIG. 1A  is a perspective view, partially broken away, of another bedding product incorporating the pocketed spring assembly of  FIG. 1 ; 
         FIG. 1B  is a perspective view, partially broken away, of another bedding product incorporating the pocketed spring assembly of  FIG. 1 ; 
         FIG. 2  is an enlarged perspective view of a portion of a string of pocketed coil springs used in the pocketed spring assembly of  FIG. 1 ; 
         FIG. 2A  is an enlarged perspective view of a portion of an alternative string of pocketed coil springs which may be used in accordance with the present invention; 
         FIG. 3  is a cross-sectional view, partially broken away, of one of the strings of springs of the pocketed spring assembly of  FIG. 1 ; 
         FIG. 3A  is a perspective view, partially broken away, of an alternative string of springs for use in a pocketed spring assembly; 
         FIG. 3B  is a perspective view, partially broken away, of an alternative string of springs for use in a pocketed spring assembly; 
         FIG. 3C  is a perspective view, partially broken away, of an alternative string of springs for use in a pocketed spring assembly; 
         FIG. 3D  is a perspective view, partially broken away, of an alternative string of springs for use in a pocketed spring assembly; 
         FIG. 3E  is a perspective view, partially broken away, of an alternative string of springs for use in a pocketed spring assembly; 
         FIG. 4  is an enlarged perspective view of a portion of the pocketed spring assembly of the bedding product of  FIG. 1 ; 
         FIG. 5  is an enlarged perspective view of a portion of an alternative embodiment of pocketed spring assembly for use in a bedding or seating product; 
         FIG. 5A  is a cross-sectional view of a portion of a string of springs used in the bedding product of  FIG. 1  without any load on the string of springs; 
         FIG. 5B  is a cross-sectional view of the portion of the string of springs of  FIG. 5A  with a load on the string of springs; 
         FIG. 5C  is a cross-sectional view of the portion of the string of springs of  FIG. 5A  with an angled load on the string of springs; 
         FIG. 5D  is a cross-sectional view of the portion of the string of springs of  FIG. 5A  showing travel of a spring inside a pocket; 
         FIG. 6A  is an enlarged perspective view of a portion of a string of springs used in the pocketed spring assembly of the bedding product of  FIG. 1 ; 
         FIG. 6B  is a perspective view of a portion of a string of springs used in the pocketed spring assembly of the bedding product of  FIG. 1 ; 
         FIG. 7  is a perspective view, partially broken away, of a bedding product incorporating another embodiment of pocketed spring assembly in accordance with the present invention; 
         FIG. 8  is a perspective view, partially broken away, of a bedding product incorporating another embodiment of pocketed spring assembly; 
         FIG. 9  is a perspective view, partially broken away, of a bedding product incorporating another embodiment of pocketed spring assembly; 
         FIG. 10  is a cross-sectional view, partially broken away, of a string of springs used in the product of  FIG. 9 ; 
         FIG. 11  is a perspective view, partially broken away, of an alternative embodiment of bedding or seating product; 
         FIG. 12A  is an enlarged perspective view of a portion of the interior of the product of  FIG. 11 ; 
         FIG. 12B  is an enlarged perspective view of a portion of an alternative interior of a bedding or seating product; 
         FIG. 12C  is an enlarged perspective view of a portion of an alternative interior of a bedding or seating product; 
         FIG. 13A  is a cross-sectional view, partially broken away, of a portion of the interior of the product of  FIG. 11 ; 
         FIG. 13B  is a cross-sectional view, partially broken away, of a portion of an alternative interior of a bedding or seating product like that shown in  FIG. 12B ; 
         FIG. 14  is a perspective view of one of the foam inserts which may be used in any embodiment shown or described herein; 
         FIG. 15  is a perspective view of one of another foam cushion which may be used in any embodiment shown or described herein; 
         FIG. 16  is a perspective view of one of another foam cushion which may be used in any embodiment shown or described herein; and 
         FIG. 17  is a perspective view of one of another foam cushion which may be used in any embodiment shown or described herein. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     With reference to  FIG. 1 , there is illustrated a bedding product in the form of a single-sided mattress  10  incorporating this invention. This product or mattress  10  comprises a pocketed spring assembly  12  over the top of which there lay conventional padding or cushioning layers  14 ,  16  which may be foam, fiber, gel or any other suitable materials. The pocketed spring assembly  12  is surrounded with a border  17  made of foam or any other suitable material (only a portion being shown in  FIG. 1 ). Although one type of border  17  is illustrated, the border may assume other forms or shapes of any desired size. Alternatively, the border  17  may be omitted in this embodiment or any embodiment described or shown herein. This complete assembly is mounted upon a base  18  and is completely enclosed within an upholstered covering material  20 . The base  18  and border  17  are known in the industry as a “bucket” into which a pocketed spring assembly  12  is inserted before the “bucket” is covered with one or more padding or cushioning layers. 
