Patent Description:
Sleep is critical for people to feel and perform their best, in every aspect of their lives. Sleep is an essential path to better health and reaching personal goals. Indeed, sleep affects everything from the ability to commit new information to memory to weight gain. It is therefore essential for people to use bedding that suit both their personal sleep preference and body type in order to achieve comfortable, restful sleep.

Mattresses may include a plurality of springs that form a spring assembly. One side of a mattress can wear out over time, while the opposite side is maintained in a relatively new state. Moreover, when one or more sleepers consistently sleep on one side of a mattress, weight from the sleeper or sleepers' body(ies) can cause permanent depressions in the mattress. As such, many mattress manufactures of mattresses with spring assemblies suggest flipping a mattress at least once a year to increase the life of the mattress and/or prevent sagging or the creation of depressions in the mattress.

Some conventional spring assemblies position at least some of the springs in pockets to create strings of springs that are arranged to form the spring assembly. However, these spring assemblies do not allow for independent movement between adjacent springs or allow for independent movement between adjacent springs on both sides of the spring assembly. As such, there is no independent movement between adjacent springs when the mattress is flipped over. This disclosure describes an improvement over these prior art technologies.

<CIT> discloses a known spring assembly with two types of pocket springs achieved by springs of different diameters.

According to the invention, a spring assembly is provided that includes a first zone comprising a plurality of first strings of springs and a second zone comprising a plurality of second strings of springs. Each of the first strings is joined to another one of the first strings or one of the second strings. The first strings have a first configuration and the second strings have a second configuration that is different than the first configuration. Each of the first strings comprises first and second plies of fabric that define a plurality of first pockets formed along a length of the first string by first vertical seams that join the plies. The first vertical seams each include an upper slit that extends through a top surface of the first string and a lower slit that extends through a bottom surface of the first string. Each of the first pockets comprises at least one spring positioned therein. According to the invention, each of the second strings comprises third and fourth plies of fabric that define a plurality of second pockets formed along a length of the second string by second vertical seams that join the third and fourth plies, the second vertical seams being free of any slits that extend through a top surface of the second string and free of any slits that extend through a bottom surface of the second string, each of the second pockets comprising at least one spring positioned therein. In some embodiments, each of the first and second pockets comprises only one spring positioned therein. In some embodiments, each of the first pockets comprises only one spring positioned therein and each of the second pockets comprises more than one spring positioned therein. In some embodiments, each of the first pockets comprises more than one spring positioned therein and each of the second pockets comprises more than one spring positioned therein. In some embodiments, the first zone comprises a plurality of first zones and the second zone comprises a plurality of second zones, the first zones being spaced apart by one of the second zones. In some embodiments, the first zone comprises a plurality of first zones and the second zone comprises first, second and third regions and the second zone comprises fourth and fifth regions, the first and second regions being spaced apart from one another by the fourth region and the second and third regions being spaced apart from one another by the fifth region. In some embodiments, the first region is configured to support a sleeper's head while the second region supports the sleeper's midsection and the third region supports the sleeper's legs. In some embodiments, the first region is divided into separate sections, the second zone extending between the separate sections.

In one embodiment, in accordance with the principles of the present disclosure, a mattress is provided that includes a spring assembly as defined above. The first zone comprises a plurality of first zones and the second zone comprises a plurality of second zones, the first zones being spaced apart by one of the second zones. The mattress comprises a cushioning material positioned above the top surfaces and a base material positioned below the bottom surfaces.

Like reference numerals indicate similar parts throughout the figures.

The present disclosure may be understood more readily by reference to the following detailed description of the disclosure taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this disclosure is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention.

Also, as used in the specification and including the appended claims, the singular forms "a," "an," and "the" include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from "about" or "approximately" one particular value and/or to "about" or "approximately" another particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment. It is also understood that all spatial references, such as, for example, horizontal, vertical, top, upper, lower, bottom, left and right, are for illustrative purposes only and can be varied within the scope of the disclosure. For example, the references "upper" and "lower" are relative and used only in the context to the other, and are not necessarily "superior" and "inferior.

The exemplary embodiments of the disclosed spring assemblies are discussed in terms of strings of pocketed springs that are used to form one or more spring assemblies that make up all or a portion of a mattress. Reference will now be made in detail to the exemplary embodiments of the present invention, which are illustrated in the accompanying figures, as specified above. Turning to <FIG>, there are illustrated components of a spring assembly <NUM> and a mattress 30a that includes spring assembly <NUM>.

Spring assembly <NUM> includes one or a plurality of first strings, such as, for example, strings <NUM>. Strings <NUM> each include a first ply of fabric <NUM> and a second ply of fabric <NUM>, as best shown in <FIG>. In some embodiments, plies <NUM>, <NUM> are formed by folding a single piece of material, such as for example, material <NUM>. That is, first ply <NUM> may be a first end of material <NUM> and second ply <NUM> may be a second end of material <NUM>, wherein material <NUM> is folded about a midsection <NUM> of material <NUM>, as best shown in <FIG>. In some embodiments, material <NUM> is arranged such that midsection <NUM> forms a top surface <NUM> of string <NUM> and plies <NUM>, <NUM> are joined at an opposite bottom surface <NUM> of string <NUM>, as shown in <FIG>. It is envisioned that this configuration may be reversed such that midsection <NUM> forms bottom surface <NUM> of string <NUM> and plies <NUM>, <NUM> are joined at top surface <NUM> of string <NUM>. In some embodiment, material <NUM> can comprise acrylic, acetate, cotton, linen, silk, polyester, wool, nylon, rayon, spandex, lycra, hemp, manmade materials, natural materials (e.g., hemp) and blends and/or combinations thereof.

