Patent ID: 12245701

DETAILED DESCRIPTION OF THE INVENTION

Referring first toFIG.1, there is illustrated a bedding product in the form of a single-sided mattress10incorporating the principles of the present invention. This product or mattress10comprises a pocketed spring assembly12over the top of which lay conventional padding or cushioning layers14,16which may be foam, fiber, gel, a pocketed spring blanket or any other suitable materials or any combination thereof. Although two cushioning layers14,16are shown inFIGS.1and1A, any number of cushioning layers may be incorporated into the product.

The pocketed spring assembly12may include upper and lower scrim sheets18attached with adhesive to upper and lower surfaces of the strings of springs26of the pocketed spring assembly12. The lower scrim sheet18may be adhesively secured to a base19which may be made of foam, fiber or any other desired material. In any of the embodiments shown or described herein, one scrim sheet or both scrim sheets may be omitted. Similarly, in any of the embodiments shown or described herein, the base19may be omitted. The pocketed spring assembly12and base19(if there is one) may be completely enclosed within an upholstered cover20.

As shown inFIG.1, fully assembled, the product10has a length “L” defined as the linear distance between opposed end surfaces22(only one being shown inFIG.1). Similarly, the assembled product10has a width “W” defined as the linear distance between opposed side surfaces24(only one being shown inFIG.1). In the product shown inFIG.1, the length is illustrated as being greater than the width. However, it is within the scope of the invention that the length and width may be identical, as in a square product.

As shown inFIG.1, pocketed spring assembly12is manufactured from multiple strings26a,26bof pocketed springs28joined together. As described below, strings26aare called exterior strings of pocketed springs, and strings26bare called interior strings of pocketed springs in this document. Each string26a,26bextends longitudinally or from head-to-foot along the full length of the pocketed spring assembly12.

Although the strings are illustrated as extending longitudinally or from head-to-foot in the pocketed spring assembly12ofFIG.1, the strings may extend transversely or from side-to-side as shown in the pocketed spring assembly13shown in the product10ashown inFIG.1A. As shown inFIG.1A, pocketed spring assembly13comprises multiple transversely extending strings27of pocketed springs.

FIG.1Billustrates a double-sided mattress or product10bcomprising pocketed spring assembly12and scrim sheets18identical to those shown in the mattress10ofFIG.1. However, mattress10bofFIG.1Bhas conventional padding layers14,16above and below the pocketed spring assembly12. Although two cushioning layers14,16are shown per side, any number of cushioning layers may be incorporated into the product on either side.

As shown inFIG.1, pocketed spring assembly12comprises a plurality of strings26a,26bof pocketed springs extending from head-to-foot or longitudinally. As shown inFIG.1A, pocketed spring assembly13comprises a plurality of strings27of pocketed springs extending from side-to-side or transversely. Due to the symmetric nature of the springs inside the strings, any embodiment of pocketed spring assembly shown or described herein may be used in a single-sided and/or a double-sided product.

Any of the padding or cushioning layers may be omitted in any of the embodiments shown or described herein. The novel features reside in the pocketed spring assembly. A pocketed spring assembly in accordance with the invention is not intended to be limited to use in products shown or described herein; but rather may be used in any product.

These strings and any other strings of pocketed springs described or shown herein, may be connected in side-by-side relationship in any manner as, for example, by gluing the sides of the strings together in an assembly machine, to create an assembly or matrix having multiple rows and columns of pocketed springs bound together as by gluing, welding or any other conventional assembly process commonly used to create pocketed spring cores or assemblies. Referring toFIGS.1and1B, the longitudinally extending strings26aand26bmay be joined so that the individually pocketed springs are aligned in transversely extending rows30and longitudinally extending columns31. The same is true with transversely extending strings27shown inFIG.1A.

FIGS.2,3and4show one embodiment of pocketed spring assembly12which comprises two different longitudinally extending strings of pocketed springs: exterior strings of springs26aand interior strings of springs26b. As shown inFIGS.3and3A, each of the strings26a,26bof pocketed spring assembly12is approximately the same height “H”, providing pocketed spring assembly12a generally uniform height “H”, but not need be a uniform height. As shown inFIG.2, pocketed spring assembly12comprises two exterior longitudinally extending strings26aon each side of multiple interior strings26b. The number of exterior and interior strings26a,26bdepends on the size of the product10. Each exterior string26aand each interior string26b, respectively, extends the entire length “L” of the pocketed spring assembly.

As shown inFIG.2, each set of two exterior strings26acomprises a side section66of pocketed spring assembly12. In some applications, each side section of a pocketed spring assembly may comprise more than or less than two strings of springs per side section. In other words, the number of exterior strings26amay vary depending on the size of the product or other factors, such as the desired amount of side edge support.

