Patent Description:
Comfort layers are commonly used in seating or bedding products above/below a core, which may or may not include a spring assembly. Such comfort layers may include foam, fiber and gel products. <CIT> discloses a comfort layer made of pocketed springs. Such spring assemblies may be made of strings of individually pocketed coil springs joined together or multiple coil springs joined together by helical lacing wires.

Comfort layers comprising mini pocketed coil springs have heretofore been a uniform firmness throughout. The mini pocketed coil springs have all been the same.

One desirable feature of known pocketed spring assemblies used as the core of bedding products is posturized support, i.e., one or more sections of the pocketed spring assembly being firmer than another section or other sections of the pocketed spring assembly. Due to the configuration of the human body laying on a bedding or seating product, additional support in a middle or lumbar section of the product may be desirable. Comfort layers are commonly used in seating or bedding products above/below a central core. The central core may or may not include a spring assembly. The central core is most commonly a pocketed or un-pocketed spring core. However, the central core of a bedding or seating product may be made partially or entirely of foam.

<CIT> and <CIT> each disclose a comfort layer made of pocketed mini coil springs configured to overlay a spring core of a bedding or seating product. Such comfort layers commonly have at least one layer of fabric above and at least one layer of fabric below individually pocketed mini coil springs.

One drawback to such pocketed spring comfort layers is that a mattress manufacturer may desire to place one or more foam or fiber layers above such a pocketed spring comfort layer so that a user does not detect or feel the pocketed spring comfort layer. In the case of a double-sided bedding or seating product, a mattress manufacturer may place one or more foam or fiber layers above one pocketed spring comfort layer and below another pocketed spring comfort layer on the opposite surface of the central core of the product.

It is therefore an objective of this invention to provide a pocketed spring comfort layer adapted to overlay a central core of a seating or bedding product which may eliminate or reduce the need for a mattress manufacturer to place one or more foam or fiber layers above the pocketed spring comfort layer and yet obtain a posturized effect.

It is another objective of this invention to provide a pocketed spring comfort layer adapted to overlay a central core of a seating or bedding product which may reduce the number or thickness of foam or fiber layers a mattress manufacturer may elect to place above such a pocketed spring comfort layer, thereby reducing the cost of the finished mattress by the cost of such layers and the associated cost of applying them while still obtaining different firmness in different regions.

It is another objective of this invention to provide a pocketed spring comfort layer for a seating or bedding product which has different regions or sections of different firmness. Comfort layers according to the prior art are known from documents <CIT> and <CIT>.

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 example comfort layer. 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 posturized comfort layer <NUM> constructed in accordance with one embodiment of the invention. A second conventional cushioning pad <NUM> may be located above the posturized comfort layer <NUM>. In some applications, one or both 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 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. Either the cushioning pad or pads, on top and/or bottom of the core, may be omitted. The novel features of the invention reside in the comfort layer.

<FIG> illustrates another mattress 10a having the same components as mattress <NUM> except a pocketed spring core 12a rather than a conventional spring core <NUM> shown in <FIG>. 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 conventional spring cores.

<FIG> illustrate the components of one example of posturized comfort layer <NUM> incorporated into the mattress <NUM> shown in <FIG>. As best shown in <FIG>, the posturized 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>, <NUM> therebetween. The fabric pieces <NUM>, <NUM> are made of non-woven polypropylene in one embodiment, but may be made of any known material. The fabric pieces <NUM>, <NUM> are preferably made of the same material, but may be made of different materials. The fabric pieces <NUM>, <NUM> are joined together with rectangular weld seams <NUM>, each rectangular seam <NUM> surrounding one of the mini coil springs <NUM> or <NUM>.

Each rectangular seam <NUM> comprises multiple straight or linear weld segments <NUM> with gaps <NUM> therebetween. The first and second pieces of fabric <NUM>, <NUM> are joined together along each straight or linear weld segment <NUM> of each rectangular 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 rectangular seam <NUM>. The straight or linear weld segments <NUM> are strategically placed around a mini coil spring <NUM>, <NUM> and create the rectangular seam <NUM>. The two pieces of fabric <NUM>, <NUM>, in combination with one of the rectangular weld seams <NUM>, define a pocket <NUM>, <NUM> inside of which is at least one mini coil spring <NUM>, <NUM>, respectively. For purposes of this document, the two pieces of fabric <NUM>, <NUM>, in combination with one of the rectangular weld seams <NUM> and at least one mini coil spring <NUM>, <NUM> define a pocketed mini coil spring <NUM>, <NUM>, respectively.

<FIG> illustrate the components of posturized comfort layer <NUM> shown in <FIG>, but with solid rectangular weld seams <NUM> in place of segmented weld seams <NUM>. In any of the embodiments described herein or shown, solid or partially solid weld seams may replace segmented weld seams of any shape, including circular weld seams. <FIG> are merely one example.

As best shown in <FIG> and <FIG>, the pocketed mini coil springs <NUM>, <NUM> are arranged in a matrix of aligned transversely extending rows <NUM> extending from side-to-side and longitudinally extending columns <NUM> extending from head-to-foot.

During the welding process, the mini coil springs <NUM>, <NUM> may be at least partially compressed before pocket <NUM>, <NUM> is closed and thereafter.

The size of the straight or linear weld segments <NUM> of rectangular seams <NUM> are not intended to be limited by the illustrations; they may be any desired size. Similarly, the size of the illustrated rectangular seams <NUM>, is not intended to be limiting. The placement of the rectangular seams <NUM> shown in the drawings is not intended to be limiting either. Any desired arrangement of rectangular seams may be incorporated into any embodiment shown or described herein.

The weld segments <NUM> may assume shapes other than the straight or linear weld segments illustrated. For example, the weld seams <NUM> may be other shapes, such as triangles or circles or ovals of the desired size and pattern. This holds true for any of the weld seams described herein regardless of whether circular or rectangular and regardless of the comfort layer described herein or shown in this document.

<FIG> illustrates the posturized comfort layer <NUM> having a center section <NUM> and two end sections <NUM> on opposite sides of the center section <NUM>. Each of the three sections <NUM>, <NUM> is illustrated being generally rectangular shaped and approximately the same size. However, any one of the sections may be a different size than any other section. For example, the end sections <NUM> may be a different size than the middle or center section <NUM>. The drawings are not intended to be limiting.

Each of the end sections <NUM> has identical pocketed mini coil springs <NUM>. For purposes of this document, each of the end sections <NUM> will be referred to as a "tall" section, and each of the pocketed mini coil springs <NUM> will be referred to as a "tall" pocketed mini coil spring. Each tall pocketed mini coil spring <NUM>, shown in detail in <FIG> and <FIG>, comprises a partially compressed mini coil spring <NUM> and first and second pieces <NUM>, <NUM> of fabric joined together with a rectangular weld seam <NUM>. As shown in <FIG>, each mini coil spring <NUM> has an out-of-pocket height H1 in its relaxed or non-compressed condition. As shown in <FIG>, each mini coil spring <NUM> has a diameter of D1 in its relaxed or non-compressed condition. As shown in <FIG> and <FIG>, each mini coil spring <NUM>, when pocketed, creates a tall pocketed mini coil spring <NUM> having a pocketed height H3, less than the out-of-pocket height H1 of mini coil spring <NUM>.