Strings <NUM> each extend along a longitudinal axis L between opposite ends <NUM>, <NUM> of strings <NUM>. Plies <NUM>, <NUM> are joined together at spaced apart portions of material <NUM> by vertical seams <NUM> to define a plurality of pockets <NUM> along longitudinal axis L. Vertical seams <NUM> define an end surface of end <NUM> and an end surface of end <NUM>, as shown in <FIG>. In some embodiment, strings <NUM> each include the same number of pockets <NUM>. In some embodiment, strings <NUM> each include different numbers of pockets <NUM>. It is envisioned that strings <NUM> may each include any number of pockets <NUM>. In some embodiments, strings <NUM> each include between about <NUM> and about <NUM> pockets <NUM>. In some embodiments, strings <NUM> each include about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, or about <NUM> pockets <NUM>.

In some embodiments, vertical seams <NUM> are evenly spaced apart from one another along longitudinal axis L such that each of pockets <NUM> has the same width, the width of each of pockets <NUM> being defined by the distance from one of vertical seams <NUM> to an adjacent one of vertical seams <NUM>. In some embodiments, vertical seams <NUM> are not evenly spaced apart from one another along longitudinal axis L such that at least one of pockets <NUM> have a width that is different than a width another one of other pockets <NUM>, the widths of pockets <NUM> being defined by the distance from one of vertical seams <NUM> to an adjacent one of vertical seams <NUM>. Vertical seams <NUM> each have a length defined by the distance from top surface <NUM> to bottom surface <NUM>. In some embodiments, vertical seams <NUM> each have the same length. In some embodiments, the length of at least one of vertical seams <NUM> is different than the length of at least another one of vertical seams <NUM>.

In some embodiments, vertical seams <NUM> are formed by sewing, adhering, or welding first ply <NUM> to second ply <NUM> along at least a portion of the length of each vertical seam <NUM>. In some embodiments, vertical seams <NUM> are formed by a horizontal weld <NUM>. In some embodiments, horizontal weld <NUM> comprises a series of horizontal welds <NUM> that each extend parallel to or substantially parallel to longitudinal axis L and are spaced apart from one another along the length of vertical seam <NUM>, as shown in <FIG>. In some embodiments, horizontal weld(s) <NUM> define a section or section of each vertical seam <NUM> in which first ply <NUM> is joined with second ply <NUM>. In some embodiments, horizontal weld(s) <NUM> are formed by thermal welding and/or ultrasonic welding. In some embodiments, horizontal weld(s) <NUM> are spaced apart from one another by portions <NUM> of vertical seam <NUM>. In some embodiments, first ply <NUM> is spaced apart from second ply <NUM> at portions <NUM>. That is, first ply <NUM> is not joined with second ply <NUM> at portions <NUM>.

In some embodiments, horizontal welds <NUM> each have a width w along longitudinal axis L that is greater than a height h of horizontal welds <NUM> along a length of vertical seam <NUM>, as shown in <FIG>. In some embodiments, width w is about <NUM> to about <NUM> times greater than height h. In some embodiments, width w is about <NUM> times greater than height h, about <NUM> times greater than height h, about <NUM> times greater than height h, about <NUM> times greater than height h, about <NUM> times greater than height h, about <NUM> times greater than height h, or about <NUM> times greater than height h. Portions <NUM> each have a width along longitudinal axis L that is equal to width w. In some embodiments, portions <NUM> each have a height h1 that is equal to height h. In some embodiments, height h1 is greater than height h. In some embodiments, height h1 is less than height h.

In some embodiments, horizontal weld(s) <NUM> may be disposed at alternate orientations, relative to longitudinal axis L, such as, for example, transverse and/or other angular orientations such as acute or obtuse, co-axial and/or may be offset or staggered. In some embodiments, horizontal weld(s) <NUM> may have various shapes or configurations, such as, for example, oval, oblong, triangular, rectangular, square, polygonal, irregular, uniform, non-uniform, variable, tubular and/or tapered.

In some embodiments, vertical seams <NUM> are formed by a vertical weld <NUM>. In some embodiments, vertical weld <NUM> comprises a series of vertical welds <NUM> that each extend perpendicular or substantially perpendicular to longitudinal axis L and are spaced apart from one another along the length of vertical seam <NUM>, as shown in <FIG>. In some embodiments, vertical weld(s) <NUM> define a section or section of each vertical seam <NUM> in which first ply <NUM> is joined with second ply <NUM>. In some embodiments, vertical weld(s) <NUM> are formed by thermal welding and/or ultrasonic welding. In some embodiments, vertical weld(s) <NUM> are spaced apart from one another by portions <NUM> of vertical seam <NUM>. In some embodiments, first ply <NUM> is spaced apart from second ply <NUM> at portions <NUM>. That is, first ply <NUM> is not joined with second ply <NUM> at portions <NUM>.

In some embodiments, vertical welds <NUM> each have a width w1 along longitudinal axis L that is less than a height h2 of vertical welds <NUM> along a length of vertical seam <NUM>, as shown in <FIG>. In some embodiments, height h2 is about <NUM> to about <NUM> times greater than width w1. In some embodiments, height h2 is about <NUM> times greater than width w1, about <NUM> times greater than width w1, about <NUM> times greater than width w1, about <NUM> times greater than width w1, about <NUM> times greater than width w1, about <NUM> times greater than width w1, or about <NUM> times greater than width w1. Portions <NUM> each have a width along longitudinal axis L that is equal to width w1. In some embodiments, portions <NUM> each have a height h3 that is equal to height h2. In some embodiments, height h3 is greater than height h2. In some embodiments, height h3 is less than height h2.