     As shown in  FIG. 1 , fully assembled, the product  10  has a length “L” defined as the linear distance between opposed end surfaces  22  (only one being shown in  FIG. 1 ). Similarly, the assembled product  10  has a width “W” defined as the linear distance between opposed side surfaces  24  (only one being shown in  FIG. 1 ). In the products  10 ,  10 ′ and  10 ″ shown in  FIGS. 1, 1A and 1B , respectively, as well as any of the products shown or described herein, the length is illustrated as being greater than the width. However, it is within the contemplation of the present invention that the length and width may be identical, as in a square product. 
     As shown in the embodiment illustrated in  FIGS. 1, 2 and 3 , pocketed spring assembly  12  is manufactured from multiple strings of pocketed springs  26  joined together. Each string of pocketed springs  26  extends from side-to-side or transversely across the full width of the product  10 . Although the strings of pocketed springs  26  are illustrated as extending transversely or from side-to-side in the pocketed spring assembly  12  of  FIG. 1 , they may extend longitudinally or from end-to-end in this or any other pocketed spring assembly shown or described herein. 
     These strings of pocketed springs  26  are connected in side-by-side relationship as, for example, by gluing the sides of the strings together in an assembly machine, so as to create an assembly or matrix of springs having multiple rows and columns of pocketed springs bound together as by gluing, welding or any other conventional assembly process commonly used to create pocketed spring cores or assemblies. 
     As shown in  FIGS. 1 and 4 , the strings of pocketed springs  26  may be joined so that the individually pocketed springs  28  are aligned in transversely extending rows  30  and longitudinally extending columns  32 . Alternatively, as shown in  FIG. 5 , the strings of pocketed springs  26  may be offset from one another in a pocketed spring assembly  12 ′. In such an arrangement, the individually pocketed springs  28  are not aligned in rows and columns; instead the individually pocketed springs  28  fill gaps or voids  88  of the adjacent strings of pocketed springs  26 . 
     While the mattress  10  illustrated in  FIG. 1  is a single-sided mattress, the pocketed spring assembly  12 , or any other pocketed spring assembly shown or described herein, may be incorporated into any bedding or seating product, including a double-sided mattress or seating cushion. 
       FIG. 1A  illustrates a double-sided mattress  10 ′ comprising a pocketed spring assembly  12  and border  17  identical to those shown in the mattress  10  of  FIG. 1 . However, the mattress  10 ′ of  FIG. 1A  has conventional padding layers  14 ,  16  above and below the pocketed spring assembly  12 . 
       FIG. 1B  illustrates a single-sided mattress  10 ″ comprising a pocketed spring assembly  12  and border  17  identical to those shown in the mattress  10  of  FIG. 1 . However, the mattress  10 ″ of  FIG. 1B  has a pocketed topper  19  employing miniature or small strings of pocketed coil springs in addition to padding layers  14 ,  16  above the pocketed topper  19 . A scrim layer  21  separates the pocketed topper  19  from the pocketed spring assembly  12 . 
     According to the practice of this invention, any of the padding or cushioning layers, including the pocketed topper  19 , may be omitted in any of the embodiments shown or described herein. The novel features reside in the pocketed spring assembly  12 . 
     As best illustrated in  FIGS. 2 and 3 , each string of pocketed springs  26  comprises a row of interconnected fabric pockets  34 . Each of the fabric pockets  34  contains at least one coil spring  36 . As best shown in  FIG. 2 , each coil spring  36  has a central or longitudinal axis A, an upper end turn  38 , a lower end turn  40  and a plurality of central convolutions  42  between the end turns.  FIGS. 2 and 3  illustrate a barrel-shaped coil spring  36  in which the diameter of the end turns  38 ,  40  is less than the diameter of the central convolutions  42 , the central convolutions  42  tapering or decreasing in diameter as one moves from the center of the coil spring towards the end turns. However, coil springs in which the diameter of the end turns is identical to the diameter of the central convolutions, or an hourglass-shaped spring in which the diameter of the end turns is greater than the diameter of the central convolutions, may be used in any of the embodiments shown or described herein in accordance with the present invention. 