The center section <NUM> has identical pocketed mini coil springs <NUM>. For purposes of this document, the center section <NUM> will be referred to as a "short" section, and each of the pocketed mini coil springs <NUM> will be referred to as a "short" pocketed mini coil spring. Each short pocketed mini coil spring <NUM>, shown in detail in <FIG> and <FIG>, comprises a mini coil spring <NUM> and first and second pieces <NUM>, <NUM> of fabric joined together with a rectangular weld seam <NUM>. As shown in <FIG>, each mini coil spring <NUM> has an out-of-pocket height H2 in its relaxed or non-compressed condition, greater than the out-of-pocket height H1 of mini coil spring <NUM> shown in <FIG>. As shown in <FIG>, each mini coil spring <NUM> has diameter D2 in its relaxed or non-compressed condition greater than the diameter D1 of mini coil spring <NUM> shown in <FIG>. As shown in <FIG> and <FIG>, each mini coil spring <NUM>, when pocketed, creates a short pocketed mini coil spring <NUM> having a height H4, less than the height H3 of tall pocketed mini coil spring <NUM> shown in <FIG> and less than the out-of-pocket height H2 of mini coil spring <NUM>.

Each of the pocketed mini coil springs of the center section <NUM> is illustrated being a short pocketed mini coil spring <NUM>, as described herein and shown in <FIG> and <FIG>. Each of the pocketed mini coil springs of each of the end sections <NUM> is illustrated being a tall pocketed mini coil spring <NUM>, as described herein and shown in <FIG> and <FIG>. As shown in <FIG>, each row <NUM> of tall pocketed mini coil springs <NUM> in the end sections <NUM> is identical. Similarly, each row <NUM> of short pocketed mini coil springs <NUM> in the center section <NUM> is identical. The center section <NUM> is shorter than the end sections <NUM> because the rows <NUM> of short pocketed mini coil springs <NUM> are shorter than the rows <NUM> of tall pocketed mini coil springs <NUM> in the end sections <NUM>. As best seen in <FIG>, each longitudinally extending column <NUM> of pocketed mini coil springs <NUM>, <NUM> is identical along the length of the posturized comfort layer <NUM>.

Any dimensions shown or described herein may be any desired dimensions and are not intended to be limited by this document. For example, dimensions H1-H5, D1 and D2 may be any desired dimensions. However, in one preferred embodiment, the out-of-pocket height H1 of mini coil spring <NUM> shown in <FIG> and the out-of-pocket height H1 of mini coil spring <NUM> shown in <FIG> may be approximately <NUM>,<NUM> (<NUM> inches). In the same preferred embodiment, the out-of-pocket height H2 of mini coil spring <NUM> shown in <FIG>, the out-of-pocket height H2 of mini coil spring <NUM> shown in <FIG> and the out-of-pocket height H5 of mini coil springs <NUM>, <NUM> shown in <FIG>, respectively, may be approximately <NUM> (<NUM> inches). In the same preferred embodiment, the diameter D1 of the uncompressed mini coil spring <NUM> shown in <FIG> and the mini coil spring <NUM> shown in <FIG> may be approximately <NUM> (<NUM> inches). In the same preferred embodiment, the diameter D2 of the uncompressed mini coil spring <NUM> shown in <FIG> and the mini coil spring <NUM> shown in <FIG> may be approximately <NUM> (<NUM> inches). In most embodiments, the height of the pocketed mini coil springs is less than <NUM> (three inches).

According to one aspect of the invention, the mini coil springs within a comfort layer, such as mini coil springs <NUM>, <NUM>, may be made of the same wire. In one embodiment, these mini coil springs <NUM>, <NUM> may be both made of seventeen-gauge wire. However, any of the mini coil springs described herein or shown may be made of any gauge wire.

<FIG> show an alternative mini coil spring <NUM> in an out-of-pocket condition which may be at least partially compressed and pocketed to create a tall pocketed mini coil spring <NUM> shown in <FIG>. Tall pocketed mini coil spring <NUM> may be incorporated into any of the comfort layers shown or described herein, including posturized comfort layer <NUM>. In place of tall pocketed mini coil springs <NUM>, tall pocketed mini coil springs <NUM>, shown in <FIG>, may be used in any of the comfort layers shown or described herein, including in each of the end sections <NUM> of posturized comfort layer <NUM>. Each tall pocketed mini coil spring <NUM>, shown in detail in <FIG>, comprises a mini coil spring <NUM>, shown in a relaxed or non-compressed condition in <FIG>, and first and second pieces <NUM>, <NUM> of fabric joined together with a rectangular weld seam <NUM>. As shown in <FIG>, each mini coil spring <NUM> has an out-of-pocket height H2 in its relaxed or non-compressed condition. As shown in <FIG>, each mini coil spring <NUM> has diameter of D1 in its relaxed or non-compressed condition. As shown in <FIG>, each mini coil spring <NUM>, when pocketed, creates a tall pocketed mini coil spring <NUM> having a pocketed height H3.

<FIG> show an alternative mini coil spring <NUM> in an out-of-pocket condition, which may be at least partially compressed and pocketed to create a short pocketed mini coil spring <NUM> shown in <FIG>. Short pocketed mini coil springs <NUM> may be incorporated into any of the comfort layers shown or described herein, including posturized comfort layer <NUM>. In place of short pocketed mini coil springs <NUM> shown in <FIG>, short pocketed mini coil springs <NUM> shown in <FIG> may be used in any of the short sections of any of the posturized comfort layers shown or descried herein, including the center section <NUM> of posturized comfort layer <NUM>. Each short pocketed mini coil spring <NUM>, shown in detail in <FIG>, comprises a mini coil spring <NUM> partially compressed between first and second pieces <NUM>, <NUM> of fabric joined together with a rectangular weld seam <NUM>. As shown in <FIG>, each mini coil spring <NUM> has an out-of-pocket height H1 in its relaxed or non-compressed condition, less than the out-of-pocket height H2 of mini coil spring <NUM> shown in <FIG>. As shown in <FIG>, each mini coil spring <NUM> has diameter D2 in its relaxed or non-compressed condition greater than the diameter D1 of the mini coil spring <NUM> shown in <FIG>. As shown in <FIG>, each mini coil spring <NUM>, when at least partially compressed and pocketed, creates a short pocketed mini coil spring <NUM> having a height H4, less than the height H3 of tall pocketed mini coil spring <NUM> shown in <FIG>.

According to one aspect of the invention, the mini coil springs within a comfort layer, such as mini coil springs <NUM>, <NUM>, may be made of the same wire. In one embodiment, mini coil springs <NUM>, <NUM> may be both made of seventeen-gauge wire. However, mini coil springs <NUM>, <NUM> may be made of any gauge wire, including different gauge wires.

In any of the comfort layers shown or described herein, including posturized comfort layer <NUM>, tall pocketed mini coil springs <NUM>, like the one shown in <FIG> and short pocketed mini coil springs <NUM> like the one shown in <FIG>, may be used together in the same comfort layer. Similarly, the tall pocketed mini coil springs <NUM>, like the one shown in <FIG> and short pocketed mini coil springs <NUM> like the one shown in <FIG>, may be used together in the same comfort layer.

<FIG> illustrate another set of tall and short pocketed mini coil springs, which may be used together in any of the comfort layers shown or described herein. <FIG> show an alternative mini coil spring <NUM> in an out-of-pocket condition, which may be partially compressed and pocketed to create a tall pocketed mini coil spring <NUM>, shown in <FIG>. Tall pocketed mini coil springs <NUM> may be incorporated into any of the comfort layers shown or described herein, including in any of the tall sections of any of the posturized comfort layers shown or described herein, including the end sections <NUM> of posturized comfort layer <NUM>. Each tall pocketed mini coil spring <NUM>, shown in detail in <FIG>, comprises a mini coil spring <NUM> and first and second pieces <NUM>, <NUM> of fabric joined together with a rectangular weld seam <NUM>. As shown in <FIG>, each mini coil spring <NUM> has an out-of-pocket height H5 in its relaxed or non-compressed condition. As shown in <FIG>, each mini coil spring <NUM> has diameter of D1 in its relaxed or non-compressed condition. As shown in <FIG>, each mini coil spring <NUM>, when pocketed, creates a tall pocketed mini coil spring <NUM> having a pocketed height H3.

