Patent Description:
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.

<CIT> and <CIT>, 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 <CIT> and <CIT> 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 <CIT> and <CIT>, 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. <CIT> 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's upwardly directed force on the fabric. Relevant prior art is provided by <CIT> and <CIT>.

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.

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. According to the invention, at least one of the fabrics is a four-mesh fabric.

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 airflows 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:.

With reference to <FIG>, there is illustrated a single-sided mattress <NUM> incorporating one embodiment of comfort layer in accordance with this invention. This mattress <NUM> comprises a spring core <NUM> over the top of which there is a conventional cushioning pad <NUM>, which may be partially or entirely made of foam or fiber or gel, etc. The cushioning pad <NUM> may be covered by a comfort layer <NUM> constructed in accordance with the present invention. A second conventional cushioning pad <NUM> may be located above the comfort layer <NUM>. In some applications, one or both of the cushioning pads <NUM> may be omitted. This complete assembly may be mounted upon a base <NUM> and is completely enclosed within an upholstered cover <NUM>.

As shown in <FIG>, mattress <NUM> 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'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 <NUM> 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>), 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> illustrates the components of one embodiment of comfort layer <NUM> incorporated into the mattress <NUM> shown in <FIG>. The comfort layer <NUM> comprises a first or upper piece of fabric <NUM> and a second or lower piece of fabric <NUM> with a plurality of mini coil springs <NUM> therebetween. Each of the first and second pieces of fabric <NUM>, <NUM> is made of nonwoven spunlaced aperture fabric having a pattern of apertures <NUM> therethrough which allow air to flow quickly through the fabric. One of the apertures <NUM> is shown in detail in <FIG>.

The fabric pieces <NUM>, <NUM> are joined together with circular containments or weld seams <NUM>, each weld seam <NUM> surrounding a mini coil spring <NUM>. Each weld seam <NUM> comprises multiple arced or curved weld segments <NUM> with gaps <NUM> therebetween. The first and second pieces of fabric <NUM>, <NUM> are joined together along each arced or curved weld segment <NUM> of each circular weld seam <NUM>. The first and second pieces of fabric <NUM>, <NUM> are not joined together along each gap <NUM> between adjacent weld segments <NUM> of each circular weld seam <NUM>. The curved weld segments <NUM> are strategically placed around a mini coil spring <NUM> and create the circular weld seam <NUM>. The two pieces of fabric <NUM>, <NUM>, in combination with one of the circular weld seams <NUM>, define a cylindrical-shaped pocket <NUM>, inside of which is at least one mini coil spring <NUM>.

During the welding process, the mini coil springs <NUM> may be at least partially compressed before pocket <NUM> 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 <NUM> of weld seams <NUM> 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 <NUM>, is not intended to be limiting. The placement of the weld seams <NUM> shown in the drawings is not intended to be limiting either. For example, the weld seams <NUM> may be organized into aligned rows and columns, as shown in <FIG> or organized with adjacent columns being offset from each other, as illustrated in <FIG>. 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 <NUM> in a relaxed condition may be between approximately <NUM> and <NUM> 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 <NUM>, each of the mini coil springs <NUM> may be approximately one and one-half inches tall. However, the mini coil springs <NUM> 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 <NUM>, <NUM>. Although the drawings show the first and second pieces of fabric <NUM>, <NUM> being identical, it is within the scope of the present invention that only one of the first and second pieces of fabric <NUM>, <NUM> be the aperture fabric shown in the drawings.

As best shown in <FIG>, each of the apertures <NUM> shown throughout each of the first and second pieces of fabric <NUM>, <NUM> 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 (<NUM>) millimeters and the width dimension "W" is <NUM> millimeters. This fabric is known in the industry as a four-mesh fabric. According to the invention at least one of the fabrics (<NUM>, <NUM>) is 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 <NUM> 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 <NUM> millimeters and the width dimension "W" is <NUM> 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 <NUM> millimeters and the width dimension "W" is <NUM> millimeter. This fabric is known in the industry as a twenty-two mesh fabric.