In some embodiments, vertical seams <NUM> are each defined by a column C1 of vertical welds <NUM> and a column C2 of vertical welds <NUM> that is spaced apart from column C1 by a section <NUM>, as shown in <FIG>. In some embodiments, first ply <NUM> is spaced apart from second ply <NUM> at section <NUM>. That is, first ply <NUM> is not joined with second ply <NUM> at section <NUM>. In some embodiments, column C1 and/or column C2 each include a single column of vertical welds <NUM>.

In some embodiments, column C1 includes an outer column C3 of vertical welds <NUM> and an inner column C4 of vertical welds <NUM> and column C2 includes an outer column C5 of vertical welds <NUM> and an inner column C6 of vertical welds <NUM>, as shown in <FIG>. Columns C4, C6 are spaced apart from one another by section <NUM>. In some embodiments, vertical welds <NUM> in column C3 engage vertical welds <NUM> in column C4. In some embodiments, vertical welds <NUM> in column C3 are spaced apart from vertical welds <NUM> in column C4 along longitudinal axis L. In some embodiments, vertical welds <NUM> in column C5 engage vertical welds <NUM> in column C6. In some embodiments, vertical welds <NUM> in column C5 are spaced apart from vertical welds <NUM> in column C6 along longitudinal axis L.

In some embodiments, vertical welds <NUM> in column C3 that engage vertical welds <NUM> in column C4 are staggered such that a top surface 54a of a vertical weld <NUM> in column C3 is offset along column C1 from a top surface 54a of the vertical weld <NUM> in column C4 that the vertical weld <NUM> in column C3 engages; and a bottom surface 54b of the vertical weld <NUM> in column C3 is offset along column C1 from a bottom surface 54b of the vertical weld <NUM> in column C4 that the vertical weld <NUM> in column C3 engages, as shown in <FIG>. Likewise, vertical welds <NUM> in column C5 that engage vertical welds <NUM> in column C6 are staggered such that a top surface 54a of a vertical weld <NUM> in column C5 is offset along column C2 from a top surface 54a of the vertical weld <NUM> in column C6 that the vertical weld <NUM> in column C5 engages; and a bottom surface 54b of the vertical weld <NUM> in column C5 is offset along column C2 from a bottom surface 54b of the vertical weld <NUM> in column C6 that the vertical weld <NUM> in column C5 engages, as also shown in <FIG>.

In some embodiments, a top surface 54a of one of vertical welds <NUM> in column C3 is coaxial with a top surface 54a of one of vertical welds <NUM> in column C6, as shown in <FIG>. Likewise, a bottom surface 54b of one of vertical welds <NUM> in column C3 is coaxial with a bottom surface 54b of one of vertical welds <NUM> in column C6. In some embodiments, a top surface 54a of one of vertical welds <NUM> in column C4 is coaxial with a top surface 54a of one of vertical welds <NUM> in column C5, as shown in <FIG>. Likewise, a bottom surface 54b of one of vertical welds <NUM> in column C4 is coaxial with a bottom surface 54b of one of vertical welds <NUM> in column C5.

In some embodiments, heights h2 of vertical welds <NUM> in column C3 are the same as heights h2 of vertical welds <NUM> in column C4. In some embodiments, heights h2 of vertical welds <NUM> in column C3 are less than heights h2 of vertical welds <NUM> in column C4. In some embodiments, heights h2 of vertical welds <NUM> in column C3 are greater than heights h2 of vertical welds <NUM> in column C4. In some embodiments, heights h2 of vertical welds <NUM> in column C5 are the same as heights h2 of vertical welds <NUM> in column C6. In some embodiments, heights h2 of vertical welds <NUM> in column C5 are less than heights h2 of vertical welds <NUM> in column C6. In some embodiments, heights h2 of vertical welds <NUM> in column C5 are greater than heights h2 of vertical welds <NUM> in column C6.

According to the invention, each vertical seam <NUM> includes an upper slit, such as, for example, a slit <NUM> that extends through top surface <NUM> of string <NUM> and a bottom slit, such as, for example, a slit <NUM> that extends through bottom surface <NUM> of string <NUM>, as shown in <FIG>. In some embodiments, slits <NUM>, <NUM> are each positioned between columns C1, C2 of one vertical seam <NUM>. In some embodiments, slits <NUM>, <NUM> are each equidistant between columns C1, C2 of one vertical seam <NUM>. In some embodiments, at least one of slits <NUM>, <NUM> is closer to one of columns C1, C2 of one vertical seam <NUM> than another one of columns C1, C2 of the same vertical seam <NUM>.

According to the invention, slits <NUM>, <NUM> have the same length, as shown in <FIG>. This allows mattress 30a to be flipped such that spring assembly <NUM> will provide the same amount of movement between pockets <NUM> whether top surface <NUM> is positioned adjacent a sleep surface (e.g., a surface of mattress 30a that is furthest from the floor) or bottom surface <NUM> is positioned adjacent the sleep surface, as discussed herein.

Not according to the invention, slits <NUM>, <NUM> can have different lengths, as shown in <FIG>. That is, slits <NUM> may be longer than slits <NUM> or slits <NUM> may be longer than slits <NUM>. This allows mattress 30a to be flipped to allow different amounts of movement between pockets <NUM>. That is, when top surface <NUM> is positioned adjacent the sleep surface, slits <NUM> will allow a first amount of movement between pockets <NUM>. When mattress 30a is flipped such that bottom surface <NUM> is positioned adjacent the sleep surface, slits <NUM> will allow a second amount of movement between pockets <NUM>, wherein the first amount of movement is different than the second amount of movement. The first amount of movement can be greater than the second amount of movement. The first amount of movement can be less than the second amount of movement. Increasing the length of slit <NUM> or slit <NUM> increases the amount of movements between pockets <NUM>. Likewise, decreasing the length of slit <NUM> or slit <NUM> decreases the amount of movements between pockets <NUM>.