<FIG> show a mini coil spring <NUM> in an out-of-pocket condition, which may be partially compressed and pocketed to create a short pocketed mini coil spring <NUM>, shown in <FIG>. Short pocketed mini coil springs <NUM> may be incorporated into any of the comfort layers shown or described herein, including in any of the short sections of any of the posturized comfort layers shown or described herein, such as the center section <NUM> of posturized comfort layer <NUM>. Each short pocketed mini coil spring <NUM>, shown in detail in <FIG>, comprises a mini coil spring <NUM> partially compressed between first and second pieces <NUM>, <NUM> of fabric joined together with a rectangular weld seam <NUM>. As shown in <FIG>, each mini coil spring <NUM> has an out-of-pocket height H5 in its relaxed or non-compressed condition, the same out-of-pocket height as the out-of-pocket height H5 of mini coil spring <NUM> shown in <FIG>. As shown in <FIG>, each mini coil spring <NUM> has diameter D2 in its relaxed or non-compressed condition, greater than the diameter D1 of the mini coil spring <NUM> shown in <FIG>. As shown in <FIG>, each mini coil spring <NUM>, when partially compressed and pocketed, creates a short pocketed mini coil spring <NUM> having a height H4, less than the height H3 of tall pocketed mini coil spring <NUM> shown in <FIG>.

According to one aspect of the invention, within a comfort layer, such as mini coil springs <NUM>, <NUM>, may be made of the same wire. In one embodiment, mini coil springs <NUM>, <NUM> may be both made of seventeen-gauge wire. However, mini coil springs <NUM>, <NUM> may be made of any gauge wire, including different gauge wires.

In posturized comfort layer <NUM>, the end sections <NUM> are firmer than the center section <NUM> because the pocketed mini coil springs of the end sections <NUM> are tall pocketed mini coil springs <NUM> and the pocketed mini coil springs of the center section <NUM> are short pocketed mini coil springs <NUM>. Any of the other combinations of short and tall pocketed mini coil springs, such as those shown in <FIG> or <FIG>, may be incorporated into posturized comfort layer <NUM>, as well as any other comfort layer shown or described herein.

<FIG> illustrates another posturized comfort layer 16a in which the orientation of the pocketed mini coil springs is different than the orientation of the pocketed mini coil springs in posturized comfort layer <NUM>. <FIG> illustrates the posturized comfort layer 16a having a center section 40a and two end sections 42a on opposite sides of the center section 40a. Each of the three sections 40a, 42a is generally rectangular shaped and approximately the same size. However, any one of the sections may be a different size than any other section. For example, the end sections 42a may be a different size than the middle or center section 40a. The drawings are not intended to be limiting.

The center section 40a is firmer than the end sections 42a because the pocketed mini coil springs of the center section 40a are tall pocketed mini coil springs <NUM> and the pocketed mini coil springs of the end sections <NUM> are short pocketed mini coil springs <NUM>. Any of the other combinations of short and tall pocketed mini coil springs, such as those shown in <FIG> or <FIG>, may be incorporated into posturized comfort layer 16a, as well as any other posturized comfort layer shown or described herein.

As best shown in <FIG>, the pocketed mini coil springs <NUM>, <NUM> are arranged in a matrix of aligned transversely extending rows 48a extending from side-to-side and longitudinally extending columns 50a extending from head-to-foot. Each of the pocketed mini coil springs of the center section 40a is illustrated being a tall mini coil spring <NUM>, as described herein and shown in <FIG> and <FIG>. Each of the pocketed mini coil springs of the end sections 42a is illustrated being a short pocketed mini coil spring <NUM>, as described below and shown in <FIG> and <FIG>. As shown in <FIG>, each row 48a of short pocketed mini coil springs <NUM> in the end sections 42a is identical. Similarly, each row 48a of tall pocketed mini coil springs <NUM> in the center section 40a is identical. The center section 40a is taller than the end sections 42a because the rows 48a of pocketed mini coil springs <NUM> in the center section 40a are taller than the rows 48a of pocketed mini coil springs <NUM> in the end sections 42a. Each longitudinally extending column 50a of pocketed mini coil springs <NUM>, <NUM> is identical along the length of the posturized comfort layer 16a.

<FIG> illustrates another posturized comfort layer 16b. <FIG> illustrates the posturized comfort layer 16b having a firm section <NUM> and a soft section <NUM> side-by-side. Each of the firm and soft sections <NUM>, <NUM> is generally rectangular and approximately the same size. However, one of the sections <NUM>, <NUM> may be a different size than the other section. The drawings are not intended to be limiting.

In posturized comfort layer 16b, the firm section <NUM> is firmer than the soft section <NUM> because the pocketed mini coil springs of the firm section <NUM> are tall pocketed mini coil springs <NUM> and the pocketed mini coil springs of the soft section <NUM> are short pocketed mini coil springs <NUM>. Any of the other combinations of short and tall pocketed mini coil springs, such as those shown in <FIG> or <FIG>, may be incorporated into posturized comfort layer 16b, as well as any other comfort layer shown or described herein.

As best shown in <FIG>, the pocketed mini coil springs <NUM>, <NUM> are arranged in a matrix of aligned transversely extending rows 48b extending from side-to-side and longitudinally extending columns 50b extending from head-to-foot. Each of the pocketed mini coil springs of the firm section <NUM> is illustrated being a tall mini coil spring <NUM>, as described herein and shown in <FIG> and <FIG>. Each of the pocketed mini coil springs of the soft section <NUM> is illustrated being a short pocketed mini coil spring <NUM>, as described below and shown in <FIG> and <FIG>. As shown in <FIG>, each column 50b of short pocketed mini coil springs <NUM> in the soft section <NUM> is identical. Similarly, each column 50b of tall pocketed mini coil springs <NUM> in the firm section <NUM> is identical, taller than the columns <NUM> of pocketed mini coil springs <NUM> in the soft section <NUM>. Each transversely extending row 48b of pocketed mini coil springs <NUM>, <NUM> is identical in the posturized comfort layer 16b.

<FIG>, <FIG> illustrate another posturized comfort layer 16c having pocketed mini coil springs 44c, 46c having circular welds, rather than rectangular welds, joining the first and second pieces of fabric <NUM>, <NUM>. <FIG> illustrates the posturized comfort layer 16c having a center section 40c and two end sections 42c on opposite sides of the center section 40c. Each of the three sections 40c, 42c is generally rectangular and approximately the same size. However, any one of the sections may be a different size than any other section. For example, the end sections 42c may be a different size than the middle or center section 40c. The drawings are not intended to be limiting.

In posturized comfort layer 16c, the end sections 42c are firmer than the center section 40c because the pocketed mini coil springs of the end sections 42c are tall pocketed mini coil springs 44c and the pocketed mini coil springs of the center section 40c are short pocketed mini coil springs 46c. Any of the other combinations of short and tall pocketed mini coil springs, such as those shown in <FIG> or <FIG>, may be incorporated into posturized comfort layer 16c, as well as any other comfort layer shown or described herein.

As best shown in <FIG>, the pocketed mini coil springs 44c, 46c are arranged in a matrix of aligned transversely extending rows 48c extending from side-to-side and aligned longitudinally extending columns 50c extending from head-to-foot. Each of the pocketed mini coil springs of the center section 40c is illustrated being a short mini coil spring 46c, as described herein and shown in <FIG>, <FIG>. Each of the pocketed mini coil springs of the end sections 42c is illustrated being a tall pocketed mini coil spring 44c, as described below and shown in <FIG>, <FIG>. As shown in <FIG>, each row 48c of tall pocketed mini coil springs 44c in each of the end sections 42c is identical. Similarly, each row 48c of short pocketed mini coil springs 46c in the center section 40c is identical. The rows 48c are shorter than the rows <NUM> of pocketed mini coil springs 44c in the end sections 42c. Each longitudinally extending column 50c of pocketed mini coil springs is identical, having both pocketed mini coil springs 44c, 46c.