Each of the first and second pieces of fabric <NUM>, <NUM> preferably has a fabric weight of between <NUM> grams per square meter and <NUM> 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 <NUM> 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>, there is illustrated a portion of a mobile ultrasonic welding horn <NUM> and anvil <NUM>. The movable ultrasonic welding horn <NUM> has a plurality of spaced cut-outs or slots <NUM> along its lower edge <NUM>. The remaining portions <NUM> of the ultrasonic welding horn's bottom <NUM> between the slots <NUM> are the portions which weld the two pieces of fabric <NUM>, <NUM> together and create the curved weld segments <NUM>. Along the ultrasonic welding horn's bottom edge <NUM>, the ultrasonic welding horn <NUM> can be milled to make the slots a desired length to allow a desired airflow between the curved weld segments <NUM> as illustrated by the arrows <NUM> of <FIG>. The airflows affect the feel/compression of the individually pocketed mini coil springs <NUM> when a user lays on the mattress <NUM>.

As shown in <FIG>, underneath the second piece of fabric <NUM> is an anvil <NUM> comprising a steel plate of <NUM>/<NUM>th inch thickness. However, the anvil may be any desired thickness. During the manufacturing process, the ultrasonic welding horn <NUM> contacts the anvil <NUM>, the two pieces of fabric <NUM>, <NUM> therebetween, to create the circular weld seams <NUM> and, hence, cylindrical-shaped pockets <NUM>, at least one mini coil spring being in each pocket <NUM>.

These curved weld segments <NUM> are created by the welding horn <NUM> of a machine (not shown) having multiple spaced protrusions <NUM> on the ultrasonic welding horn <NUM>. As a result of these circular weld seams <NUM> joining pieces <NUM>, <NUM>, the pieces <NUM>, <NUM> define a plurality of spring-containing pockets <NUM> of the comfort layer <NUM>. One or more mini coil springs <NUM> may be contained within an individual pocket <NUM>.

<FIG> illustrates another apparatus for forming the circular weld seams <NUM> comprising multiple curved weld segments <NUM> having gaps <NUM> therebetween for airflow. In this apparatus, the ultrasonic welding horn 32a has no protrusions on its bottom surface <NUM>. Instead, the bottom surface <NUM> of ultrasonic welding horn 32a is smooth. As shown in <FIG>, the anvil 42a has a plurality of curved projections <NUM>, which together form a projection circle <NUM>. A plurality of projection circles <NUM> extend upwardly from the generally planar upper surface <NUM> of anvil 42a. When the ultrasonic welding horn 32a moves downwardly and sandwiches the plies <NUM>, <NUM> of fabric between one of the projection circles <NUM> and the smooth bottom surface <NUM> of ultrasonic welding horn 32a, a circular weld seam <NUM> is created, as described above. Thus, a plurality of pockets <NUM> are created by the circular weld seams <NUM>, each pocket <NUM> containing at least one mini coil spring <NUM>.

Upon being subjected to a load, a pocket <NUM> containing at least one mini coil spring <NUM> is compressed by compressing the mini coil spring(s) <NUM> and air contained within the pocket <NUM>. Air exits the pocket <NUM> through apertures <NUM> in the fabric and gaps <NUM> between the curved weld segments <NUM> of the circular weld seams <NUM>. Similarly, when a load is removed from the pocket <NUM>, the mini coil spring <NUM> separates the fabric layers <NUM>, <NUM>, and air reenters the pocket <NUM> though apertures <NUM> in the fabric and through the gaps <NUM> between the curved weld segments <NUM> of the circular weld seams <NUM>. As shown in <FIG>, the size of the gaps <NUM> between the segments <NUM> of circular seams <NUM> of perimeter pockets <NUM> may affect how quickly air may enter or exit the comfort layer <NUM>.

