WO2017116406A1 - Ensembles de ressorts hélicoïdaux à poche ayant des coutures séparées et coussins de support comprenant ceux-ci - Google Patents

Ensembles de ressorts hélicoïdaux à poche ayant des coutures séparées et coussins de support comprenant ceux-ci Download PDF

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Publication number
WO2017116406A1
WO2017116406A1 PCT/US2015/067775 US2015067775W WO2017116406A1 WO 2017116406 A1 WO2017116406 A1 WO 2017116406A1 US 2015067775 W US2015067775 W US 2015067775W WO 2017116406 A1 WO2017116406 A1 WO 2017116406A1
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WO
WIPO (PCT)
Prior art keywords
pocketed coil
coil springs
seam
adjacent
pocketed
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2015/067775
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English (en)
Inventor
Darin T. Thomas
Larry K. Demoss
Brian M. Manuszak
Kevin TAR
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sealy Technology LLC
Original Assignee
Sealy Technology LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sealy Technology LLC filed Critical Sealy Technology LLC
Priority to US16/065,483 priority Critical patent/US20190000239A1/en
Priority to PCT/US2015/067775 priority patent/WO2017116406A1/fr
Publication of WO2017116406A1 publication Critical patent/WO2017116406A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
    • A47C27/06—Spring inlays or spring units therefor
    • A47C27/07—Attaching, or interconnecting of, springs in spring inlays
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
    • A47C27/06—Spring inlays or spring units therefor
    • A47C27/063—Spring inlays or spring units therefor wrapped or otherwise protected
    • A47C27/064—Pocketed springs
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
    • A47C27/06—Spring inlays or spring units therefor
    • A47C27/068—Spring inlays or spring units therefor made from a single wire

Definitions

  • the present invention relates to pocketed coil spring assemblies and support cushions including the pocketed coil spring assemblies.
  • the present invention relates to pocketed coil spring assemblies having seams that are positioned between each of the pocketed coil springs and that allow one or more ends of each pocketed coil spring to move independently of an adjacent pocketed coil spring.
  • pocketed coil springs which are also known as wrapped coils, encased coils, encased springs, or Marshall coils, are generally recognized as providing a unique feel to a mattress when used as a part of a spring assembly because each discrete coil is capable of moving independently to support the body of a user, or a portion thereof, resting on the mattress.
  • each coil is wrapped in a fabric pocket and moves substantially independently of the other coils in the spring core to thereby provide individualized comfort and contouring to the body of a user.
  • pocketed coils also do not directly transfer motion from one pocketed coil to another, and, consequently, the movement of one user resting on a mattress assembly using pocketed coils will not disturb another user resting on the mattress assembly.
  • mattress assemblies constructed with a spring core using pocketed coil springs are generally recognized as providing a soft and luxurious feel, and are often more desirable than a traditional inner spring mattress. Accordingly, a spring core that makes use of pocketed coil springs and that further improves the unique feel and support provided by traditional pocketed coil springs would be both highly desirable and beneficial.
  • the present invention includes pocketed coil spring assemblies and support cushions including the pocketed coil spring assemblies.
  • the present invention includes pocketed coil spring assemblies having seams that are positioned between each of the pocketed coil springs and that allow one or more ends of each pocketed coil spring to move independently of an adjacent pocketed coil spring.
  • a support cushion includes a plurality of rows of pocketed coil springs with each of the rows of pocketed coil springs being substantially identical to one another and arranged side-by-side to form a matrix.
  • Each of the pocketed coil springs in each row are also substantially identical to one another with each of the pocketed coil springs including a coil spring surrounded by a flexible enclosure.
  • a seam is also positioned between each one of the plurality of pocketed coil springs and an adjacent one of the plurality of pocketed coil springs such that the seam connects each of the flexible enclosures of the pocketed coil springs.
  • an adhesive is also positioned between each row of pocketed coil springs and an adjacent row of pocketed coil springs to connect each of the rows of pocketed coils springs to one another.
  • each seam generally includes a top portion and a bottom portion and has a height substantially equal to the height of the each of the pocketed coil springs.
  • each seam defines a separation or further includes one or more welds that define a separation at the top portion of each seam to allow the upper ends of each of the pocketed coil springs to move independently of one another.