     Preferably, one piece of fabric is used to create the string of pocketed springs  26 , the piece of fabric being folded over onto itself around the coil springs  36 . As best shown in  FIGS. 2 and 3 , opposite sides or plies  44 ,  46  of the fabric are sewn, welded or otherwise secured together in order to create a longitudinal seam  50  and a plurality of separating seams  52 , including outermost separating seams  54 .  FIG. 3  illustrates ply  44  being closest to the reader and ply  46  being behind the springs  36 . 
     Although the seams in all of the embodiments shown herein are shown as being spaced rectangles, any of the seams may be spaced dots, triangles or solid line segments without spaces. 
     As best shown in  FIGS. 2 and 6B , opposed edges  56  of the piece of fabric used to create the string of pocketed springs  26  are aligned and spaced from the longitudinal seam  50  a distance indicated by numeral  58 . Although the drawings indicate the longitudinal seam  50  being below the free edges  56  of the piece of fabric, the longitudinal seam  50  may be above the free edges  56  of the piece of fabric. 
     As shown in  FIGS. 2 and 3 , the string of pocketed springs  26  has a generally planar top surface  60  in a top plane P 1  and a parallel generally planar bottom surface  62  in a bottom plane P 2 . The linear distance between the top and bottom surfaces of the string of pocketed springs  26  defines a height H of the string of pocketed springs  26 . This linear distance further defines the height H of the pocketed spring assembly  12  because each of the strings of springs  26  has the same height. However, it is within the scope of the present invention that different strings of springs of a pocketed spring assembly have different heights. 
     In accordance with one embodiment of the present invention, a separating seam  52  separates adjacent pockets  34  and, therefore, adjacent pocketed springs  28 . At each end of the string of springs  26 , a separating seam  54 , identical to separating seams  52 , is formed to hold the outermost springs  36  in place. As best shown in  FIGS. 2 and 3 , each separating seam  52 ,  54  comprises a pair of V-shaped end portions  64  and a linear or straight portion  66  joining the V-shaped end portions  64 . As best illustrated in  FIGS. 2 and 3 , from the ends of the linear portion  66  at locations  72 , the separating seam  52 ,  54  diverges or splits into two diverging branches or legs  74 . At their ends, the branches  74  are separated by a linear distance “S” along the top and bottom edges  76  of the string of springs  26  between the individual pockets  34 . As further described herein, the greater the linear distances “S” between the branches  74  of the end portions  64  of separating seams  52 ,  54  of a string of springs, the softer the feel of a spring assembly or portion of a spring assembly made from such strings of springs. As best illustrated in  FIGS. 2 and 3 , the triangular region, bridging portion or bridge  86  between the branches  74  of each of the end portions  64  of each of the separating seams  52 ,  54  within a string of springs  26  comprises four plies created by tucking the fabric downwardly as shown in  FIG. 6A  before the plies are welded to create the separating seams  52 ,  54 . This process enables the upper and lower surfaces  60 ,  62  of the string of springs  26  to be generally planar in planes P 1  and P 2  without the fabric between the individually pocketed springs extending above and below the upper and lower surfaces  60 ,  62  of the string of springs  26 . 
       FIGS. 5A-5D  illustrates one primary advantage of the present invention. Although these drawings show one configuration of coil spring inside the pockets of a string of springs, other coil springs, such as barrel-shaped coil springs, may be used. The advantages of the present invention, as shown and described herein, apply to pocketed spring assemblies made from strings of pocketed springs using any of the coil springs described or shown herein. Due to the unique configuration of the separating seams  52 ,  54 , the end turns  38 ,  40  of coil springs  36  inside pockets  34  of strings of springs  26  return to their original position inside the pocket  34  after compression or loading of the pocketed coil springs  36 . As shown in  FIG. 5A , due to the V-shaped end portions  64  of the separating seams  52 ,  54  on opposite sides of the pocket  34 , the end turns  38 ,  40  of coil spring  36  inside the pocket  34  abut the V-shaped end portions  64  of the separating seams  52 ,  54 , on opposite sides of the pocket  34 . As shown in  FIG. 5A , the end turns  38 ,  40  and central convolutions  42  of pocketed coil spring  36 , have the same diameter or width W 2 , which is approximately the same linear distance between the ends of the V-shaped end portions  64  of adjacent separating seams  52 ,  54 , on opposite sides of the pocket  34 . The end turns  38 ,  40  of coil spring  36  remain trapped between the ends of the V-shaped end portions  64  of the separating seams  52 ,  54 , on opposite sides of the pocket  34  when the coil spring  36  is uncompressed or not loaded, as shown in  FIG. 5A . 