<FIG> illustrates the components of one example of comfort layer 16c shown in <FIG> and <FIG>. The comfort layer 16c 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>, <NUM> therebetween. The fabric pieces <NUM>, <NUM> are joined together with circular weld seams <NUM>, each circular seam <NUM> surrounding a mini coil spring <NUM>, <NUM>. Each circular 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 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 seam <NUM>. The curved weld segments <NUM> are strategically placed around a mini coil spring <NUM>, <NUM> and create the circular seam <NUM>. The two pieces of fabric <NUM>, <NUM>, in combination with one of the circular weld seams <NUM>, define a cylindrical-shaped pocket 36c, 38c inside of which is at least one mini coil spring <NUM>, <NUM>.

During the welding process, the mini coil springs <NUM>, <NUM> may be at least partially compressed before pocket 36c, 38c is closed and thereafter.

The example of posturized comfort layer 16c shown in <FIG>, <FIG> illustrates all the circular weld seams <NUM> being the same diameter D3. The difference in the height of the pocketed mini coil springs 44c, 46c is due to the different mini coil springs being inside the pockets.

Although the drawings show a certain size of the curved weld segments <NUM> of circular weld seams <NUM>, the size of the curved weld segments <NUM> of circular weld seams <NUM> are not intended to be limited by the illustrations; they may be any desired size. Similarly, although the drawings show the circular weld seams <NUM> having a certain diameter D3, the diameter of the illustrated circular weld seams <NUM> is not intended to be limiting.

<FIG>, <FIG>, <FIG> illustrate another posturized comfort layer 16d having identical mini coil springs <NUM> throughout, but circular welds of different diameters D3 and D4 joining the first and second pieces of fabric <NUM>, <NUM>. <FIG> illustrates the posturized comfort layer 16d having a center section 40d and two end sections 42d on opposite sides of the center section 40d. Each of the three sections 40d, 42d is generally rectangular shaped and approximately the same size. However, any one of the sections may be a different size than any other section. For example, the end sections 42d may be a different size than the middle or center section 40d. The drawings are not intended to be limiting.

In posturized comfort layer 16d, the end sections 42d are firmer than the center section 40d because the pocketed mini coil springs of the end sections 42d are tall pocketed mini coil springs 44d and the pocketed mini coil springs of the center section 40d are short pocketed mini coil springs 46d.

As best shown in <FIG>, the tall pocketed mini coil springs 44d of each end section 42d are arranged in a matrix of aligned transversely extending rows 48d extending from side-to-side and aligned longitudinally extending columns 50d extending from head-to-foot. Likewise, the short pocketed mini coil springs 46d of the center section 40d are arranged in a matrix of aligned transversely extending rows <NUM> extending from side-to-side. As best shown in <FIG>, each aligned longitudinally extending column 50d extending from head-to-foot is identical and has a group or set of short pocketed mini coil springs 46d between groups or sets of tall pocketed mini coil springs 44d.

As shown in <FIG>, each row 48d of tall pocketed mini coil springs 44d in each of the end sections 42d is identical. Similarly, each row <NUM> of short pocketed mini coil springs 46d in the center section 40d is identical. The rows <NUM> have a different height (shorter) than the rows 48d of pocketed mini coil springs 44d in the end sections 42d.

Each of the pocketed mini coil springs of the center section 40d is illustrated being a short pocketed mini coil spring 46d, as described herein and shown in <FIG>. Each of the pocketed mini coil springs 44d of the end sections 42d is illustrated being a tall pocketed mini coil spring 44d, as described below and shown in <FIG>.

<FIG> illustrates the components of one of the short pocketed mini coil springs 46d. The short pocketed mini coil spring 46d comprises a first or upper piece of fabric <NUM> and a second or lower piece of fabric <NUM> with a partially compressed mini coil spring <NUM> therebetween. The fabric pieces <NUM>, <NUM> are joined together with circular weld seams <NUM>. As best shown in <FIG>, each circular seam <NUM> has a diameter D3 and surrounds a partially compressed mini coil spring <NUM>. As shown in <FIG>, each mini coil spring <NUM> has an out-of-pocket height H6 in its relaxed or non-compressed condition. As shown in <FIG>, each mini coil spring <NUM> has diameter of D5 in its relaxed or non-compressed condition.

As best seen in <FIG>, each small circular 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 small circular 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 small circular seam <NUM>. The curved weld segments <NUM> are strategically placed around a mini coil spring <NUM> and create the small circular seam <NUM>. The two pieces of fabric <NUM>, <NUM>, in combination with one of the small circular weld seams <NUM>, define a cylindrical-shaped pocket 38d inside of which is at least one partially compressed mini coil spring <NUM>.

<FIG> illustrates the components of one of the tall pocketed mini coil springs 44d. The tall pocketed mini coil spring 44d comprises a first or upper piece of fabric <NUM> and a second or lower piece of fabric <NUM> with a partially compressed mini coil spring <NUM> therebetween. The fabric pieces <NUM>, <NUM> are joined together with large circular weld seams <NUM>. As best shown in <FIG>, each large circular seam <NUM> has a diameter D4, greater than the diameter D3 of the small circular weld seams <NUM> of the short pocketed mini coil springs 46d. Each large circular seam <NUM> surrounds a partially compressed mini coil spring <NUM>. As shown in <FIG>, each mini coil spring <NUM> has an out-of-pocket height H6 in its relaxed or non-compressed condition. As shown in <FIG>, each mini coil spring <NUM> has diameter of D5 in its relaxed or non-compressed condition.

As best seen in <FIG>, each circular 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 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 seam <NUM>. The curved weld segments <NUM> are strategically placed around a mini coil spring <NUM> and create the circular seam <NUM>. The two pieces of fabric <NUM>, <NUM>, in combination with one of the circular weld seams <NUM>, define a cylindrical-shaped pocket 36d inside of which is at least one partially compressed mini coil spring <NUM>.

During the welding process, the mini coil springs <NUM> may be at least partially compressed before pocket 36d, 38d 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 resilient material, other than foam which returns to its original configuration after a load is removed from the material, may be used inside the pockets.

The example of posturized comfort layer 16d shown in <FIG>, <FIG>, <FIG> illustrates small and large circular weld seams <NUM>, <NUM>, respectively, of different diameters. The difference in the height of the pocketed mini coil springs 44d, 46d in the different sections is due to the different diameters of the circular weld seams, the mini coil springs inside the pockets being identical.

Although the drawings show a certain size of the curved weld segments <NUM>, <NUM> of circular weld seams <NUM>, <NUM>, respectively, the size of the curved weld segments <NUM>, <NUM> of circular weld seams <NUM>, <NUM>, respectively, are not intended to be limited by the illustrations; they may be any desired size. Similarly, although the drawings show the circular weld seams <NUM>, <NUM> having a certain diameters D3, D4, respectively, the diameter of the illustrated circular weld seams <NUM>, <NUM> is not intended to be limiting.

Although the posturized comfort layer 16d shows a center section 40d having a softer feel than the feel of the end sections 42d because the circular weld seams <NUM> of the short pocketed mini coil springs 46d have a smaller diameter than the circular weld seams <NUM> of the tall pocketed mini coil springs 46d, it is within the scope of the invention that any comfort layer shown or described herein may incorporate different diameter weld seams with the same mini coil springs to create pocketed mini coil springs of different heights and different firmness. For example, a posturized comfort layer like the posturized comfort layer 16a shown in <FIG> or a posturized comfort layer like the posturized comfort layer 16b shown in <FIG> may be created using circular weld seams of different diameters with the same mini coil springs.