  • each seam includes a first weld that extends from adjacent the lower ends of two adjacent pocketed coil springs to a node positioned on the seam at a height less than the height of the seam.
  • a second weld then extends from the node to the upper end of one pocketed coil spring, and a third weld extends from the node to the upper end of the adjacent pocketed coil spring, such that the separation of the seam is defined by the second weld and the third weld and such that the seam and the welds have a Y-shaped configuration.
  • the seam includes a first weld that extends from adjacent the lower end to adjacent the upper end of one of the plurality of pocketed coil springs and a second weld that extends from adjacent the lower end to adjacent the upper end of an adjacent one of the plurality of pocketed coil springs.
  • the separation that is defined by the seam is then defined by the seam itself between the first weld and the second weld.
  • each seam comprises a first weld that extends from adjacent the lower end to adjacent the upper end of each one of the plurality of pocketed coil springs, a second weld that extends from adjacent the lower end to adjacent the upper end of an adjacent one of the plurality of pocketed coil springs, and a third weld that is positioned between the first weld and the second weld and that extends to a height less than that of the first weld and the second weld.
  • the separation defined by the seam in such an embodiment is then again defined by the seam itself between the first weld and the second weld and above the third weld.
  • the upper ends of each of the pocketed coils springs in one particular row are further configured to move independently of the upper ends of each of the pocketed coil springs in an adjacent row.
  • an adhesive is applied to the flexible enclosures of each of the pocketed coils springs in a particular row and in an adjacent row.
  • the adhesive is generally positioned on the flexible enclosure of the pocketed coil springs below the upper end of each pocketed coil spring so as to allow the top ends of the pocketed coil springs in adjacent rows to move independent of one another.
  • such an arrangement of the pocketed coils springs in the rows not only causes less interaction between the upper ends of the pocketed coil springs in a particular row and an adjacent row, but such an arrangement also provides a user resting on the mattress with an increased amount of
  • an exemplary support cushion can also be provided where there is no separation formed in the seam at all, but yet, because of the configuration of the adhesive positioned between the rows of pocketed coil spring assemblies, the exemplary support cushion is still capable of providing increased amounts of conformance and less motion transfer.
  • the flexible enclosures and the seams are typically made of a non- woven fabric that can be joined or welded together by heat and pressure (e.g., via ultrasonic welding or similar thermal welding procedure) to form a generally cylindrical construction for each flexible enclosure and a generally planar construction for each seam.
  • the coil spring of each of the pocketed coil springs is generally made of a continuous wire having a length and forming a plurality of convolutions that are each made up of a portion of the continuous wire substantially equal to about one turn of the continuous wire (i.e., about 360° of the helical path of the continuous wire).
  • the continuous wire of each coil spring forms an upper end convolution, a lower end convolution opposite the upper end convolution, and a number of intermediate helical convolutions that helically spiral between the lower end convolution and the upper end convolution.
  • the upper end convolution of each coil spring forms a substantially closed circular loop at the topmost portion of the coil spring, while the lower end convolution similarly forms a substantially closed circular loop at the lowermost portion of the coil spring. In this way, such a coil spring thus terminates at either end in a generally planar form that serves as the supporting end structures of the exemplary pocketed coil springs.
  • the upper end convolution, the intermediate helical convolutions, and the lower end convolution of each coil spring are generally arranged such that the coil spring has a lower section and an upper section. Further, by forming the coil spring from a continuous wire, the upper end convolution, the intermediate helical convolutions, and the lower end convolution each have a respective diameter, and the continuous wire also defines various pitches between the lower end convolution, the intermediate helical convolutions, and the upper end convolution.
  • the diameters, the pitches, or both the diameters and the pitches included in the coil springs that are utilized in the pocketed coil spring assemblies of the present invention are utilized in the pocketed coil spring assemblies of the present invention, however, a variable and non-linear loading response is provided in some embodiments where the upper section has a first spring constant that provides a softer feel as the spring is initially compressed, and where the lower section has a second spring constant that provides a firmer feel as the compression of the coil spring increases.