The drawings show each of the exterior strings26abeing uniform from head-to-foot, i.e. not having sections with different springs in the pockets. The pockets of the exterior strings26aare shown being the same diameter as the pockets of the interior strings, but may be any desired diameter or height. The exterior strings26afunction as side edge support and are not the focus of the present invention. It is within the scope of the present invention that a pocketed spring assembly has no exterior strings and each of the strings has at least two sections with different springs in at least two of the sections.

As best shown inFIG.2, each interior string26bhas three outer pockets58at each end and inner pockets60therebetween. As best shown inFIG.4, each outer pocket58has a firm spring36therein and each inner pocket60has a soft spring62therein. In the illustrated springs, the firm springs36have more convolutions than the soft springs62.

As best shown inFIG.3, each firm spring36has a central or longitudinal axis A, an upper end turn38, a lower end turn40, and a plurality of central convolutions42between the end turns.FIG.3illustrates a barrel-shaped firm spring36in which the diameter of the end turns38,40is less than the diameter of the central convolutions42. As best shown inFIG.3, each barrel-shaped firm spring36is symmetrical, having a center or middle portion44and two identical end portions46.

As best shown inFIG.4, each soft coil spring62has an upper end turn68, a lower end turn69and a plurality of central convolutions70between the end turns.FIG.4illustrates a barrel-shaped soft coil spring62in which the diameter of the end turns68,69is less than the diameter of the central convolutions70. As best shown inFIG.4, at least one of the central convolutions70has an out-of-pocket barrel diameter greater than the diameters of the other convolutions of the soft spring62. Although the firm and soft coil springs36,62are illustrated as being barrel-shaped, either one may be any known shape including hour-glass, uniform diameter or any other known configuration.

As shown inFIG.4, each interior string26bhas three sections, two end sections S1(only one being shown) and a middle section S2between the end sections. Adjacent sections are welded or spliced together with a weld76, as shown inFIG.4. In the example illustrated inFIGS.6-15, each end section S1originates from a second supply string74containing all firm springs36. The middle section S2originates from a first supply string72containing all soft springs62. The coil springs within the first supply string72are soft springs62and the coil springs within the second supply string74are firm springs36.

Preferably, one piece of fabric is used to create each section S1, S2of each interior string26b.FIG.3illustrates an end section S1of an interior string26bcomprising a piece of fabric being folded over onto itself around three firm coil springs36at each end. As best shown inFIG.3, opposite sides or plies47,49of the fabric are welded or otherwise secured together to create a longitudinal seam50and a plurality of separating or transverse seams52of any desired length.FIG.3illustrates ply47being closest to the reader and ply49being behind the springs36or away from the reader. Although the drawings show separating or transverse seams52being a certain length, they may be any intended length and are not intended to be limited to the drawings. For example, they may be less than the height of the string in which they are used, as is known in the industry as “split top”.

Although the seams or welds in the embodiments shown herein are shown as being heat-welded spaced rectangles, any of the seams described herein may be spaced dots, triangles or solid line segments without spaces.

As best shown inFIG.3, opposed edges56of the piece of fabric used to create the end section S1of an interior string26bare aligned and spaced from the longitudinal seam50a linear distance indicated by numeral57. Although the drawings indicated the longitudinal seam50being below the free edges56of the piece of fabric, the longitudinal seam50may be above the free edges56of the piece of fabric.

As shown inFIG.3, section S1of interior string26bhas a generally planar top surface54in a top plane P1and a parallel generally planar bottom surface55in a bottom plane P2. The linear distance between the top and bottom surfaces54,55of the interior string26bdefines a height H of the section S1of interior string26b. This linear distance further defines the height H of the pocketed spring assembly12because each of the exterior strings26aand interior strings26bhas approximately the same height. Each section S1, S2of the interior strings26bhas approximately the same height H because the height of the first supply string is the same height H. However, it is within the contemplation of the present invention that the heights of the supply strings be different resulting in interior strings having different heights.

Referring toFIG.2, each interior string26bof pocketed spring assembly12comprises a row of interconnected fabric pockets58,60of the same height. Three fabric pockets58are located at each end of each interior string26bwith fabric pockets60therebetween. For purposes of this document, the outermost pockets58are considered outer pockets of the interior string26b, and the pockets60therebetween are considered inner pockets of the interior string26b. As shown inFIG.4, within each interior string26b, each outer pocket58contains a firmer spring36than the springs62within each inner pocket60for edge support. Although the drawings show each interior string26bof pocketed spring assembly12having three outer pockets58at each end, it is within the scope of the invention that each interior string26bmay have one, two or any number of outer pockets60at each end of the interior string26b.

As shown inFIG.2, pocketed spring assembly12has opposite end sections64made up of solely firm pocketed springs36. The end sections64and side sections66make up a picture-frame shape of edge support which provides increased stiffness around the perimeter of the pocketed spring assembly12because of the different springs within the pockets.