<FIG> illustrates another posturized comfort layer 16e having four tall sections <NUM> and three short sections <NUM>, each of the sections <NUM>, <NUM> extending the full length of the posturized comfort layer 16e. Adjacent tall sections <NUM> are separated by a longitudinally extending short section <NUM> of short pocketed mini coil springs <NUM>. The pocketed mini coil springs of each of the tall sections <NUM> are tall pocketed mini coil springs <NUM>, thus resulting in firmer sections than the short sections <NUM> of the posturized comfort layer 16e. Each of the tall sections <NUM> is generally rectangular shaped, comprises multiple columns and is approximately the same size. However, any one of the sections may be a different size than any other section. For example, any of the tall sections <NUM> may be a different size than any other tall section.

Although <FIG> shows each short section <NUM> comprising only one longitudinally extending column of short pocketed mini coil springs <NUM> between adjacent tall sections <NUM>, one or more short sections <NUM> may comprise two or more longitudinally extending columns of short pocketed mini coil springs <NUM> between adjacent tall sections <NUM>. Similarly, although <FIG> shows each tall section <NUM> comprising four columns of tall pocketed mini coil springs <NUM>, each tall section may comprise any desired number of columns of tall pocketed mini coil springs. Although <FIG> shows four tall sections <NUM> and three short sections <NUM>, such a posturized comfort layer may have any number of tall sections and short sections. The sections may extend from side-to-side rather than from head-to-foot as shown in <FIG>, in which case each section would comprise multiple rows of pocketed mini coil springs of a desired height. The drawings are not intended to be limiting.

As best shown in <FIG>, each longitudinally extending column of short pocketed mini coil springs <NUM> between adjacent tall sections <NUM> is known in the art as a "spacer" column. One purpose/benefit of the spacer column(s) is the manufacturer of the comfort layer uses the same amount of fabric material along the entire width and length of the comfort layer 16e which results in a rectangular comfort layer, within normal manufacturing tolerances. For manufacturing purposes, a comfort layer which is rectangular, within normal manufacturing tolerances, is more desirable than a product which is not so evenly dimensioned. This benefit of the spacer column(s) or row(s) applies to any of the examples or embodiments shown or described herein, including the comfort layers shown in <FIG>, even if the comfort layer only has one spacer row or column of spacer pocketed springs. This benefit applies regardless of the height and direction and length of the spacer column(s) or row(s).

As best shown in <FIG>, the pocketed mini coil springs <NUM>, <NUM> are arranged in a matrix of aligned transversely extending rows 48e extending from side-to-side and longitudinally extending columns 50e extending from head-to-foot. In this example, each of the pocketed mini coil springs along each of the columns is identical. However, the pocketed mini coil springs within the columns of the tall sections are different than the pocketed mini coil springs within the columns of the short sections. Each of the pocketed mini coil springs of each of the tall sections <NUM> is illustrated being a tall pocketed mini coil spring <NUM>, as described herein and shown in <FIG>. Each of the pocketed mini coil springs of each short section <NUM> is illustrated being a short pocketed mini coil spring <NUM>, as described herein and shown in <FIG>. In place of tall pocketed mini coil springs <NUM>, tall pocketed mini coil springs, like tall pocketed mini coil springs <NUM> shown in <FIG> or tall pocketed mini coil springs <NUM> shown in <FIG>, may be used in any of the tall sections <NUM> of posturized comfort layer 16e. Similarly, in place of short pocketed mini coil springs <NUM>, short pocketed mini coil springs, like short pocketed mini coil springs <NUM> shown in <FIG> or short pocketed mini coil springs <NUM> shown in <FIG>, may be used in any of the short sections <NUM> of posturized comfort layer 16e.

Although <FIG> illustrates the pocketed mini coil springs having rectangular weld seams, circular weld seams may be incorporated into the pocketed mini coil springs in this or any example or embodiment shown or described herein.

Although <FIG> illustrates the sections extending the full length of the comfort layer longitudinally or from head-to-foot, the sections may extend the full width of the comfort layer transversely or from side-to-side. In such an example, each of the pocketed mini coil springs of each of the rows would identical. The pocketed mini coil springs within the rows of the tall sections would be different than the pocketed mini coil springs within the rows of the short sections.

<FIG> illustrates another posturized comfort layer 16f having a center section 40f and two end sections 42f on opposite sides of the center section 40f. Each of the three sections 40f, 42f is generally rectangular shaped and approximately the same size. However, any one of the sections may be a different size than any other section. For example, the end sections 42f may be a different size than the center section 40f. The drawings are not intended to be limiting.

Each of the end sections 42f is illustrated having four tall sections <NUM>, adjacent tall sections <NUM> being separated by a longitudinally extending short section <NUM> of short pocketed mini coil springs <NUM>. The pocketed mini coil springs of each of the tall sections <NUM> are tall pocketed mini coil springs <NUM>, thus resulting in firmer sections than the short sections <NUM> of each of the end sections <NUM> of posturized comfort layer 16f. Each of the tall sections <NUM> of each end section 42f is generally rectangular shaped and approximately the same size. However, any section may be a different size than any other section. For example, any one of the tall sections <NUM> may be a different size than any other tall section in one or both end sections 42f.

Although <FIG> shows each short section <NUM> of each end section 42f comprising only one longitudinally extending partial column of short pocketed mini coil springs <NUM> between adjacent tall sections <NUM>, one or more short sections <NUM> may comprise two or more longitudinally extending partial columns of short pocketed mini coil springs <NUM> between adjacent tall sections <NUM> in one or both end sections 42f. As shown in <FIG>, each longitudinally extending partial column(s) <NUM> of short pocketed mini coil springs <NUM> between adjacent tall sections <NUM> is known in the art as a spacer partial column(s) with the benefits described above. Although <FIG> shows each tall section <NUM> comprising four partial columns of tall pocketed mini coil springs <NUM>, each tall section <NUM> may comprise any desired number of partial columns of tall pocketed mini coil springs. The drawings are not intended to be limiting.

As best shown in <FIG>, the pocketed mini coil springs <NUM>, <NUM> are arranged in a matrix of aligned transversely extending rows 48f extending from side-to-side and longitudinally extending columns 50f extending from head-to-foot. Each of the pocketed mini coil springs of each of the end sections 42f is illustrated being a tall mini coil spring <NUM>, as described herein and shown in <FIG>, except for the pocketed mini coil springs <NUM> of the short sections <NUM> within each end section 42f. Each of the pocketed mini coil springs of each short section <NUM> and is illustrated being a column of short pocketed mini coil springs <NUM>, as described herein and shown in <FIG>. In place of tall pocketed mini coil springs <NUM>, tall pocketed mini coil springs, like tall pocketed mini coil springs <NUM> shown in <FIG> or tall pocketed mini coil springs <NUM> shown in <FIG>, may be used in any of the tall sections <NUM> of posturized comfort layer 16e. Similarly, in place of short pocketed mini coil springs <NUM>, short pocketed mini coil springs, like short pocketed mini coil springs <NUM> shown in <FIG> or short pocketed mini coil springs <NUM> shown in <FIG>, may be used in any of the short sections <NUM> or 40f of posturized comfort layer 16f. As best shown in <FIG>, each transversely extending row 48f of each end section 42f of pocketed mini coil springs is identical and comprises short and tall pocketed mini coil springs <NUM>, <NUM>. Each transversely extending row 48f of center section 40f of pocketed mini coil springs is identical and comprises solely short pocketed mini coil springs <NUM>.

Although <FIG> illustrates the pocketed mini coil springs having rectangular weld seams, circular weld seams may be incorporated into the pocketed mini coil springs in this or any example or embodiment shown or described herein. Although <FIG> illustrates only end sections 42f having spacer partial columns, it is within the scope of the invention that only center section 40f have spacer partial columns and end sections 42f lack spacer partial columns.