In the present invention the fabric material is permeable to airflow, so the rate at which the mini coil springs <NUM> compress when a load is applied to a pocketed spring core comfort layer <NUM> is not slowed or retarded by the air entrapped within the individual pockets as the pocketed spring comfort layer <NUM> 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 <NUM> of the pocketed spring comfort layer <NUM>. Air passes through the apertures in the first and second pieces of fabric <NUM>, <NUM> when the pocket <NUM> is compressed and when the pocket <NUM> is unloaded, enlarging or expanding due to the inherent characteristics of the mini springs <NUM>. In addition, air passes through the gaps <NUM> between the curved weld segments <NUM> of the circular weld seams <NUM>, as described above.

As best illustrated in <FIG>, the individual pockets <NUM> of comfort layer <NUM> may be arranged in longitudinally extending columns <NUM> extending from head-to-foot of the bedding product and transversely extending rows <NUM> extending from side-to-side of the bedding product. As shown in <FIG>, the individual pockets <NUM> of one column <NUM> are aligned with the pockets <NUM> of adjacent columns <NUM>.

<FIG> illustrate another comfort layer <NUM> having the same pockets <NUM> and same springs <NUM> as does the embodiment of comfort layer <NUM> of <FIG>. As best illustrated in <FIG>, the individual pockets <NUM> of comfort layer <NUM> are arranged in longitudinally extending columns <NUM> extending from head-to-foot of the bedding product and transversely extending rows <NUM> extending from side-to-side of the bedding product. As shown in <FIG>, the individual pockets <NUM> of one column <NUM> are offset from, rather than aligned with, the pockets <NUM> of the adjacent columns <NUM>.

<FIG> illustrates an alternative embodiment of comfort layer <NUM> incorporated into a single-sided mattress <NUM>. Single-sided mattress <NUM> comprises a pocketed spring core <NUM>, a cushioning pad <NUM> on top of the pocketed spring core <NUM>, a base <NUM>, another cushioning pad <NUM> above comfort layer <NUM>, and an upholstered covering material <NUM>. Pocketed spring core <NUM> 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 <NUM> may be used in any conventional core, including a spring core made with non-pocketed conventional springs, such as coil springs.

<FIG> illustrates the components of the comfort layer <NUM> incorporated into the mattress <NUM> shown in <FIG>. The comfort layer <NUM> comprises a first piece of fabric <NUM> and a second piece of fabric <NUM> joined together with multiple linear weld segments <NUM>. The first and second pieces of fabric <NUM>, <NUM> are made of the same nonwoven spunlaced aperture fabric described herein with respect to first and second pieces of fabric <NUM>, <NUM>. Each of the first and second pieces of fabric <NUM>, <NUM> is made of nonwoven spunlaced aperture fabric having a pattern of apertures <NUM> therethrough which allow air to flow quickly through the fabric. One of the apertures <NUM> is shown in detail in <FIG>.

The weld segments <NUM> are strategically placed around a mini coil spring <NUM> and create a rectangular containment or seam <NUM>. During the welding process, the mini coil springs <NUM> may be compressed. The length and/or width of the linear weld segments <NUM> of seams <NUM> 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 <NUM> 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>, there is illustrated a portion of an ultrasonic welding horn <NUM> and anvil <NUM>. The mobile or movable ultrasonic welding horn <NUM> has a plurality of spaced cut-outs or slots <NUM> between projections <NUM>. The projections <NUM> of the ultrasonic welding horn <NUM> are the portions which weld the two pieces of fabric <NUM>, <NUM> together and create the linear weld segments <NUM> in rectangular weld seams <NUM>. Along the ultrasonic welding horn's lower portion <NUM>, the ultrasonic welding horn <NUM> can be milled to allow a desired airflow between the linear weld segments <NUM> as illustrated by the arrows <NUM> of <FIG>. The airflows affect the feel/compression of the individually pocketed mini coil springs <NUM> when a user lays on the mattress <NUM>.

As shown in <FIG>, underneath the second piece of fabric <NUM> is an anvil <NUM> comprising a steel plate of <NUM>/<NUM>th inch thickness. However, the anvil may be any desired thickness. During the manufacturing process, the ultrasonic welding horn <NUM> contacts the anvil <NUM>, the two pieces of fabric <NUM>, <NUM> being therebetween, to create the rectangular weld seams <NUM> and, hence, pockets <NUM>, at least one mini coil spring <NUM> being in each pocket <NUM>.