Slits <NUM>, <NUM> can have different widths, as shown in <FIG>. In some embodiments, slits <NUM> and slits <NUM> have the same width. In some embodiments, the width of slits <NUM> is different than the width of slits <NUM>. In some embodiments, the width of slits <NUM> is greater than the width of slits <NUM>. In some embodiments, the width of slits <NUM> is less than the width of slits <NUM>.

Strings <NUM> can have different configurations of slits <NUM>, <NUM>. In one embodiment, shown in <FIG>, string <NUM> includes slits <NUM>, <NUM> between each adjacent pocket <NUM>. That is, each vertical seam <NUM> includes both a slit <NUM> and a slit <NUM>. Slit <NUM> in one vertical seam <NUM> is parallel and/or coaxial with slit <NUM> in the same vertical seam <NUM>.

In an example not forming part of the invention as shown in <FIG>, string <NUM> includes slits <NUM>, <NUM> in every other vertical seam <NUM> and the vertical seams <NUM> between the vertical seams <NUM> that include slits <NUM>, <NUM> do not include slits <NUM>, <NUM>. That is, each vertical seam <NUM> includes either no slits <NUM>, <NUM> or both slit <NUM> and slit <NUM>. Slit <NUM> in one vertical seam <NUM> is parallel and/or coaxial with slit <NUM> in the same vertical seam <NUM>.

In an example not forming part of the invention as shown in <FIG>, string <NUM> includes slits <NUM>, <NUM> in every third vertical seam <NUM> and the vertical seams <NUM> between the vertical seams <NUM> that include slits <NUM>, <NUM> do not include slits <NUM>, <NUM>. That is, each vertical seam <NUM> includes either no slits <NUM>, <NUM> or both slit <NUM> and slit <NUM>. Slit <NUM> in one vertical seam <NUM> is parallel and/or coaxial with slit <NUM> in the same vertical seam <NUM>.

In an example not forming part of the invention as shown in <FIG>, string <NUM> includes slits <NUM> in every other vertical seam <NUM> and slits <NUM> in every other vertical seam <NUM>, wherein the vertical seams <NUM> that include a slit <NUM> do not include a slit <NUM> and the vertical seams <NUM> that include a slit <NUM> do not include a slit <NUM>.

Pockets <NUM> each include at least one spring <NUM> positioned therein. In some embodiments, springs <NUM> each have the same configuration. In some embodiments, at least one of springs <NUM> has a configuration that is different than another one of springs <NUM>. For example, at least one of springs <NUM> may be more rigid than another one of springs <NUM>. In some embodiments, each of pockets <NUM> includes only one spring <NUM> positioned therein. In some embodiments, each of pockets <NUM> includes more than one spring <NUM> positioned therein. In some embodiments, each of pockets <NUM> includes two springs <NUM> positioned therein, wherein the springs one of the springs is positioned within the other spring in a nested configuration. In some embodiments, at least one of pockets <NUM> includes only one spring <NUM> positioned therein and at least one of pockets <NUM> includes a plurality of springs <NUM> positioned therein. In some embodiments, the pockets <NUM> that include one spring <NUM> alternate with the pockets <NUM> that include more than one spring <NUM> such that every other pocket <NUM> includes only one spring <NUM> and every other pocket <NUM> includes more than one spring <NUM>.

In some embodiments, spring assembly <NUM> consists only of strings <NUM>. In some embodiment, spring assembly <NUM> comprises strings <NUM> and one or a plurality of second strings, such as, for example, strings <NUM>, as shown in <FIG>. Strings <NUM> each include a first ply of fabric and a second ply of fabric, similar to plies <NUM>, <NUM> of strings <NUM>. In some embodiments, the plies that strings <NUM> are made from are formed by folding a single piece of material, such as for example, a material similar to material <NUM>. That is, the first ply may be a first end of the material and the second ply may be a second end of the material, wherein the material is folded about a midsection of the material. In some embodiments, the material is arranged such that the midsection forms a top surface 66a of string <NUM> and the plies are joined at an opposite bottom surface 66b of string <NUM>. It is envisioned that this configuration may be reversed such that the midsection forms the bottom surface of string <NUM> and the plies are joined at the top surface of string <NUM>. Top and bottom surfaces 66a, 66b each extend from end <NUM> to end <NUM>. In some embodiment, the material can comprise acrylic, acetate, cotton, linen, silk, polyester, wool, nylon, rayon, spandex, lycra, hemp, manmade materials, natural materials (e.g., hemp) and blends and/or combinations thereof.

Strings <NUM> each extend along a longitudinal axis L1 between opposite ends <NUM>, <NUM> of strings <NUM>, as shown in <FIG>. The plies are joined together at spaced apart portions of the material by vertical seams <NUM> to define a plurality of pockets <NUM> along longitudinal axis L1. Vertical seams <NUM> define opposite end surfaces of string <NUM>. In some embodiment, strings <NUM> each include the same number of pockets <NUM>. In some embodiment, strings <NUM> each include different numbers of pockets <NUM>. It is envisioned that strings <NUM> may each include any number of pockets <NUM>. In some embodiments, strings <NUM> each include between about <NUM> and about <NUM> pockets <NUM>. In some embodiments, strings <NUM> each include about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, about <NUM> pockets <NUM>, or about <NUM> pockets <NUM>. In some embodiments, strings <NUM> each include the same number of pockets <NUM> as strings <NUM> include pockets <NUM>. That is, the number of pockets <NUM> in each of strings <NUM> is the same as the number of pockets <NUM> in each of strings <NUM>.