     Referring to  FIG. 5A , the central convolutions  42  of pocketed coil spring  36  are spaced a linear distance W 1  from the linear portions  66  of adjacent separating seams  52 ,  54 , on opposite sides of the pocket  34  when the pocketed coil spring  36  is at rest (under no load). 
     As shown in  FIG. 5B , when a load indicated by arrows  68  is placed upon the pocketed coil spring  36 , the central convolutions  42  of pocketed coil spring  36  increase in diameter or expand to a diameter or linear distance W 3 , which is greater than the diameter or distance W 2  of  FIG. 5A . Due to the linear distances W 1  on opposite sides of the pocket  34 , upon being loaded, at least some of the central convolutions  42  of pocketed coil spring  36  have room to expand in the pocket  34  without stressing the adjacent separating seams  52 ,  54 , on opposite sides of the pocket  34 . In its compressed condition shown in  FIG. 5B , end turns  38 ,  40  of pocketed coil spring  36  remain trapped between the ends of the V-shaped end portions  64  of the separating seams  52 ,  54 , on opposite sides of the pocket  34 . 
     As shown in  FIG. 5C , when an angled load indicated by arrows  70  is placed upon the pocketed coil spring  36 , the central convolutions  42  of pocketed coil spring  36  have room to buckle or move laterally, as well as increase in diameter inside the pocket  34 , without stressing either of the separating seams  52 ,  54  on opposite sides of the pocket  34 . Due to the linear distances W 1  on opposite sides of the pocket  34 , upon being loaded, the pocketed coil spring  36  has room to move from an unloaded condition or position shown in dashed lines to a loaded condition or position shown in solid lines without stressing either of the separating seams  52 ,  54 , on opposite sides of the pocket  34 . In its condition shown in  FIG. 5C , end turns  38 ,  40  of pocketed coil spring  36  remain trapped between the ends of the V-shaped end portions  64  of the separating seams  52 ,  54 , on opposite sides of the pocket  34  and do not move relative to the material of the pocket. 
     As shown in  FIG. 5D , in the event a person puts a load, indicated by arrows  78 , on a specific area of a pocketed spring assembly, such as putting an elbow or knee on the pocketed spring assembly, the upper end turn  38  of pocketed coil spring  36  may move downwardly from a position shown in dashed lines to a position shown in solid lines. Due to the unique configuration of the V-shaped end portions  64  of separating seams  52  (or  54 ) on opposite sides of the pocket  34 , when the load is removed, the upper end turn  38  of pocketed coil spring  36  is guided by the branches or legs  74  of the end portion  64  back to its original position. In its “at rest” condition shown in dashed lines in  FIG. 5D , end turns  38 ,  40  of pocketed coil spring  36  remain trapped between the ends of the V-shaped end portions  64  of the separating seams  52 ,  54 , on opposite sides of the pocket  34 . 
       FIGS. 2A and 3A  illustrate an alternative string of springs  26   a  which may be used in any of the embodiments or products shown or described herein. String of springs  26   a  is identical to string of springs  26  except that two spaced separating seams  52   a  separate adjacent pockets  34  and, therefore, adjacent pocketed springs  36 . At each end of the string of springs  26   a , two separating seams  54   a  identical to separating seams  52   a  are formed to hold the outermost springs  36  in place in accordance with the present invention. As best shown in  FIGS. 2A and 3A , each separating seam  52   a ,  54   a  is generally Y-shaped. Each Y-shaped separating seam  52   a ,  54   a  comprises a V-shaped end portion  64   a  and a stem or linear or straight portion  66   a . A gap  82  exists with no seam between the two Y-shaped separating seams  52   a ,  54   a  separating adjacent pockets  34  and pocketed springs  36 . More particularly, the gap  82  is defined as the linear distance between the ends of the linear or straight portions  66   a  of the two Y-shaped separating seams  52   a ,  54   a  separating adjacent pockets  34  and pocketed springs  36 . As best illustrated in  FIGS. 2A and 3A , from the ends of the linear or straight portion  66   a  at location  72   a , the separating seam  52   a ,  54   a  diverges or splits into two branches  74   a . At their ends, the branches  74   a  are separated by a linear distance “SA” along the top and bottom edges  76  of the string of springs  26   a  between the individual pockets  34 . As further described herein, the greater the linear distances “SA” of the triangular regions or bridges  86  between the branches  74   a  of each of the end portions  64   a  of each of the separating seams  52   a ,  54   a  within a string of springs  26   a , the softer the feel of a spring assembly or portion of a spring assembly made from the strings of springs. This is true in any of the embodiments of strings of springs shown or described herein. 