These linear weld segments <NUM> may be created by the welding horn <NUM> of a machine (shown in <FIG> and described below) having multiple spaced protrusions <NUM> on the ultrasonic welding horn <NUM>. As a result of these rectangular weld seams <NUM> defining the spring-containing pockets <NUM> of the comfort layer <NUM>, each mini coil spring <NUM> is contained within its own individual pocket <NUM>. Air exits the pocket <NUM> through gaps <NUM> between the weld segments <NUM> of the rectangular weld seams <NUM>. Similarly, when a load is removed from the pocket <NUM>, the mini coil spring <NUM> separates the fabric layers <NUM>, <NUM>, and air reenters the pocket <NUM> though the gaps <NUM> between the weld segments <NUM> of the rectangular weld seams <NUM>. As shown in <FIG>, the size of the gaps <NUM> between the segments <NUM> of rectangular weld seams <NUM> of the pockets <NUM> may assist how quickly air may enter or exit the comfort layer <NUM>.

<FIG> illustrates another apparatus for forming the rectangular weld seams <NUM> comprising multiple linear weld segments <NUM> having gaps <NUM> therebetween for airflow. In this apparatus, the ultrasonic welding horn 72a has no protrusions on its bottom surface <NUM>. Instead, the bottom surface <NUM> of ultrasonic welding horn 72a is smooth. The anvil 74a has a plurality of linear projections <NUM>, which together form a projection pattern <NUM>, shown in <FIG>. A plurality of spaced projections <NUM> in pattern <NUM> extend upwardly from the generally planar upper surface <NUM> of anvil 74a. When the ultrasonic welding horn 72a moves downwardly and sandwiches the pieces <NUM>, <NUM> of fabric between the projections <NUM> and the smooth bottom surface <NUM> of ultrasonic welding horn 72a, rectangular weld seams <NUM> are created. Thus, a plurality of pockets <NUM> are created by the rectangle weld seams <NUM>, each pocket <NUM> containing at least one mini coil spring <NUM>.

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 <NUM>.

In an air permeability test known in the industry as the ASTM Standard D737, <NUM> (<NUM>), "Standard Test Method for Air Permeability of Textile Fabrics," ASTM International, West Conshohocken, PA <NUM>, 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 <NUM> cubic feet per minute ("CFM"). Using the same test with semi-impermeable fabric available from Hanes Industries of Conover, North Carolina disclosed in <CIT> resulted in a range of between <NUM> and <NUM> CFM. Using the same test with conventional nonwoven spunbond polypropylene bedding fabric resulted in an average of <NUM> 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, North Carolina disclosed in <CIT>. 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, North Carolina disclosed in <CIT>. 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>, the individual pockets <NUM> of comfort layer <NUM> may be arranged in longitudinally extending columns <NUM> extending from head-to-foot of the bedding product and transversely extending rows <NUM> extending from side-to-side of the bedding product. As shown in <FIG>, the individual pockets <NUM> of one column <NUM> are aligned with the pockets <NUM> of the adjacent columns <NUM>. Air may flow between pockets <NUM> and into and out of the comfort layer <NUM> between the linear segments <NUM> of seams <NUM>.

<FIG> illustrates one corner of comfort layer <NUM> of mattress <NUM> showing airflow between the curved weld segments <NUM> of the peripheral pockets <NUM>, as illustrated by the arrows <NUM>. Although <FIG> illustrates the arrows <NUM> only on one corner pocket <NUM>, each of the pockets <NUM> around the periphery of the comfort layer <NUM> allows airflow through the gaps <NUM> between the weld segments <NUM> of circular seams <NUM>. This airflow affects the amount of air entering the comfort layer <NUM> when a user changes position or gets off the bedding or seating product, thus allowing the springs <NUM> in the pockets <NUM> to expand and air to flow into the comfort layer <NUM>. Similarly, when a user gets onto a bedding or seating product, the springs <NUM> compress and cause air to exit the pockets <NUM> around the periphery of the comfort layer <NUM> and exit the comfort layer. The amount of air exiting the comfort layer <NUM> affects the feel/compression of the individually pocketed mini coil springs <NUM> when a user lays on the mattress <NUM>.