In some embodiments, vertical seams <NUM> are evenly spaced apart from one another along longitudinal axis L1 such that each of pockets <NUM> has the same width, the width of each of pockets <NUM> being defined by the distance from one of vertical seams <NUM> to an adjacent one of vertical seams <NUM>. In some embodiments, vertical seams <NUM> are not evenly spaced apart from one another along longitudinal axis L1 such that at least one of pockets <NUM> have a width that is different than a width another one of other pockets <NUM>, the widths of pockets <NUM> being defined by the distance from one of vertical seams <NUM> to an adjacent one of vertical seams <NUM>. Vertical seams <NUM> each have a length defined by the distance from the top surface of string <NUM> to the bottom surface of string <NUM>. In some embodiments, vertical seams <NUM> each have the same length. In some embodiments, the length of at least one of vertical seams <NUM> is different than the length of at least another one of vertical seams <NUM>.

In some embodiments, vertical seams <NUM> are formed by sewing, adhering, or welding the first ply to the second ply along at least a portion of the length of each vertical seam <NUM>. In some embodiments, vertical seams <NUM> are formed by a horizontal weld similar to horizontal weld <NUM>. In some embodiments, vertical seams <NUM> are formed by a vertical weld similar to vertical weld <NUM>.

Pockets <NUM> each include at least one spring, such as, for example, a spring similar to spring <NUM> positioned therein. In some embodiments, the springs within pockets <NUM> each have the same configuration. In some embodiments, at least one of the springs within pockets <NUM> has a configuration that is different than another one of the springs within pockets <NUM>.

For example, at least one of the springs within pockets <NUM> may be more rigid than another one of the springs within pockets <NUM>. In some embodiments, each of pockets <NUM> includes only one spring positioned therein. In some embodiments, each of pockets <NUM> includes more than one spring positioned therein. In some embodiments, each of pockets <NUM> includes two springs positioned therein, wherein one of the springs one spring is positioned within the other spring in a nested configuration. In some embodiments, at least one of pockets <NUM> includes only one spring positioned therein and at least one of pockets <NUM> includes a plurality of springs positioned therein. In some embodiments, the pockets <NUM> that include one spring alternate with the pockets <NUM> that include more than one spring such that every other pocket <NUM> includes only one spring and every other pocket <NUM> includes more than one spring.

The top surface 66a extends continuously from end <NUM> to end <NUM>. That is, there are no gaps in top surface 66a from end <NUM> to end <NUM>. This is in contrast to strings <NUM> that include slits <NUM>, <NUM> in top surface <NUM> and/or bottom surface <NUM> between ends <NUM>, <NUM>. Stated another way, strings <NUM> include slits <NUM> and/or slits <NUM> and strings <NUM> do not include any vertical slits in vertical seams <NUM>. It is envisioned that because strings <NUM> are free of such vertical slits, that movement between pockets <NUM> is limited. That is, slits <NUM>, <NUM> in strings <NUM> allow greater movement between pockets <NUM> than is permitted between pockets <NUM>.

The spring assembly <NUM> comprises a plurality of zones, such as, for example, a zone Z1 and a zone Z2, as shown in <FIG>. In some embodiments, spring assembly <NUM> comprises one or a plurality of zones Z1 and one or a plurality of zones Z2. In some embodiments, zone Z1 includes strings <NUM> and zone Z2 includes strings <NUM>. That is, zone Z1 includes one or a plurality of strings <NUM> and zone Z2 includes one or a plurality of strings <NUM>. It is envisioned that zones Z1, Z2 may be selectively positioned in spring assembly <NUM> such that zones Z1 are positioned at areas of mattress 30a where greater movement between pockets <NUM> is desired and that zones Z2 are positioned at areas of mattress 30a wherein less movement between pockets <NUM> is desired.

In one embodiment, shown in <FIG>, spring assembly <NUM> comprises zones Z1 at a top end <NUM> of spring assembly <NUM> and at an opposite bottom end <NUM> of spring assembly <NUM>. Zone Z1 at end <NUM> extends along and/or defines an end surface of end <NUM> and zone Z1 at end <NUM> extends along and/or defines an end surface of end <NUM>. Zones Z1 at ends <NUM>, <NUM> each extend continuously from a side <NUM> of spring assembly <NUM> to an opposite side <NUM> of spring assembly <NUM>. Spring assembly <NUM> includes an additional zone Z1 at a midsection <NUM> of spring assembly <NUM> such that zone Z1 at midsection <NUM> is positioned between zones Z1 at ends <NUM>, <NUM>. Midsection <NUM> is positioned between ends <NUM>, <NUM> and extends from side <NUM> to side <NUM>. Zone Z1 at midsection <NUM> extends from side <NUM> to side <NUM>. Zone Z1 at end <NUM> is spaced apart from zone Z1 at midsection <NUM> by a zone Z2 and zone Z1 at end <NUM> is spaced apart from zone Z1 at midsection <NUM> by a zone Z2. In some embodiments, zones Z1 at ends <NUM>, <NUM> are equally spaced apart from zone Z1 at midsection <NUM>. In some embodiments, zones Z2 each extend continuously from side <NUM> to side <NUM>.

In some embodiments, end <NUM> is configured to be positioned at a head of mattress 30a and end <NUM> is configured to be positioned at a foot of mattress 30a. As such, zone Z1 at end <NUM> is configured to support a sleeper's head, zone Z2 is configured to support the sleeper's legs and/or feet and zone Z1 at midsection <NUM> is configured to support the sleeper's midsection or torso. It is envisioned that lengths of zones Z1 between ends <NUM>, <NUM> can be selectively adjusted such that each of zones Z1 supports all or a portion of the sleeper's head, the sleeper's legs and/or the sleeper's feet and midsection or torso, respectively.