       FIG. 3B  illustrates an alternative string of springs  26   b , which may be used in any of the embodiments or products shown or described herein. String of springs  26   b  is identical to string of springs  26 , except for the separating seams  52   b ,  54   b  separating adjacent pockets  34  and, therefore, adjacent pocketed springs  36 . At each end of the string of springs  26   b , two separating seams  54   b  identical to separating seams  52   b  are formed to hold the outermost springs  36  in place in accordance with the present invention. As best shown in  FIG. 3B , each separating seam  52   b ,  54   b  comprises a pair of V-shaped end portions  64   b  and a linear or straight portion  66   b  joining the V-shaped end portions  64   b . As best illustrated in  FIGS. 2 and 3 , from the ends of the linear or straight portion  66   b  at locations  72   b , each separating seam  52   b ,  54   b  diverges or splits into two branches  74   b . At their ends, the branches  74   b  are separated by a linear distance “SB” along the top and bottom edges  76  of the string of springs  26   b  between the individual pockets  34 . As further described herein, the greater the linear distances “SB” between the individually pocketed springs of a string of springs, the softer the feel of a pocketed spring assembly or portion of a pocketed spring assembly made from the strings of springs. For example, a pocketed spring assembly or portion of a pocketed spring assembly made from string of springs  26   b  would be “softer” or less firm than a pocketed spring assembly or portion of a pocketed spring assembly made from string of springs  26  because, at least in part, linear distances “SB” between the individually pocketed springs of strings of springs  26   b  are greater than the linear distances “S” between the individually pocketed springs of strings of springs  26  shown in  FIG. 3 . 
       FIG. 3C  illustrates an alternative string of springs  26   c  which may be used in any of the embodiments or products shown or described herein. String of springs  26   c  is identical to string of springs  26 , except for the separating seams  52   c ,  54   c  separating adjacent pockets  34  and, therefore, adjacent pocketed springs  28 . At each end of the string of springs  26   c , two separating seams  54   c  identical to separating seams  52   c  are formed to hold the outermost springs  36  in place in accordance with the present invention. As best shown in  FIG. 3C , each separating seam  52   c ,  54   c  comprises a pair of V-shaped end portions  64   c  and a linear or straight portion  66   c  joining the V-shaped end portions  64   c . As best illustrated in  FIG. 3C , from the ends of the linear or straight portion  66   c  at locations  72   c , each separating seam  52   c ,  54   c  diverges or splits into two branches  74   c . At their ends, the branches  74   c  are separated by a linear distance “SC” along the top and bottom edges  76  of the string of springs  26   c  between the individual pockets  34 . The linear distance “SC” between the ends of the branches  74   c  is approximately the same as the linear distance “S” between ends of the branches  74  of separating seams  52 ,  54  of string of springs  26  shown in  FIGS. 2 and 3 . However, the depth of the V-shaped end portions  64   c  of the separating seams  52   c ,  54   c  of the string of springs  26   c  is greater than the depth of the V-shaped end portions  64  of the separating seams  52 ,  54  of the string of springs  26 . 
       FIG. 3D  illustrates an alternative string of springs  26   d  which may be used in any of the embodiments or products shown or described herein. String of springs  26   d  is identical to string of springs  26 , except for the separating seams  52   d ,  54   d  separating adjacent pockets  34  and, therefore, adjacent pocketed springs  36 . At each end of the string of springs  26   d , two separating seams  54   d  identical to separating seams  52   d  are formed to hold the outermost springs  36  in place in accordance with the present invention. As best shown in  FIG. 3D , each separating seam  52   c ,  54   c  comprises a pair of U-shaped end portions  64   d  and a linear or straight portion  66   d  joining the U-shaped end portions  64   d . As best illustrated in  FIG. 3D , from the ends of the linear or straight portion  66   d  at locations  72   d , each separating seam  52   d ,  54   d  diverges or splits into two branches  74   d . At their ends, the branches  74   d  are separated by a linear distance “S” along the top and bottom edges  76  of the string of springs  26   d  between the individual pockets  34 . The linear distance “S” between the ends the of branches  74   d  is approximately the same as the linear distance “S” between ends of the branches  74  of separating seams  52 ,  54  of string of springs  26  shown in  FIGS. 2 and 3 . However, the shape of the end or branch portions  64   d  of the separating seams  52   d ,  54   d  of the string of springs  26   d  is U-shaped, rather than the V-shaped end or branch portions  64  of the separating seams  52 ,  54  of the string of springs  26 , shown in  FIG. 3 . 