<FIG> illustrates one corner of comfort layer <NUM> of mattress <NUM> of <FIG> showing airflow between the weld segments <NUM> of the peripheral pockets <NUM>, as illustrated by the arrows <NUM>. Although <FIG> illustrates the arrows <NUM> only on one corner pocket <NUM>, each of the pockets <NUM> around the periphery of the comfort layer <NUM> allows airflow through the gaps <NUM> between the weld segments <NUM> of rectangular seams <NUM>. This airflow affects the amount of air entering the comfort layer <NUM> when a user changes position or gets off the bedding or seating product, thus allowing the springs <NUM> in the pockets <NUM> to expand and air to flow into the comfort layer <NUM>. Similarly, when a user changes position or gets onto a bedding or seating product, the springs <NUM> compress and cause air to exit the pockets <NUM> around the periphery of the comfort layer <NUM> and exit the comfort layer. The amount of air exiting the comfort layer <NUM> affects the feel/compression of the individually pocketed mini coil springs <NUM> when a load is applied to the mattress <NUM>.

<FIG> illustrates one corner of an alternative embodiment of comfort layer 16a, which may be used in any bedding or seating product. The comfort layer 16a comprises aligned rows <NUM> and columns <NUM> of pockets 44a, each pocket 44a comprising a circular seam 30a joining upper and lower plies of fabric, as described above. However, each of the circular seams 30a 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 30a of pockets 44a allow no airflow through the seams 30a. Therefore, the fabric material of the first and second plies of pockets 44a of comfort layer 16a must be made of permeable material to allow airflow into and out of the pockets 44a of comfort layer 16a. The type of material used for comfort layer 16a solely controls the amount of air entering the comfort layer 16a when a user gets off the bedding or seating product, thus allowing the springs <NUM> in the pockets 44a to expand and air to flow into the comfort layer 16a. Similarly, when a user gets onto a bedding or seating product, the springs <NUM> compress and cause air to exit the pockets 44a of the comfort layer 16a and exit the comfort layer. The amount of air exiting the comfort layer 16a affects the feel/compression of the individually pocketed mini coil springs <NUM> when a user lays on the product incorporating the comfort layer 16a.

<FIG> illustrates one corner of an alternative embodiment of comfort layer 56a, which may be used in any bedding or seating product. The comfort layer 56a comprises aligned rows <NUM> and columns <NUM> of pockets 84a, each pocket 84a comprising a rectangular seam 70a joining upper and lower plies of fabric as described above. However, each of the rectangular seams 70a is a continuous seam, as opposed to a seam having weld segments with gaps therebetween to allow airflow through the seam. These rectangular seams 70a of pockets 84a allow no airflow through the seams 70a. Therefore, the fabric material of the first and second plies of pockets 84a of comfort layer 56a must be made of permeable material to allow airflow into and out of the pockets 84a of comfort layer 56a. The type of material used for comfort layer 56a solely controls the amount of air entering the comfort layer 56a when a user gets off the bedding or seating product, thus allowing the springs <NUM> in the pockets 84a to expand and air to flow into the comfort layer 56a. Similarly, when a user gets onto a bedding or seating product, the springs <NUM> compress and cause air to exit the pockets 84a of the comfort layer 56a and exit the comfort layer. The amount of air exiting the comfort layer 56a affects the feel/compression of the individually pocketed mini coil springs <NUM> when a user lays on the product incorporating the comfort layer 56a.

<FIG> illustrates a machine <NUM> used to make several of the comfort layers shown and disclosed herein, including comfort layer <NUM> shown in <FIG>. Some parts of the machine <NUM> may be changed to make other comfort layers shown or described herein, such as comfort layer <NUM> shown in <FIG>. Machine <NUM> comprises a pair of ultrasonic welding horns <NUM>, and at least one stationary anvil <NUM>, as shown in <FIG>. Alternatively, ultrasonic welding horns 32a and anvil 42a of <FIG> may be used in the machine.