In some embodiments, zones Z1 at ends <NUM>, <NUM> of spring assembly <NUM> shown in <FIG> each include the same number of strings <NUM>. In some embodiments, zone Z1 at end <NUM> of spring assembly <NUM> shown in <FIG> includes more or less strings <NUM> than zone Z1 at end <NUM>. In some embodiments, zones Z1 of spring assembly <NUM> shown in <FIG> each include the same number of strings <NUM>. In some embodiments, zone Z1 at midsection <NUM> of spring assembly <NUM> shown in <FIG> includes more strings <NUM> than zones Z1 at ends <NUM>, <NUM>. In some embodiments, zone Z1 at midsection <NUM> of spring assembly <NUM> shown in <FIG> includes fewer strings <NUM> than zones Z1 at ends <NUM>, <NUM>. In some embodiments, zones Z2 at ends <NUM>, <NUM> of spring assembly <NUM> shown in <FIG> each include the same number of strings <NUM>. In some embodiments, zone Z2 at end <NUM> of spring assembly <NUM> shown in <FIG> includes more or less strings <NUM> than zone Z2 at end <NUM>.

In one embodiment, shown in <FIG>, spring assembly <NUM> comprises zones Z1 at end <NUM> of spring assembly <NUM> and at end <NUM> of spring assembly <NUM>. Zone Z1 at end <NUM> extends along and/or defines a portion of the end surface of end <NUM> and zone Z1 at end <NUM> extends along and/or defines a portion of the end surface of end <NUM>. Spring assembly <NUM> includes an additional zone Z1 at midsection <NUM> such that zone Z1 at midsection <NUM> is positioned between zones Z1 at ends <NUM>, <NUM>. Zone Z1 at end <NUM> is spaced apart from zone Z1 at midsection <NUM> by a zone Z2 and zone Z1 at end <NUM> is spaced apart from zone Z1 at midsection <NUM> by a zone Z2. Zones Z1, Z2 are each positioned between one or a plurality of strings <NUM> that each extend continuously from the end surface of end <NUM> to the end surface of end <NUM>. That is, zones Z1, Z2 are each spaced inwardly from side surfaces of sides <NUM>, <NUM> by strings <NUM>. In some embodiments, zones Z1 at ends <NUM>, <NUM> are equally spaced apart from zone Z1 at midsection <NUM>.

In some embodiments, zones Z1 at ends <NUM>, <NUM> of spring assembly <NUM> shown in <FIG> each include the same number of strings <NUM>. In some embodiments, zone Z1 at end <NUM> of spring assembly <NUM> shown in <FIG> includes more or less strings <NUM> than zone Z1 at end <NUM>. In some embodiments, zones Z1 of spring assembly <NUM> shown in <FIG> each include the same number of strings <NUM>. In some embodiments, zone Z1 at midsection <NUM> of spring assembly <NUM> shown in <FIG> includes more strings <NUM> than zones Z1 at ends <NUM>, <NUM>. In some embodiments, zone Z1 at midsection <NUM> of spring assembly <NUM> shown in <FIG> includes less strings <NUM> than zones Z1 at ends <NUM>, <NUM>. In some embodiments, zones Z2 at ends <NUM>, <NUM> of spring assembly <NUM> shown in <FIG> each include the same number of strings <NUM>. In some embodiments, zone Z2 at end <NUM> of spring assembly <NUM> shown in <FIG> includes more or less strings <NUM> than zone Z2 at end <NUM>.

In one embodiment, shown in <FIG>, spring assembly <NUM> comprises zones Z1 at end <NUM> of spring assembly <NUM> and at end <NUM> of spring assembly <NUM>. Zone Z1 at end <NUM> is spaced apart from the end surface of end <NUM> by a zone Z2 that extends along and/or defines the end surface of end <NUM> and zone Z1 at end <NUM> is spaced apart from the end surface of end <NUM> by a zone Z2 that extends along and/or defines the end surface of end <NUM>. Spring assembly <NUM> includes an additional zone Z1 at midsection <NUM> such that zone Z1 at midsection <NUM> is positioned between zones Z1 at ends <NUM>, <NUM>. Zone Z1 at end <NUM> is spaced apart from zone Z1 at midsection <NUM> by a zone Z2 and zone Z1 at end <NUM> is spaced apart from zone Z1 at midsection <NUM> by a zone Z2. In some embodiments, zones Z1 at ends <NUM>, <NUM> are equally spaced apart from zone Z1 at midsection <NUM>.

In some embodiments, zones Z1 at ends <NUM>, <NUM> of spring assembly <NUM> shown in <FIG> each include the same number of strings <NUM>. In some embodiments, zone Z1 at end <NUM> of spring assembly <NUM> shown in <FIG> includes more or less strings <NUM> than zone Z1 at end <NUM>. In some embodiments, zones Z1 of spring assembly <NUM> shown in <FIG> each include the same number of strings <NUM>. In some embodiments, zone Z1 at midsection <NUM> of spring assembly <NUM> shown in <FIG> includes more strings <NUM> than zones Z1 at ends <NUM>, <NUM>. In some embodiments, zone Z1 at midsection <NUM> of spring assembly <NUM> shown in <FIG> includes less strings <NUM> than zones Z1 at ends <NUM>, <NUM>. In some embodiments, zones Z2 that extend along and/or define the end surfaces of ends <NUM>, <NUM> of spring assembly <NUM> shown in <FIG> each include the same number of strings <NUM>. In some embodiments, zone Z2 that extends along and/or defines the end surface of end <NUM> of spring assembly <NUM> shown in <FIG> includes more or less strings <NUM> than zone Z2 that extends along and/or defines the end surface at end <NUM>. In some embodiments, zones Z2 that are positioned between zone Z1 at end <NUM> and zone Z1 at midsection <NUM> and between zone Z1 at end <NUM> and zone Z1 at midsection <NUM> each include the same number of strings <NUM>. In some embodiments, zone Z2 positioned between zones Z1 at end <NUM> and midsection <NUM> includes more or less strings <NUM> than zone Z2 positioned between zone Z1 at end <NUM> and zone Z1 at midsection <NUM>. In some embodiments, zones Z2 that are positioned between zone Z1 at end <NUM> and zone Z1 at midsection <NUM> and between zone Z1 at end <NUM> and zone Z1 at midsection <NUM> each include the same number of strings <NUM> as zones Z2 that extend along and/or define the end surfaces of ends <NUM>, <NUM>. In some embodiments, at least one of zones Z2 that are positioned between zone Z1 at end <NUM> and zone Z1 at midsection <NUM> and between zone Z1 at end <NUM> and zone Z1 at midsection <NUM> includes more of less strings <NUM> than at least one of zones Z2 that extend along and/or define the end surfaces of ends <NUM>, <NUM>.