       FIG. 3E  illustrates an alternative string of springs  26   e , which may be used in any of the embodiments or products shown or described herein. String of springs  26   e  is identical to string of springs  26   a , except for the separating seams  52   e ,  54   e  separating adjacent pockets  34  and, therefore, adjacent pocketed springs  36 . At each end of the string of springs  26   e , two separating seams  54   e  identical to separating seams  52   e  are formed to hold the outermost springs  36  in place in accordance with the present invention. As best shown in  FIG. 3E , each separating seam  52   e ,  54   e  comprises a U-shaped end portion  64   e  and a stem or linear or straight portion  66   e  extending inwardly from the U-shaped end portion  64   e . As best illustrated in  FIG. 3E , from the end of the linear or straight portion  66   e  at location  72   e , each separating seam  52   e ,  54   e  diverges or splits into two branches  74   e . At their ends, the branches  74   e  are separated by a linear distance “SA” along the top and bottom edges  76  of the string of springs  26   e  between the individual pockets  34 . 
       FIGS. 6A and 6B  illustrate another feature of the string of springs  26 . As shown in  FIG. 6A , the piece of fabric used to create the string of springs  26  is folded downwardly in the direction of arrow  84  between adjacent pockets  34  so that the fabric does not extend above the upper surface  60  of the string of springs  26 . This folding of the fabric between adjacent pockets  34  creates an area or region of four plies, two plies  44 ,  45  being formed from the material of the first ply  44  and two other plies  46 ,  47  being formed from the material of the second ply  46 . As shown in  FIG. 6B , this folding of the fabric between adjacent pockets  34  creates upper and lower edges  76 , which are located generally in the planes P 1  and P 2  of the string of springs  26 , as shown in  FIG. 2 . 
       FIG. 7  illustrates an alternative embodiment of bedding product  100 . This product  100  is illustrated as being a single-sided product, like the mattress or bedding product  10  of  FIG. 1 . However, the pocketed spring assembly  120  is different than the pocketed spring assembly  12  used in the mattress  10 . The pocketed spring assembly  120  of this embodiment is posturized or has different regions of different firmness due to the constructions of the strings of springs used in the pocketed spring assembly  120 . Although illustrated only in a single-sided mattress, such a posturized pocketed spring assembly  120  may be incorporated into any of the bedding or seating products described or illustrated herein. 
     As illustrated in  FIG. 7 , the pocketed spring assembly  120  has a plurality of longitudinally extending strings of springs  26 ,  26   b  joined together. The pocketed spring assembly  120  of the mattress  100  has a “firm” side or region F 1  and a “soft” side or region F 2 , the “firm” portion F 1  being firmer than the “soft” portion F 2 , due to the construction of the strings of springs making up each side, portion or region. For example, the “firm” side F 1  of pocketed spring assembly  120  may comprise strings of springs  26  shown in  FIGS. 2 and 3 , while the “soft” side F 2  of pocketed spring assembly  120  may comprise strings of springs  26   b  shown in  FIG. 3B . Because the linear distance “SB” of the triangular regions or bridges  86  between the branches  74   b  of each of the end portions  64   b  of each of the separating seams  52   b ,  54   b  of strings of springs  26   b  is larger than the linear distance “S” of the triangular regions or bridges  86  between the branches  74  of each of the end portions  64  of each of the separating seams  52 ,  54  of strings of springs  26 , the firmness of the group of connected strings of springs  26   b  in section F 2  of pocketed spring assembly  120  is less firm or “softer” than the firmness of the group of connected strings of springs  26  in section F 1  of pocketed spring assembly  120 . Although  FIG. 7  is illustrated with strings of springs  26 ,  26   b , any of the strings of springs shown or described herein may be used in a posturized pocketed spring assembly, like the pocketed spring assembly  120 . 
       FIG. 8  illustrates another alternative embodiment of bedding product  100   a . This product  100   a  is illustrated as being a single-sided product, like the mattress or bedding product  10  of  FIG. 1 . However, the pocketed spring assembly  120   a  is different than the pocketed spring assembly  12  used in the mattress  10 . The pocketed spring assembly  120   a  of this embodiment is posturized or has different regions of different firmness due to the constructions of the strings of springs used in the pocketed spring assembly  120   a . Although illustrated only in a single-sided mattress, such a posturized pocketed spring assembly  120   a  may be incorporated into any of the bedding or seating products described or illustrated herein. 