<FIG> illustrates another posturized comfort layer <NUM> having four short sections <NUM> and three tall sections <NUM>, each of the sections <NUM>, <NUM> extending the full length of the posturized comfort layer <NUM>. Adjacent short sections <NUM> are separated by a longitudinally extending tall section <NUM> of tall pocketed mini coil springs <NUM>. The pocketed mini coil springs of each of the short sections <NUM> are short pocketed mini coil springs <NUM>, thus resulting in softer sections than the tall sections of the posturized comfort layer <NUM>. Each of the short sections <NUM> is generally rectangular shaped, comprises multiple columns and is approximately the same size. However, any one of the sections may be a different size than any of the other sections. For example, any one of the short sections <NUM> may be a different size than any other short section.

Although <FIG> shows each tall section <NUM> comprising only one longitudinally extending column of tall pocketed mini coil springs <NUM> between adjacent short sections <NUM>, one or more tall sections <NUM> may comprise two or more longitudinally extending columns of tall pocketed mini coil springs <NUM> between adjacent short sections <NUM>. As shown in <FIG>, each longitudinally extending column(s) of tall pocketed mini coil springs <NUM> between adjacent short sections <NUM> is known in the art as a spacer column(s) with the benefits described herein. Similarly, although <FIG> shows each short section <NUM> comprising four columns of short pocketed mini coil springs <NUM>, each short section may comprise any desired number of columns of short pocketed mini coil springs. Although <FIG> shows four short sections <NUM> and three tall sections <NUM>, such a posturized comfort layer may have any number of tall sections and short sections. The sections may extend from side-to-side rather than from head-to-foot as shown in <FIG>, in which case each section would comprise multiple rows of pocketed mini coil springs of a desired height. The drawings are not intended to be limiting.

As best shown in <FIG>, the pocketed mini coil springs <NUM>, <NUM> are arranged in a matrix of aligned transversely extending rows <NUM> extending from side-to-side and longitudinally extending columns <NUM> extending from head-to-foot. In this example, each of the pocketed mini coil springs along each of the columns is identical. However, the pocketed mini coil springs within the columns of the tall sections are different than the pocketed mini coil springs within the columns of the short sections. Each of the pocketed mini coil springs of each of the short sections <NUM> is illustrated being a short mini coil spring <NUM>, as described herein and shown in <FIG>. Each of the pocketed mini coil springs of each tall section <NUM> is illustrated being a column of tall pocketed mini coil springs <NUM>, as described herein and shown in <FIG>. In place of tall pocketed mini coil springs <NUM>, tall pocketed mini coil springs, like tall pocketed mini coil springs <NUM> shown in <FIG> or tall pocketed mini coil springs <NUM> shown in <FIG>, may be used in any of the tall sections <NUM> of posturized comfort layer <NUM>. Similarly, in place of short pocketed mini coil springs <NUM>, short pocketed mini coil springs, like short pocketed mini coil springs <NUM> shown in <FIG> or short pocketed mini coil springs <NUM> shown in <FIG>, may be used in any of the short sections <NUM> of posturized comfort layer <NUM>.

<FIG> illustrates another posturized comfort layer <NUM> having a center section <NUM> and two end sections <NUM> on opposite sides of the center section <NUM>. Each of the three sections <NUM>, <NUM> is generally rectangular shaped and approximately the same size. However, any one of the sections may be a different size than any of the other sections. For example, the end sections <NUM> may be a different size than the center section <NUM>. The drawings are not intended to be limiting.

Each of the end sections <NUM> is illustrated having four short sections <NUM>, adjacent short sections <NUM> being separated by a longitudinally extending tall section <NUM> of tall pocketed mini coil springs <NUM>. The pocketed mini coil springs of each of the tall sections <NUM> are tall pocketed mini coil springs <NUM> thus resulting in firmer sections than the short sections <NUM> of the end sections <NUM> of posturized comfort layer <NUM>. Each of the short sections <NUM> of each end section <NUM> is generally rectangular shaped and approximately the same size. However, any one of the short sections <NUM> may be a different size than any other short section in one or both end sections <NUM>.

Although <FIG> shows each tall section <NUM> of each end section <NUM> comprising only one longitudinally extending partial column of tall pocketed mini coil springs <NUM> between adjacent short sections <NUM>, one or more tall sections <NUM> may comprise two or more longitudinally extending partial columns of tall pocketed mini coil springs <NUM> between adjacent short sections <NUM> in one or both end sections <NUM>. As shown in <FIG>, each longitudinally extending partial column(s) of tall pocketed mini coil springs <NUM> between adjacent short sections <NUM> is known in the art as a spacer partial column(s) with the benefits described above. Similarly, although <FIG> shows each short section <NUM> comprising four partial columns of short pocketed mini coil springs <NUM>, each short section may comprise any desired number of partial columns of short pocketed mini coil springs. The drawings are not intended to be limiting.

As best shown in <FIG>, the pocketed mini coil springs <NUM>, <NUM> are arranged in a matrix of aligned transversely extending rows <NUM> extending from side-to-side and longitudinally extending columns <NUM> extending from head-to-foot. Each of the pocketed mini coil springs of the center section <NUM> is illustrated being a tall mini coil spring <NUM>, as described herein and shown in <FIG>. Each of the pocketed mini coil springs of each of the end sections <NUM> is illustrated being short mini coil springs <NUM>, except for the tall pocketed mini coil springs <NUM> of the tall sections <NUM> within each end section <NUM>. In place of tall pocketed mini coil springs <NUM>, tall pocketed mini coil springs <NUM> shown in <FIG> or tall pocketed mini coil springs <NUM> shown in <FIG> may be used in any of the tall sections <NUM>, <NUM> of posturized comfort layer <NUM>. Similarly, in place of short pocketed mini coil springs <NUM>, short pocketed mini coil springs <NUM> shown in <FIG> or short pocketed mini coil springs <NUM> shown in <FIG> may be used in any of the short sections <NUM> of posturized comfort layer <NUM>. As best shown in <FIG>, each transversely extending row <NUM> of each end section 42f of pocketed mini coil springs is identical and comprises short and tall pocketed mini coil springs <NUM>, <NUM>. Each transversely extending row <NUM> of center section <NUM> of pocketed mini coil springs is identical and comprises solely tall pocketed mini coil springs <NUM>.

Although <FIG> illustrates the pocketed mini coil springs having rectangular weld seams, circular weld seams may be incorporated into the pocketed mini coil springs in this or any example or embodiment shown or described herein. Although <FIG> illustrates only end sections <NUM> having spacer partial columns, it is within the scope of the invention that only center section <NUM> have spacer partial columns and end sections 42f lack spacer partial columns.

<FIG>, <FIG> illustrate a comfort layer 16i according to the invention. Comfort layer 16i comprises pocketed mini coil springs <NUM>, <NUM> arranged in a matrix of aligned transversely extending rows 48i extending from side-to-side and longitudinally extending columns 50i extending from head-to-foot. Tall and short pocketed mini coil springs <NUM>, <NUM>, respectively, alternate along each row 48i and along each column 50i. In other words, every other pocketed mini coil spring is a tall pocketed mini coil spring <NUM> along each row 48i and along each column 50i. Similarly, every other pocketed mini coil spring is a short pocketed mini coil spring <NUM> along each row 48i and along each column 50i. One result of such an arrangement is a comfort layer having a uniform firmness or feel across the full width and full length of the comfort layer. In the industry, this configuration is known as a "checkerboard" pattern.

Each of the tall pocketed mini coil springs <NUM> is as described herein and shown in <FIG>. Each of the short pocketed mini coil springs <NUM> is as described herein and shown in <FIG>. Regardless of which tall and short pocketed mini coil springs are used, the diameter of the mini coil springs of the tall pocketed mini coil springs is less than the diameter of the mini coil springs of the short pocketed mini coil springs. Similarly, regardless of which tall and short pocketed mini coil springs are used, the pocketed height of the tall pocketed mini coil springs is greater than the pocketed height of the short pocketed mini coil springs.