Although the firm springs36of the end sections S1are illustrated having more convolutions or turns than the interior soft springs62of middle section S2of each interior string26b, the springs of the end sections S1of the interior strings26bmay be firmer than the springs within the middle section due to any of the following or any combination thereof: being made of heavier gauge wire as described below and shown inFIG.4A; having a greater out-of-pocket height; having more convolutions, having a different shape or anything else which is known in the industry as a different geometry.

In this embodiment, the pocketed spring assembly12has a four-sided perimeter section110surrounding an interior or core section112. The perimeter section110of pocketed spring assembly12comprises pocketed tall springs36. The core section112comprises pocketed soft springs62. The pocketed spring assembly12has a uniform height H. Each side of the perimeter section110is firmer than the core section112due to the properties of the two different springs (firm and soft springs) in the two different sections: perimeter section110and core section112. SeeFIG.2.

FIG.4Aillustrates an alternative interior string26bbin which the firmer springs of the end sections are made of thicker or heavier gauge wire than the wire of the springs of the middle section. As shown inFIG.4A, the firm springs36′ of the end sections S1(only one being shown) may be made of a thicker or heavier gauge wire than soft springs62of middle section S2of each interior string26b. In one embodiment, the firm springs36′ are made of 13.75-gauge wire, and the soft springs62are made of 14-gauge wire. These gauges are not intended to be limiting, but merely an example.

As shown inFIG.5, the end sections S1each have a fabric tab78at each end (only one being shown) and the middle section S2has a fabric tab80at each end (only one being shown). The welding apparatus82shown inFIGS.6-15illustrates clamps used to locate the fabric tabs so two tabs overlap to be welded together with weld76.FIG.5shows the fabric tabs78,80separated before being overlapped and welded. This method is used whenever any two sections having different springs are spliced or welded together.

FIGS.6-15illustrate a method of making a finished sectioned continuous string of pocketed springs86which is passed to an assembler for assembly into a pocketed spring assembly. SeeFIG.15.FIGS.6-15illustrate a welding apparatus82for joining two sections of pocketed springs with a splice or weld.

FIG.6illustrates a starting string of pocketed springs88downstream of the welding apparatus82. The starting string of pocketed springs88has an upstream tab78held in place with clamps104. For purposes of example only, the pockets90of the starting string of pocketed springs88downstream of the welding apparatus82all contain a soft spring62. Originally, the starting string of pocketed springs88and the first supply string of pocketed springs72described below were one string of springs originating from coiler1before being cut and separated.

FIG.6shows a first supply string of pocketed springs72upstream of the welding apparatus82in an offset position from the direction of the starting string of pocketed springs88. The first supply string of pocketed springs72has a downstream tab78held in placed and moved with clamps94. The pockets90of the first supply string of pocketed springs72contain the same spring from coiler1. For purposes of example only, the pockets90of the starting string of pocketed springs88all contain a soft spring62and came from coiler1. However, they could contain a different spring.

FIG.6also shows a second supply string of pocketed springs74upstream of the welding apparatus82in an in-line position from the direction of the starting string of pocketed springs88. The second supply string of pocketed springs74has a downstream tab80held in placed and moved with clamps96. The pockets92of the second supply string of pocketed springs74contain the same springs from coiler2different than coiler1. For purposes of example only, the pockets92all contain a firm spring36. However, they could contain a different spring.

As shown inFIGS.6-15, the welding apparatus82comprising a cutter99, a sonotrode or welding horn100and an anvil102.FIG.6shows the cutter99in a raised position in which it is not being used. Although the drawings show one configuration of welding apparatus82, the welding apparatus may be different than shown in the drawings.

FIG.7shows the first supply string of pocketed springs72upstream of the welding apparatus82after being clamped using clamps94and cut to separate the starting string of pocketed springs88downstream of the welding apparatus82from the first supply string of pocketed springs72upstream of the welding apparatus82.FIG.7shows the first supply string of pocketed springs72upstream of the welding apparatus82being moved from an in-line position with the starting string of pocketed springs88downstream of the welding apparatus82to an offset position (to the right inFIG.7) from the direction of the starting string of pocketed springs88. See arrow106. Such movement may be perfected by a channel changer (not shown).

FIG.8shows the second supply string of pocketed springs74upstream of the welding apparatus82originating from coiler2being moved to an in-line position with the direction of the starting string of pocketed springs88. As shown inFIG.4, the upstream tab of fabric78of the starting string of pocketed springs88downstream of the welding apparatus82is overlapped with the upstream tab of fabric80of the second supply string of pocketed springs using clamps104and96.

FIG.9illustrates the next step in the process.FIG.9shows the anvil102and welding horn100are moved together simultaneously between clamps104and96to meet to weld the overlapped tabs of fabric78,80together, resulting in a weld76, as shown inFIG.4. After the weld76is complete, the combined string of pocketed springs will be referred to herein as a combined string of pocketed springs84.