     As illustrated in  FIG. 8 , the pocketed spring assembly  120   a  has a plurality of transversely extending strings of springs  26 ,  26   b  joined together. The pocketed spring assembly  120   a  of the mattress  100   a  has a “firm” area or region F 1  and two “soft” areas or regions F 2  on opposite sides of the firm region F 1 , the “firm” portion F 1  being firmer than the “soft” portions F 2 , due to the construction of the strings of springs making up each portion or region F 1 , F 2 . For example, the “firm” region F 1  of pocketed spring assembly  120   a  may comprise strings of springs  26  shown in  FIGS. 2 and 3 , while the “soft” regions F 2  of pocketed spring assembly  120   a  may comprise strings of springs  26   b  shown in  FIG. 3B . Because the linear distance “SB” of the triangular regions or bridges  86  between the branches  74   b  of each of the end portions  64   b  of each of the separating seams  52   b ,  54   b  of strings of springs  26   b  is larger than the linear distance “S” of the triangular regions or bridges  86  between the branches  74  of each of the end portions  64  of each of the separating seams  52 ,  54  of strings of springs  26 , the firmness of the group of connected strings of springs  26   b  in sections F 2  of pocketed spring assembly  120   a  is less firm or “softer” than the firmness of the group of connected strings of springs  26  in section F 1  of pocketed spring assembly  120   a . Although  FIG. 8  is illustrated with strings of springs  26 ,  26   b , any of the strings of springs shown or described herein may be used in a posturized pocketed spring assembly, like the pocketed spring assembly  120   a.    
       FIG. 9  illustrates an alternative embodiment of bedding product  100   b . This product  100   b  is illustrated as being a single-sided product, like the mattress or bedding product  10  of  FIG. 1 . However, the pocketed spring assembly  120   b  is different than the pocketed spring assembly  12  used in the mattress  10 . The pocketed spring assembly  120   b  of this embodiment is posturized or has different regions of different firmness due to the constructions of the strings of springs used in the pocketed spring assembly  120   b . Although illustrated only in a single-sided mattress, such a posturized pocketed spring assembly  120   b  may be incorporated into any of the bedding or seating products described or illustrated herein. 
     As illustrated in  FIG. 9 , the pocketed spring assembly  120   b  has a plurality of transversely extending strings of springs  260  joined together. One of these strings of springs  260  is illustrated in detail in  FIG. 10 . The pocketed spring assembly  120   b  of the mattress  100   b  has a “firm” side or region F 1  and a “soft” side or region F 2 , the “firm” portion F 1  being firmer than the “soft” side or portion F 2 , due to the construction of the strings of springs  260  making up the pocketed spring assembly  120   b . Each of the transversely extending strings of springs  260  is identical, but has different separating seams therein. As shown in  FIG. 10 , each string of springs  260  has a “firm” side F 1  and a “soft” side F 2  due to different separating seams  52 ,  52   b  being incorporated into each of the strings of springs  260 . Because the linear distance “SB” of the separating seams  52   b  of portion F 2  of strings of springs  260  is larger than the linear distance “S” of the separating seams  52  of portion F 1  of strings of springs  260 , the firmness of one side or portion F 1  of the string of springs  260  is greater than the firmness of the other side or portion F 2  of the string of springs  260 . Even though the pocketed spring assembly  120   b  is made up of identical strings of springs  260  joined together, the pocketed spring assembly  120   b  is posturized or has regions of different firmness. The same side (section F 2 ) of each of the strings of springs  260  of pocketed spring assembly  120   b  is less firm or “softer” than the other side of each of the strings of springs  260  (section F 1 ) of pocketed spring assembly  120 . Although the string of springs  260  illustrated in  FIG. 10  has two separating seams  52 ,  52   b , any of the separating seams shown or described herein may be used in such a posturized string of springs to create a posturized pocketed spring assembly, like the pocketed spring assembly  120   b.    
       FIG. 11  illustrates an alternative embodiment of bedding product or mattress  200 . This product  200  is illustrated as being a single-sided product, like the mattress or bedding product  10  of  FIG. 1 . For simplicity, the same parts have the same numbers in the different embodiments. The interior  202  of the bedding product or mattress  200  is different than the interior of the mattress or bedding product  10  of  FIG. 1  and other interiors of products shown or described herein due to the addition of inserts  204 ,  205 . The strings of springs  26  may be joined to each other as in the other embodiments. However, in addition, multiple inserts  204 ,  205  are inserted into voids between adjacent strings of springs  26 . As shown in  FIGS. 12A-12C , inserts  204 ,  205  are arranged in transversely extending rows  206  and longitudinally extending columns  208 . 