<FIG> illustrates the components of comfort layer 16i shown in <FIG> and <FIG>. The comfort layer 16i 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>, <NUM> therebetween. The fabric pieces <NUM>, <NUM> are joined together with rectangular weld seams <NUM>, each rectangular weld seam <NUM> surrounding one of the mini coil springs <NUM> or <NUM>. Each rectangular weld seam <NUM> comprises multiple straight or linear weld segments <NUM> with gaps <NUM> therebetween. The first and second pieces of fabric <NUM>, <NUM> are joined together along each straight or linear weld segment <NUM> of each rectangular 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 rectangular seam <NUM>. The straight or linear weld segments <NUM> are strategically placed around a mini coil spring <NUM>, <NUM> and create the rectangular seam <NUM>. The two pieces of fabric <NUM>, <NUM>, in combination with one of the rectangular weld seams <NUM>, define a pocket <NUM>, <NUM> inside of which is at least one mini coil spring <NUM>, <NUM>, respectively.

<FIG>, <FIG> illustrate another comfort layer 16j according to the invention having pocketed mini coil springs 44c, 46c with circular welds, rather than rectangular welds, joining the first and second pieces of fabric <NUM>, <NUM>. Comfort layer 16j comprises pocketed mini coil springs 44c, 46c arranged in a matrix of aligned transversely extending rows 48j extending from side-to-side and longitudinally extending columns 50j extending from head-to-foot. Tall and short pocketed mini coil springs 44c, 46c, respectively, alternate along each row 48i and along each column 50i. In other words, every other pocketed mini coil spring is a tall pocketed mini coil spring <NUM> along each row 48j and along each column 50j. Similarly, every other pocketed mini coil spring is a short pocketed mini coil spring <NUM> along each row 48j and along each column 50j. One result of such an arrangement is a comfort layer having a uniform firmness or feel across the full width and full length of the comfort layer. In the industry, this configuration is known as a "checkerboard" pattern.

Each of the tall pocketed mini coil springs 44c is as described herein and shown in <FIG>. Each of the short pocketed mini coil springs 46c is as described herein and shown in <FIG>.

Regardless of which tall and short pocketed mini coil springs are used, the diameter of the mini coil springs of the tall pocketed mini coil springs is less than the diameter of the mini coil springs of the short pocketed mini coil springs. Similarly, regardless of which tall and short pocketed mini coil springs are used, the pocketed height of the tall pocketed mini coil springs is greater than the pocketed height of the short pocketed mini coil springs.

<FIG> illustrates the components of comfort layer 16j shown in <FIG>, <FIG>. The comfort layer 16j 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>, <NUM> therebetween. The fabric pieces <NUM>, <NUM> are joined together with large circular weld seams <NUM>, each circular weld seam <NUM> surrounding a mini coil spring <NUM>, <NUM>. Each circular 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 seam <NUM>. The curved weld segments <NUM> are strategically placed around a mini coil spring <NUM>, <NUM> and create the circular 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>, <NUM> inside of which is at least one mini coil spring <NUM>, <NUM>, respectively.

The embodiment of comfort layer 16j shown in <FIG>, <FIG> illustrates all the circular weld seams <NUM> being the same diameter. The difference in the height of the pocketed mini coil springs <NUM>, <NUM> is due to the different mini coil springs <NUM>, <NUM> being inside the pockets <NUM>, <NUM>, respectively. As stated herein, within the scope of the invention, the mini coil springs within a comfort layer having a checkerboard arrangement may be identical, but the diameter of the circular weld seams different to create pockets of different heights.

Although the drawings show a certain size of the curved weld segments <NUM> of circular weld seams <NUM>, the size of the curved weld segments <NUM> of circular weld seams <NUM> are not intended to be limited by the illustrations; they may be any desired size. Similarly, although the drawings show the circular weld seams <NUM> having a certain diameter, the diameter of the illustrated circular weld seams <NUM> is not intended to be limiting.

<FIG>, <FIG> illustrate another comfort layer <NUM> having the same pocketed mini coil springs 44c, 46c as the comfort layer 16j shown in <FIG>, <FIG> with circular welds joining the first and second pieces of fabric <NUM>, <NUM>. The components of comfort layer <NUM> are the same as the components of comfort layer 16j. However, the orientation of the pocketed mini coil springs 44c, 46c in comfort layer <NUM> is different than the orientation of the pocketed mini coil springs 44c, 46c in comfort layer 16j.

Comfort layer <NUM> comprises pocketed mini coil springs 44c, 46c arranged in a matrix of aligned transversely extending rows <NUM> extending from side-to-side and longitudinally extending columns <NUM> extending from head-to-foot. Tall and short pocketed mini coil springs 44c, 46c, respectively, alternate along each row <NUM> and along each column <NUM>. In other words, every other pocketed mini coil spring is a tall pocketed mini coil spring <NUM> along each row <NUM> and along each column <NUM>. Similarly, every other pocketed mini coil spring is a short pocketed mini coil spring 46c along each row <NUM> and along each column <NUM>. The result of such an arrangement is a comfort layer having a uniform firmness or feel across the full width and full length of the comfort layer. As best illustrated in <FIG>, the pocketed mini coil springs of one column are offset from, rather than aligned with, the pocketed mini coil springs of the adjacent columns, which is a different configuration than the checkerboard configuration shown in comfort layer 16j illustrated in <FIG>, <FIG>. This configuration of pocketed mini coil springs in known in the industry as a nested configuration.

Each of the tall pocketed mini coil springs 44c is as described herein and shown in <FIG>. Each of the short pocketed mini coil springs 46c is as described herein and shown in <FIG>. In place of tall pocketed mini coil springs 44c, tall pocketed mini coil springs, like tall pocketed mini coil springs <NUM> shown in <FIG> or tall pocketed mini coil springs <NUM> shown in <FIG>, may be used in comfort layer <NUM>. Similarly, in place of short pocketed mini coil springs 46c, short pocketed mini coil springs like short pocketed mini coil springs <NUM> shown in <FIG> or short pocketed mini coil springs <NUM> shown in <FIG> may be used in comfort layer <NUM>. Regardless of which tall and short pocketed mini coil springs are used, the diameter of the mini coil springs of the tall pocketed mini coil springs is less than the diameter of the mini coil springs of the short pocketed mini coil springs. Similarly, regardless of which tall and short pocketed mini coil springs are used, the pocketed height of the tall pocketed mini coil springs is greater than the pocketed height of the short pocketed mini coil springs.

The embodiment of comfort layer 16j shown in <FIG>, <FIG> illustrates all the circular weld seams <NUM> being the same diameter. The difference in the height of the pocketed mini coil springs <NUM>, <NUM> is due to the different mini coil springs <NUM>, <NUM> being inside the pockets <NUM>, <NUM>, respectively. It is within the scope of the invention that the mini coil springs within comfort layer 16j shown in <FIG>, <FIG> be identical, but the diameter of the circular weld seams of pocketed mini coil springs 44c, 46c within comfort layer 16j be different to create pocketed mini coil springs of different heights.

<FIG>, <FIG> illustrate another comfort layer 16I. Comfort layer 16I comprises pocketed mini coil springs <NUM>, <NUM> arranged in a matrix of aligned transversely extending rows 48I extending from side-to-side and longitudinally extending columns 50I extending from head-to-foot. Tall and short pocketed mini coil springs <NUM>, <NUM>, respectively, extend in a repeating pattern along each row 48I and along each column 50I. In the illustrated example, every third pocketed mini coil spring is a short pocketed mini coil spring <NUM> along each row 48I and along each column <NUM>. Similarly, between a pair of adjacent short pocketed mini coil springs <NUM> are two tall pocketed mini coil springs <NUM> along each row 48I and along each column 50I. One result of such an arrangement is a comfort layer having a uniform firmness or feel across the full width and full length of the comfort layer. Although one repeating pattern is illustrated, other repeating patterns are within the scope of the invention regardless of whether along one or more columns or one or more rows.