In one embodiment, shown in <FIG>, spring assembly <NUM> comprises zones Z1 at end <NUM> of spring assembly <NUM> and at end <NUM> of spring assembly <NUM>. Zone Z1 at end <NUM> is spaced apart from the end surface of end <NUM> by a zone Z2 that extends along and/or defines a portion of the end surface of end <NUM> and zone Z1 at end <NUM> is spaced apart from the end surface of end <NUM> by a zone Z2 that extends along and/or defines a portion of the end surface of end <NUM>. Spring assembly <NUM> includes an additional zone Z1 at midsection <NUM> such that zone Z1 at midsection <NUM> is positioned between zones Z1 at ends <NUM>, <NUM>. Zone Z1 at end <NUM> is spaced apart from zone Z1 at midsection <NUM> by a zone Z2 and zone Z1 at end <NUM> is spaced apart from zone Z1 at midsection <NUM> by a zone Z2. Zones Z1, Z2 are each positioned between one or a plurality of strings <NUM> that each extend continuously from the end surface of end <NUM> to the end surface of end <NUM>. That is, zones Z1, Z2 are each spaced inwardly from the side surfaces of sides <NUM>, <NUM> by strings <NUM>. In some embodiments, zones Z1 at ends <NUM>, <NUM> are equally spaced apart from zone Z1 at midsection <NUM>.

In one embodiment, shown in <FIG>, spring assembly <NUM> comprises two spaced apart zones Z1 at end <NUM> of spring assembly <NUM> and two spaced apart zones Z1 at end <NUM> of spring assembly <NUM>. Zones Z1 at end <NUM> extend along and/or define a portion of the end surface of end <NUM> and zones Z1 at end <NUM> extend along and/or define a portion of the end surface of end <NUM>. Zones Z1 at end <NUM> are spaced apart from one another by a zone Z2 that extends continuously from the end surface of end <NUM> to the end surface of end <NUM>. Zones Z1 at end <NUM> are spaced apart by the same zone Z2 that spaces zones Z1 at end <NUM> apart. The zone Z2 that spaces zones Z1 at end <NUM> apart and zones Z1 at end <NUM> apart includes one or a plurality of strings <NUM>. Spring assembly <NUM> includes spaced apart zones Z1 at midsection <NUM> such that zones Z1 at midsection <NUM> are positioned between zones Z1 at end <NUM> and zones Z1 at end <NUM>. The zone Z2 that spaces zones Z1 at end <NUM> apart and zones Z1 at end <NUM> apart also spaces zones Z1 at midsection <NUM> apart.

Zones Z1 at end <NUM> are each spaced apart from zones Z1 at midsection <NUM> by a zone Z2. Zones Z2 that space zones Z1 at end <NUM> apart from zones Z1 at midsection <NUM> are spaced apart by the zone Z2 that spaces zones Z1 at end <NUM> apart, spaces zones Z1 at end <NUM> apart and spaces zones Z1 at midsection <NUM> apart. Zones Z1 at end <NUM> are each spaced apart from zones Z1 at midsection <NUM> by a zone Z2. Zones Z2 that space zones Z1 at end <NUM> apart from zones Z1 at midsection <NUM> are spaced apart by the zone Z2 that spaces zones Z1 at end <NUM> apart, spaces zones Z1 at end <NUM> apart and spaces zones Z1 at midsection <NUM> apart.

As shown in <FIG>, spring assembly <NUM> comprises zones Z1 adjacent side <NUM> at end <NUM>, end <NUM> and midsection <NUM> that are spaced apart from one another and zones Z1 adjacent side <NUM> at end <NUM>, end <NUM> and midsection <NUM> that are spaced apart from one another. Zones Z1 adjacent side <NUM> may be configured to accommodate the head, the legs and/or feet and the torso or midsection, respectively, of a first sleeper and that zones Z1 adjacent side <NUM> may be configured to accommodate the head, the legs and/or feet and the torso or midsection, respectively, of a second sleeper. It is envisioned that the zone Z2 that spaces zones Z1 at end <NUM> apart, spaces zones Z1 at end <NUM> apart and spaces zones Z1 at midsection <NUM> apart will reduce or eliminate movement of at least one of zones Z1 adjacent side <NUM> when there is movement within at least one of zones Z1 adjacent side <NUM>. Likewise, the zone Z2 that spaces zones Z1 at end <NUM> apart, spaces zones Z1 at end <NUM> apart and spaces zones Z1 at midsection <NUM> apart will reduce or eliminate movement of at least one of zones Z1 adjacent side <NUM> when there is movement within at least one of zones Z1 adjacent side <NUM>. As such, spring assembly <NUM> may be configured to reduce or eliminate movement on one side of spring assembly <NUM> when a sleeper on an opposite side of spring assembly <NUM> moves.