Machine <NUM> discloses a conveyor <NUM> on which are loaded multiple mini coil springs <NUM>. The conveyor <NUM> moves the mini coil springs <NUM> in the direction of arrow <NUM> (to the right as shown in <FIG>) until the mini coil springs <NUM> are located in predetermined locations, at which time the conveyor <NUM> stops moving. Machine <NUM> further discloses several actuators <NUM>, which move a pusher assembly <NUM>, including a pusher plate <NUM> in the direction of arrow <NUM>. Although two actuators <NUM> are illustrated in <FIG> and <FIG>, any number of actuators <NUM> of any desired configuration may be used to move the pusher assembly <NUM>. The pusher plate <NUM> has a plurality of spaced spring pushers <NUM> secured to the pusher plate <NUM> underneath the pusher plate <NUM>. The spring pushers <NUM> push the mini coil springs <NUM> between stationary guides <NUM> from a first position shown in <FIG> to a second position shown in <FIG> in which the mini coil springs <NUM> are located above the stationary anvil <NUM> (or above the alternative anvil 42a shown in <FIG>). <FIG> illustrates the mini coil springs <NUM> being transported from the first position to the second position, each mini coil spring <NUM> being transported between adjacent stationary guides <NUM>. The stationary guides <NUM> are secured to a stationary mounting plate <NUM>.

The machine <NUM> further comprises a compression plate <NUM>, which is movable between raised and lowered positions by lifters <NUM>. Although two lifters <NUM> are illustrated in <FIG> and <FIG>, any numbers of lifters <NUM> of any desired configuration may be used to move the compression plate <NUM>.

As best shown in <FIG>, machine <NUM> further comprises three pressers <NUM> movable between raised and lowered positions via actuators <NUM>. <FIG> and <FIG> show one of the pressers <NUM> in a raised position, while <FIG>, <FIG> and <FIG> show the presser in a lowered position. Each presser has a blade <NUM> at the bottom thereof for bringing the plies <NUM>, <NUM> of fabric together when the presser is lowered, as shown in <FIG>, <FIG> and <FIG>.

As best shown in <FIG>, machine <NUM> further comprises rollers <NUM>, <NUM> around which the plies, <NUM>, <NUM> respectively pass before they come together. After the circular seams <NUM> are created by the ultrasonic welding horn <NUM> and anvil <NUM>, thereby creating the pockets <NUM>, a main roller <NUM> and secondary roller <NUM> pull the continuous spring blanket <NUM> downwardly. Once a desired amount of continuous spring blanket <NUM> is made, a blade <NUM> cuts the continuous spring blanket <NUM> to create comfort layer <NUM> of the desired size. Of course, the machine <NUM> may be programmed to create the desired length and width of comfort layer. This machine <NUM> is adapted to make any of the comfort layers shown or disclosed herein having circular weld seams.

<FIG> illustrates the ultrasonic welding horn <NUM> in a lowered position contacting the stationary anvil <NUM> with at least one of the pressers <NUM> in a lowered position pressing the upper ply <NUM> into contact with the lower ply <NUM>. A new row of mini coil springs <NUM> has been moved into a loading position with the compression plate <NUM> in its raised position.

<FIG> illustrates the ultrasonic welding horn <NUM> in a raised position spaced from the anvil <NUM> with at least one of the pressers <NUM> in a raised position. The compression plate <NUM> is moved to its lowered position by lifters <NUM>, thereby compressing the row of mini coil springs <NUM> located on the conveyor <NUM>.

<FIG> illustrates the row of compressed mini coil springs <NUM> located on the conveyor <NUM> being pushed downstream towards the ultrasonic welding horn <NUM> and stationary anvil <NUM> by the pusher assembly <NUM>. More particularly, the pushers <NUM> secured to the pusher plate <NUM> contact the compressed mini coil springs <NUM> and move them downstream between the stationary guides <NUM> and past the raised pressers <NUM>.