     Although the pocketed spring assembly  12  of the bedding product or mattress  200  is identical to the pocketed spring assembly  12  used in the mattress  10 , the bedding product or mattress  200  has a different “feel” or firmness due to the presence of the multiple inserts  204 ,  205  in the bedding product or mattress  200 . Therefore, the bedding product or mattress  200  has a greater firmness than the firmness of the mattress or bedding product  10  of  FIG. 1  due to the addition of the inserts  204 ,  205  in the bedding product or mattress  200 , everything else being equal. However, a bedding manufacturer may be able to use a thinner wire for the pocketed springs in the strings of springs  26  of bedding product or mattress  200  than the wire used for the pocketed springs in the strings of springs  26  of bedding product or mattress  10 , due to the addition of the inserts  204 ,  205 . Although the drawings show an insert in every void, it is within the contemplation of the present invention that only select voids be filled with an insert of a desirable height and/or material. For example, inserts may be located only around the perimeter of the product for edge support. Being able to use thinner wire for the individually pocketed springs may be desirable from a cost perspective, for ease of manufacturing and other reasons. Although illustrated only in a single-sided mattress  20 , any number of inserts  204 ,  205  of any desired material(s) and/or size may be incorporated into any of the bedding or seating products described or illustrated herein in any desired locations. 
       FIG. 12A  illustrates a corner (the leftmost corner shown in  FIG. 11 ) of the interior  202  of the bedding product or mattress  200  shown in  FIG. 11 . In this embodiment of mattress  200 , the outermost two longitudinally extending columns  208  along the sides and the two outermost transversely extending rows  206  along the ends of inserts  204  are a height H approximately the same height as the height H of the pocketed springs  28  of the strings of springs  26 . See  FIG. 2 . As shown in  FIGS. 12A and 13A , the interior inserts  205  are of a height “HH” less than the height H of the perimeter inserts  204 . 
       FIGS. 12B and 13B  illustrate a corner like the corner shown in  FIG. 12A  of the interior  202   a  of another embodiment of bedding product or mattress like the bedding product or mattress  200  shown in  FIG. 11 . In this embodiment of mattress, all of the inserts  204 , including the perimeter inserts, are a height H approximately the same height as the height H of the pocketed springs  28  of the strings of springs  26 . See  FIG. 2 . As shown in  FIGS. 12B and 13B , the interior inserts  204  are of the same height as the height H of the perimeter inserts  204 . If desired, as explained above, the perimeter inserts may be made of a different material to increase the firmness of the perimeter inserts compared to the interior inserts to provide edge support or edge firmness. 
       FIG. 12C  illustrates the interior  202   a  of a mattress or bedding product with the addition of upper and lower scrim sheets  210 . Some or all of the strings of springs  26 , along with some or all the inserts  204 , may be secured to at least one of the upper and lower scrim sheets  210  in any desired manner, including the use of adhesive. If desired, only the strings of springs  26  may be secured to at least one of the scrim sheets  210 . In some applications, only one scrim sheet may be used. 
       FIG. 14  illustrates one of the inserts  204  made of one piece of foam. As explained above, the foam may be latex foam, polyurethane foam or “viscoelastic” polyurethane memory foam or any other known foam. This cushion may be used at any desired location and mixed and matched with other inserts described herein to achieve the desired firmness or “feel” in a mattress or bedding or seating product. 
       FIG. 15  illustrates another insert  214  made of two pieces of foam, piece  216  being on top of piece  218  and secured thereto. As explained above, either piece of foam may be latex foam, polyurethane foam or “viscoelastic” polyurethane memory foam or any other known foam. This insert may be used at any desired location and mixed and matched with other inserts described herein to achieve the desired firmness or “feel” in a mattress or bedding or seating product. 
       FIG. 16  illustrates another insert  220  made of one insert piece  222 , such as a fiber batt, for example, being on top of one foam piece  224  and secured thereto. As explained above, the piece of foam  224  may be latex foam, polyurethane foam or “viscoelastic” polyurethane memory foam or any other known foam. This insert  220  may be used at any desired location and mixed and matched with other inserts described herein to achieve the desired firmness or “feel” in a mattress or bedding or seating product. Although not shown, in some cases, the piece of foam  224  may be above the other insert piece  222 . 
       FIG. 17  illustrates another insert  226  made of three pieces of foam, a middle piece  228  being between end pieces  230  and secured thereto. As explained above, any of the pieces of foam may be latex foam, polyurethane foam or “viscoelastic” polyurethane memory foam or any other known foam. This insert may be used at any desired location and mixed and matched with other inserts described herein to achieve the desired firmness or “feel” in a mattress or bedding or seating product. 
     While we have described several preferred embodiments of this invention, persons skilled in this art will appreciate that other strings of springs 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. Therefore, we do not intend to be limited except by the scope of the following appended claims.