FIG.10illustrates the clamps96separated and the anvil102and welding horn100separated to allow the combined string of pocketed springs84to move downstream or indexed in the direction of arrow108a desired amount.

As shown inFIG.11, after the combined string of pocketed springs84is indexed downstream, the clamps96are brought back together as shown by arrows110to clamp the fabric for cutting between pockets. As shown inFIG.11, the portion of the combined string of pocketed springs84upstream of the clamps96is pulled upstream to stretch the fabric to increase the size of the transverse seams between adjacent pockets. See arrow112.

As shown inFIG.12, the next step is that the cutter99is lowered from its raised position to its lowered position in the direction of arrow114, thereby cutting the combined string of pocketed springs84between the clamps96. Although one cutter is shown, any known cutting device may be used. After the cutting, the combined string of pocketed springs84may be separated into two parts, each part having a tab of fabric.

As shown inFIG.13, the next step is the portion or part of the combined string of pocketed springs84upstream of the cut is moved upstream in the direction of arrow116away from the welding apparatus82.FIG.14illustrates the portion or part of the combined string of pocketed springs84upstream of the cut being moved by a conveyor system to an off-line position from the portion or part of the combined string of pocketed springs84downstream of the cut. The portion or part of the combined string of pocketed springs84upstream of the cut becomes the second supply string74.

As shown inFIG.14, the first supply string72is moved in-line with the portion or part of the combined string of pocketed springs84upstream of the cut to repeat the process thereby joining a portion of the first supply string72to the portion of the combined string of pocketed springs84downstream of the welding apparatus82to create a sectioned continuous string of springs86.

FIG.15illustrates the sectioned continuous string of springs86downstream of the cutting apparatus82. The sectioned continuous string of springs86comprises a first section118of springs62from coiler1from the original starting string of springs88, a second section120of springs36from the second supply string of springs74from coiler2and a third section122of springs62from the first supply string of springs72.

Although the drawings show two different strings upstream of the welding apparatus82, any number of strings of different strings may be positioned upstream of the welding apparatus82and moved by any known conveyor system into and out of an in-line position with the downstream string of pocketed springs.

It is also with the scope of the present invention that the positions of the first and second supply strings be interchanged in the method shown inFIGS.6-15.

In any of the embodiments shown and described herein, the drawings given are merely examples and not intended to be limiting. This includes the barrel diameter, out-of-pocket height, in-pocket height and number of convolutions of any of the springs.

Although the pocketed springs have been described herein as barrel-shaped springs, it is within the scope of the invention described herein that the springs be cylindrical, an hour-glass shape of some other shape. Likewise, the pocketed springs need not be symmetrical, but may be any desired known configuration.

FIG.16illustrates another embodiment of pocketed spring assembly12c. Pocketed spring assembly12cis manufactured from exterior and interior strings26c,26ccof pocketed springs, respectively, joined together. Each string of pocketed springs26c,26ccextends longitudinally or from head-to-foot along the full length of the assembly12c.

As shown inFIG.16, pocketed spring assembly12chas opposite end sections64cand a middle section65cmade up of pocketed springs. The end sections64c, side sections66cand middle section65c, each containing pocketed springs make up a picture-frame shape of edge support which provides increased stiffness around the perimeter of the pocketed spring assembly12and across the back of a user. The end sections64c, side sections66cand middle section65chave firmer pockets than the pockets of the white interior pockets of the interior strings26cc.

Each of the interior strings26ccof pocketed spring assembly12cis identical and comprises three outer pockets58con each end and three middle pockets59c, each containing a pocketed spring. Between the outer pockets58cand middle pockets59care inner pockets60c, each inner pocket60ccontaining at least one spring. Instead of one core section112, like in pocketed spring assembly12, pocketed spring assembly12chas two core sections112con opposite sides of the middle section65c. AlthoughFIG.16illustrates one middle section65cof increased firmness for lumbar or back support, those skilled in the art will appreciate multiple sections of increased firmness may be incorporated into a pocketed spring assembly at any desired locations by modifying the composition of the interior strings of the pocketed spring assembly.

The various embodiments of the invention shown and described are merely for illustrative purposes only, as the drawings and the description are not intended to restrict or limit in any way the scope of the claims. Those skilled in the art will appreciate various changes, modifications, and improvements which can be made to the invention without departing from the spirit or scope thereof. The invention in its broader aspects is therefore not limited to the specific details and representative apparatus and methods shown and described. Departures may therefore be made from such details without departing from the spirit or scope of the general inventive concept. For example, foam resilient members may be used instead of coil springs. The invention resides in each individual feature described herein, alone, and in all combinations of any and all of those features. Accordingly, the scope of the invention shall be limited only by the following claims and their equivalents.