<FIG> illustrates the pusher assembly <NUM> being withdrawn in the direction of arrow <NUM>. Additionally, the pressers <NUM> are moved to a lowered position pressing the upper ply <NUM> into contact with the lower ply <NUM>. Also, the compression plate <NUM> is moved to its raised position by lifters <NUM>.

<FIG> illustrates the ultrasonic welding horn <NUM> in a lowered position contacting the stationary anvil <NUM> with at least one of the pressers <NUM> in a lowered position pressing the upper ply <NUM> into contact with the lower ply <NUM>. A new row of mini coil springs <NUM> has been moved by the conveyor <NUM> into a position in which they may be compressed with the compression plate <NUM> during the next cycle.

<FIG> illustrates a machine <NUM>, like the machine <NUM> shown in <FIG> and <FIG>. However, instead of having two ultrasonic welding horns <NUM>, machine <NUM> has four ultrasonic welding horns <NUM> along with anvil <NUM>. Alternatively, ultrasonic welding horns 72a and anvil 74a of <FIG> may be used in machine <NUM>. This machine <NUM> is adapted to make any of the comfort layers shown or disclosed herein having rectangular weld seams, as opposed to circular weld seams.

<FIG> illustrates a posturized comfort layer <NUM> having three different areas or regions of firmness depending upon the airflow within each of the areas or regions. The comfort layer <NUM> has a head section <NUM>, a foot section <NUM> and a lumbar or middle section <NUM> therebetween. The size and number of segments in the seams, along with the type of material used to construct the posturized comfort layer <NUM>, 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>, 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> shows each of the segmented seams of comfort layer <NUM> being circular, a posturized comfort layer, such as the one shown in <FIG>, may have rectangular or square segmented seams.

<FIG> illustrates a posturized comfort layer <NUM> having two different areas or regions of firmness depending upon the airflow within each of the areas or regions. The comfort layer <NUM> has a first section <NUM> and a second section <NUM>. The size and number of segments in the seams, along with the type of material used to construct the posturized comfort layer <NUM>, 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>, 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> shows each of the segmented seams of comfort layer <NUM> being circular, a posturized comfort layer, such as the one shown in <FIG>, may have rectangular or square segmented seams.

<FIG> illustrates a web or blanket <NUM> of comfort layer like the blanket <NUM> described above and shown in <FIG> and <FIG> moving in the direction of arrow <NUM>. The blanket <NUM> 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 <NUM>, spaced rows <NUM> of pocketed mini coil springs <NUM> extend in a direction perpendicular to the direction of travel of the blanket <NUM> during manufacture. The spaced rows <NUM> are spaced between spaced areas <NUM> which contain no pocketed mini coil springs. In some applications, the spaced areas <NUM> may be the same size as the rows <NUM> so every other row of pocketed mini coil springs is missing or omitted. However, the spaced areas <NUM> may be any desired size. Due to the spacing between rows <NUM> extending from side-to-side, the pocketed mini coil springs <NUM> form columns <NUM> extending parallel the direction of travel of the blanket <NUM> during manufacture. Each column <NUM> comprises pocketed mini coil springs <NUM> spaced from each other a distance equal to or greater than the diameter of one circular weld seam <NUM>. The circular weld seams <NUM> may be segments or solid.

<FIG> illustrates another web or blanket <NUM> of comfort layer moving in the direction of arrow <NUM>. The blanket <NUM> 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>. In blanket <NUM>, spaced columns <NUM> of pocketed mini coil springs <NUM> extend in a direction parallel the direction of travel of the blanket <NUM> during manufacture. The spaced columns <NUM> are spaced between spaced areas <NUM> which contain no pocketed mini coil springs. In some applications, the spaced areas <NUM> may be the same size as the columns <NUM>. However, the spaced areas <NUM> may be any desired size. Due to the spacing between columns <NUM> extending in the direction of travel of the blanket <NUM>, the pocketed mini coil springs <NUM> form rows <NUM> extending perpendicular to the direction of travel of the blanket <NUM> during manufacture. Each row <NUM> comprises pocketed mini coil springs <NUM> spaced from each other a distance equal to or greater than the diameter of one circular weld seam <NUM>.