Each of the tall pocketed mini coil springs <NUM> is as described herein and shown in <FIG>. Each of the short pocketed mini coil springs <NUM> is as described herein and shown in <FIG>. In place of tall pocketed mini coil springs <NUM>, tall pocketed mini coil springs <NUM> shown in <FIG> or tall pocketed mini coil springs <NUM> shown in <FIG> may be used in comfort layer 16I. Similarly, in place of short pocketed mini coil springs <NUM>, short pocketed mini coil springs <NUM> shown in <FIG> or short pocketed mini coil springs <NUM> shown in <FIG> may be used in comfort layer 16I. Regardless of which tall and short pocketed mini coil springs are used, the diameter of the mini coil springs of the tall pocketed mini coil springs is less than the diameter of the mini coil springs of the short pocketed mini coil springs. Similarly, regardless of which tall and short pocketed mini coil springs are used, the pocketed height of the tall pocketed mini coil springs is greater than the pocketed height of the short pocketed mini coil springs.

<FIG> illustrates the components of comfort layer 16I shown in <FIG> and <FIG>. The comfort layer 16I 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>, <NUM> therebetween. The fabric pieces <NUM>, <NUM> are joined together with rectangular weld seams <NUM>, each rectangular weld seam <NUM> surrounding one of the mini coil springs <NUM> or <NUM>. Each rectangular weld seam <NUM> comprises multiple straight or linear weld segments <NUM> with gaps <NUM> therebetween. The first and second pieces of fabric <NUM>, <NUM> are joined together along each straight or linear weld segment <NUM> of each rectangular 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 rectangular seam <NUM>. The straight or linear weld segments <NUM> are strategically placed around a mini coil spring <NUM>, <NUM> and create the rectangular seam <NUM>. The two pieces of fabric <NUM>, <NUM>, in combination with one of the rectangular weld seams <NUM>, define a pocket <NUM>, <NUM> inside of which is at least one mini coil spring <NUM>, <NUM>, respectively. Although not shown, comfort layer 16I may be made with circular welds, either continuous or segmented or any combination thereof. This is true for any of the comfort layers shown or described herein.

<FIG> and <FIG> illustrate another comfort layer <NUM>. Comfort layer <NUM> comprises pocketed mini coil springs <NUM>, <NUM> arranged in a matrix of aligned transversely extending rows <NUM> extending from side-to-side and longitudinally extending columns <NUM> extending from head-to-foot. Each of the transversely extending rows <NUM> extending from side-to-side has pocketed mini coil springs of the same height along the row <NUM>. In the illustrated example, each third row <NUM> of pocketed mini coil springs comprises short pocketed mini coil springs <NUM>.

As shown in <FIG>, along each column <NUM>, tall, medium and short pocketed mini coil springs <NUM>, <NUM>, <NUM>, respectively, extend in a repeating pattern. In the illustrated example, every third pocketed mini coil spring is a short pocketed mini coil spring <NUM>, every third pocketed mini coil spring is a medium pocketed mini coil spring <NUM> and every third pocketed mini coil spring is a tall pocketed mini coil spring <NUM> along each column 50I. The medium pocketed mini coil spring <NUM> has a pocketed height greater than the pocketed height of the short pocketed mini coil spring <NUM> and less than the pocketed height of the tall pocketed mini coil spring <NUM>. One result of such an arrangement is a comfort layer having a uniform firmness or feel across the full width and full length of the comfort layer. Although one repeating pattern is illustrated, other repeating patterns are within the scope of the invention regardless of whether along one or more columns or one or more rows.

Each of the tall pocketed mini coil springs <NUM> is as described herein and shown in <FIG>. Each of the short pocketed mini coil springs <NUM> is as described herein and shown in <FIG>. In place of tall pocketed mini coil springs <NUM>, tall pocketed mini coil springs <NUM> shown in <FIG> or tall pocketed mini coil springs <NUM> shown in <FIG> may be used in comfort layer <NUM>. Similarly, in place of short pocketed mini coil springs <NUM>, short pocketed mini coil springs <NUM> shown in <FIG> or short pocketed mini coil springs <NUM> shown in <FIG> may be used in comfort layer <NUM>. Regardless of which tall and short pocketed mini coil springs are used, the diameter of the mini coil springs of the tall pocketed mini coil springs is less than the diameter of the mini coil springs of the short pocketed mini coil springs. Similarly, regardless of which tall and short pocketed mini coil springs are used, the pocketed height of the tall pocketed mini coil springs is greater than the pocketed height of the short pocketed mini coil springs.

<FIG> illustrates the components of comfort layer <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>, <NUM> therebetween. The fabric pieces <NUM>, <NUM> are joined together with rectangular weld seams <NUM>, each rectangular weld seam <NUM> surrounding one of the mini coil springs <NUM> or <NUM>. Each rectangular weld seam <NUM> comprises multiple straight or linear weld segments <NUM> with gaps <NUM> therebetween. The first and second pieces of fabric <NUM>, <NUM> are joined together along each straight or linear weld segment <NUM> of each rectangular 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 rectangular seam <NUM>. The straight or linear weld segments <NUM> are strategically placed around a mini coil spring <NUM>, <NUM> and create the rectangular seam <NUM>. The two pieces of fabric <NUM>, <NUM>, in combination with one of the rectangular weld seams <NUM>, define a pocket <NUM>, <NUM> inside of which is at least one mini coil spring <NUM>, <NUM>, respectively. See <FIG> and <FIG>. Although not shown, comfort layer <NUM> may be made with circular welds, either continuous or segmented or any combination thereof. This is true for any of the comfort layers shown or described herein.

Claim 1:
A bedding or seating product (<NUM>, 10a) comprising
a core (<NUM>, 12a), and
a comfort layer (16i, 16j) configured to overlay the core (<NUM>, 12a) said comfort layer (16i, 16j) comprising:
a matrix of mini coil springs (<NUM>, <NUM>);
a first piece of fabric (<NUM>) on one side of the matrix of mini coil springs (<NUM>, <NUM>);
a second piece of fabric (<NUM>) on another side of the matrix of mini coil springs (<NUM>, <NUM>), the first and second pieces of fabric being joined with weld seams at least partially around each of the mini coil springs (<NUM>, <NUM>) joining the first and second pieces of fabric and creating individual pockets which contain the mini coil springs (<NUM>, <NUM>);
characterized by
said comfort layer (16i, 16j) having rows and columns of pocketed mini coil springs (<NUM>, 44c, 44d, <NUM>, 46c, 46d) wherein said pocketed mini coil springs (<NUM>, 44c, 44d, <NUM>, 46c, 46d) are arranged in a checkerboard pattern, every other pocketed mini coil spring having a first height (H3) and every other pocketed mini coil spring having a second height (H4), the second height being smaller than the first height,
the mini coil springs (<NUM>) of the pocketed mini coil springs (<NUM>, 44c, 44d) having the first height (H3) have a smaller out-of-pocket height (H1) than the mini coil springs (<NUM>) of the pocketed mini coil springs (<NUM>, 46c, 46d) having the second height (H4),
the mini coil springs (<NUM>) of the pocketed mini coil springs (<NUM>, 44c, 44d) having the first height (H3) have a smaller diameter (D1) than the mini coil springs (<NUM>) of the pocketed mini coil springs (<NUM>, 46c, 46d) having the second height (H4).