In some embodiments, wherein the first and second sleepers each have the same preference as to mattress firmness, for example, zone Z1 at end <NUM> adjacent side <NUM> has the same configuration as zone Z1 at end <NUM> adjacent side <NUM> and/or zone Z1 at end <NUM> adjacent side <NUM> has the same configuration as zone Z1 at end <NUM> adjacent side <NUM> and/or zone Z1 at midsection <NUM> adjacent side <NUM> has the same configuration as zone Z1 at midsection <NUM> adjacent side <NUM>. When zones Z1 at ends <NUM>, <NUM> and midsection <NUM> are the same, mattress 30a may be flipped by rotating mattress 30a <NUM> degrees along an axis that extends from end <NUM> to end <NUM>. That is, mattress 30a is rotated side over side. Since zones Z1 at ends <NUM>, <NUM> and midsection <NUM> are the side adjacent side <NUM> and adjacent side <NUM>, the sleepers will still sleep on top of zones Z1 that have the same configuration as they did before mattress 30a was flipped.

In some embodiments, at least one of zones Z1 adjacent side <NUM> is different than at least one of zones Z1 adjacent side <NUM>. This allows spring assembly <NUM> to be customized to suit the preferences of the first and second sleepers. For example, if the sleeper that sleeps adjacent side <NUM> desires a firmer mattress than the sleeper that sleeps adjacent side <NUM>, at least one of zones Z1 adjacent side <NUM> may be firmer than at least one of zones Z1 adjacent side <NUM>. In some embodiments, the firmness (or softness) of zones Z1 may be altered by changing the material springs <NUM> or made from a harder or more rigid material to a softer or less rigid material, for example. In some embodiments, the firmness (or softness) of zones Z1 may be altered by changing the number of springs <NUM> within pockets <NUM> and/or changing the configuration of springs <NUM>. For example, where a firmer mattress is desired, pockets <NUM> can each include more than one spring <NUM> therein. In some embodiments, the firmness (or softness) of zones Z1 may be altered by changing the depth and/or width of slits <NUM> and/or slits <NUM>, as discussed herein. Indeed, because there may be a direct correlation between the depth and/or width of slits <NUM>, <NUM> and the amount of movement between pockets <NUM>, it is envisioned that increasing the depth and/or width of slits <NUM> and/or slits <NUM> may allow greater movement between pockets <NUM>, thus resulting in a less firm feel, for example.

In embodiments wherein zones Z1 at ends <NUM>, <NUM> adjacent side <NUM> are the same and zones Z1 at ends <NUM>, <NUM> adjacent side <NUM> are the same, to maintain the configuration that the sleeper that sleeps adjacent side <NUM> prefers and that the sleeper that sleeps adjacent side <NUM> prefers, the depth and/or width slits <NUM> in a given one of the zones Z1 at ends <NUM>, <NUM> should be the same as the depth and/or width of slits <NUM> in that zone Z1. Mattress 30a may then be flipped in a manner that maintains the preferences of the sleepers by rotating mattress 30a <NUM> degrees along an axis that extends perpendicular to an axis that extends from end <NUM> to end <NUM>. That is, mattress 30a is rotated end over end.

In some embodiments, zones Z1 at end <NUM> of spring assembly <NUM> shown in <FIG> each include the same number of strings <NUM> and/or zones Z1 at end <NUM> each include the same number of strings <NUM>. In some embodiments, zones Z1 at end <NUM> of spring assembly <NUM> shown in <FIG> each include more or less strings <NUM> than zones Z1 at end <NUM>. In some embodiments, zones Z1 of spring assembly <NUM> shown in <FIG> each include the same number of strings <NUM>. In some embodiments, zones Z1 at midsection <NUM> of spring assembly <NUM> shown in <FIG> each include more strings <NUM> than zones Z1 at ends <NUM>, <NUM>. In some embodiments, zones Z1 at midsection <NUM> of spring assembly <NUM> shown in <FIG> each include less strings <NUM> than zones Z1 at ends <NUM>, <NUM>. In some embodiments, zones Z2 at ends <NUM>, <NUM> of spring assembly <NUM> shown in <FIG> each include the same number of strings <NUM>. In some embodiments, zones Z2 at end <NUM> of spring assembly <NUM> shown in <FIG> include more or less strings <NUM> than zones Z2 at end <NUM>.

In some embodiments, shown in <FIG> and <FIG>, mattress 30a includes one of spring assemblies <NUM> discussed herein, a cushioning material <NUM> and/or a base material <NUM>. As shown in <FIG>, cushioning material <NUM> is positioned above spring assembly <NUM> such that a bottom surface of cushioning material <NUM> engages the top surfaces of strings <NUM> and/or strings <NUM> and base material <NUM> is positioned below spring assembly <NUM> such that a top surface of base material <NUM> engages the bottom surfaces of strings <NUM> and/or strings <NUM>. That is, spring assembly <NUM> is positioned between cushioning material <NUM> and base material <NUM>. In some embodiments, spring assembly <NUM> is fixed and/or coupled to cushioning material <NUM> and/or base material <NUM> by sewing, adhesives, etc..

Claim 1:
A spring assembly comprising:
a first zone comprising a plurality of first strings of springs; and
a second zone comprising a plurality of second strings of springs, each of the first strings being joined to another one of the first strings or one of the second strings,
wherein the first strings have a first configuration and the second strings have a second configuration that is different from the first configuration,
wherein each of the first strings comprises first and second plies of fabric that define a plurality of first pockets formed along a length of the first string by first vertical seams that join the plies, the first vertical seams each including an upper slit that extends through a top surface of the first string and a lower slit that extends through a bottom surface of the first string, the first and second plies extending continuously from the upper slits to the lower slits, the upper and lower slits each having the same length, each of the first pockets comprising at least one spring positioned therein, and
wherein each of the second strings comprises third and fourth plies of fabric that define a plurality of second pockets formed along a length of the second string by second vertical seams that join the third and fourth plies, the second vertical seams being free of any slits that extend through a top surface of the second string and free of any slits that extend through a bottom surface of the second string, each of the second pockets comprising at least one spring positioned therein.