Although <FIG> and <FIG> illustrate pocketed mini coil springs <NUM> having circular weld seams <NUM>, rectangular weld seams as described herein may be incorporated into the pocketed mini coil springs of <FIG> and <FIG>. Although the drawings show the blankets <NUM>, <NUM> made with nonwoven spunlaced aperture fabric, any fabric described or shown herein may be used to form blankets <NUM>, <NUM>.

<FIG> illustrate enlarged views of a portion of the blanket <NUM>. The circular weld seams <NUM> are segmented having gaps <NUM> between curved weld segments <NUM>, like the circular weld seams <NUM>. <FIG> show at least one mini coil spring <NUM> being in each pocket <NUM> formed by one of the circular weld seams <NUM>. Arrows <NUM> illustrate airflow between the curved weld segments <NUM> into and out of the pockets <NUM>.

<FIG> illustrate enlarged views of a portion of another blanket 160a having rectangular weld seams <NUM> rather than circular weld seams. The rectangular weld seams <NUM> are segmented having gaps <NUM> between straight weld segments <NUM>, like the rectangular weld seams <NUM>. <FIG> show at least one mini coil spring <NUM> being in each pocket <NUM> formed by one of the rectangular weld seams <NUM>. Arrows <NUM> illustrate airflow between the straight weld segments <NUM> into and out of the pockets <NUM>.

<FIG> illustrates a posturized comfort layer <NUM> having three areas or regions of differing firmness depending upon the density of pockets within each of the areas or regions. The comfort layer <NUM> has a head section <NUM>, a foot section <NUM> and a lumbar or middle section <NUM> 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>, 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 <NUM>, <NUM> may have the same firmness due to having the same density of individually pocketed mini coil springs <NUM>.

Although <FIG> shows each of the number of individually pocketed mini coil springs <NUM> in the middle section <NUM> being greater than the number of individually pocketed mini coil springs <NUM> in the head and foot sections <NUM>, <NUM>, 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> 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>, may have rectangular or square weld seams with either segmented or solid weld seams.

<FIG> illustrates a posturized comfort layer <NUM> having two different areas or regions of firmness depending upon the density of individually pocketed mini coil springs <NUM> within each of the areas or regions. The comfort layer <NUM> has a first section <NUM> and a second section <NUM>. The number of individually pocketed mini coil springs <NUM> may have different firmness due to different pocketed densities within different sections. Although two sections are illustrated in <FIG>, 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> 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>, may have rectangular or square weld seams with either segmented or solid weld seams.

Although <FIG> and <FIG> 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.

Claim 1:
A comfort layer (<NUM>, <NUM>, <NUM>, 16a, 56a, <NUM>, <NUM>, <NUM>, <NUM>, 160a, <NUM>, <NUM>) configured to overlay a spring core of a bedding or seating cushion product (<NUM>), said comfort layer comprising:
a matrix of pocketed mini coil springs (<NUM>), each mini coil spring (<NUM>) of which is contained within a pocket (<NUM>, <NUM>, 44a, 84a, <NUM>, <NUM>), said pocket being permeable to airflow through said pocket and having a weld seam (<NUM>, <NUM>, 30a, 70a, <NUM>, <NUM>) around the pocket joining first and second pieces of fabric (<NUM>, <NUM>, <NUM>, <NUM>) of the pocket;
at least one of said pieces of fabric (<NUM>, <NUM>, <NUM>, <NUM>) being made of a nonwoven aperture fabric to increase the rate at which air escapes through the fabric of the pocket when a load is placed on the pocket, the rate of compression of the mini coil springs subjected to the load being increased by apertures (<NUM>) in the fabric,
at least one of said pieces of fabric being a four-mesh or or an eight, ten, twenty or twenty-two mesh-fabric, the four-mesh fabric being a non-woven spunlaced fabric having four apertures per square centimeter wherein each of the apertures (<NUM>) has an oval shape in a relaxed condition, in which the length dimension is <NUM> millimeters and the width dimension is <NUM> millimeters.