  • the seams of the exemplary pocketed coil spring assemblies are typically further configured such that the bottom portion of each seam is positioned adjacent to the lower end of the pocketed coil springs and, consequently, each seam is also positioned adjacent to the lower section of each coil spring.
  • the top portion of the seam i.e., where the separation is defined, if present
  • the adhesive is also generally positioned adjacent to the lower end of the pocketed coil springs and,
  • each coil spring is further positioned adjacent to the lower section of each coil spring.
  • the lower sections of each coil spring are thus generally secured in the lower end of the pocketed coil springs, while the upper sections of each coil spring are configured to move more independently.
  • the lack of connection between each upper section of each coil spring provides for additional freedom of movement and thus a greater degree of comfort to a user during the initial compression.
  • each of the pocketed coil spring assemblies described herein are particularly suited for use in a mattress and can be combined with one or more supporting or foundation layers.
  • an exemplary mattress is provided that further includes an upper body supporting layer positioned above the pocketed coil springs and a lower foundation layer positioned below the pocketed coil springs.
  • a sidewall then extends between the upper body supporting layer and the lower foundation layer and around the entire periphery of the two layers, such that the pocketed coil springs are completely surrounded.
  • the mattress can also include a cover that surrounds the upper body supporting layer, the sidewall, and the lower foundation layer to protect the underlying layers and the pocketed coil spring assemblies of the mattress.
  • FIG. 1 is a partial perspective view of a support cushion made in accordance with the present invention with a portion of the support cushion removed to show a plurality of rows of pocketed coil springs arranged to form a matrix;
  • FIG. 2 is a partial side view of the support cushion of FIG. 1 with a portion of the support cushion removed to show the pocketed coil springs connected by exemplary seams in accordance with the present invention
  • FIG. 3 is a partial side view of another exemplary support cushion made in accordance with the present invention with a portion of the support cushion removed to show a plurality of pocketed coil springs connected by another seam;
  • FIG. 4 is a partial side view of another exemplary support cushion made in accordance with the present invention with a portion of the support cushion removed to show a plurality of pocketed coil springs connected by another seam;
  • FIG. 5 is a partial perspective view of another exemplary support cushion made in accordance with the present invention with a portion of the support cushion removed to show a plurality of rows of pocketed coil springs arranged to form a matrix. DESCRIPTION OF EXEMPLARY EMBODIMENTS
  • the present invention includes pocketed coil spring assemblies and support cushions including the pocketed coil spring assemblies.
  • the present invention includes pocketed coil spring assemblies having seams that are positioned between each of the pocketed coil springs and that allow one or more ends of each pocketed coil spring to move independently of an adjacent pocketed coil spring.
  • a support cushion in the form of a mattress 10 is provided that includes a plurality of rows 12a, 12b, 12c of pocketed coil springs 20a, 20b, 20c, where each of the rows 12a, 12b, 12c are substantially identical to one another and are arranged side-by-side to form a matrix that, in turn, forms the spring core of the mattress 10.
  • Each of the pocketed coil springs 20a, 20b, 20c in each row 12a, 12b, 12c are also substantially identical to one another, with each of the pocketed coil springs 20a, 20b, 20c including a coil spring 30 surrounded by a flexible enclosure 50, and with each of the pocketed coil springs 20a, 20b, 20c having an upper end 22 and a lower end 24, as further discussed below.
  • a seam 60 is also positioned between and connects each one of the plurality of pocketed coil springs 20a, 20b, 20c in each of the rows 12a, 12b, 12c. In this regard, while FIG.
  • support cushions such as mattresses
  • support cushions can be produced including any number of seams as well as any number of pocketed coil springs or any number of rows in order to produce a support cushion having a desired length and/or width without departing from the spirit and scope of the present invention.
  • each seam 60 includes a top portion 62 and a bottom portion 64 and has a height substantially equal to the height of each of the pocketed coil springs 20a, 20b, 20c.
  • Each seam 60 further includes a first weld 72, a second weld 74, and a third weld 76, with the second weld 74 and the third weld 76 collectively defining a separation 66 at the top portion 62 of each seam 60. More specifically, and as shown in the seam 60 positioned between the initial two pocketed coils springs 20a, 20b in FIG.
  • the first weld 72 extends from between and adjacent to the lower end 24 of the two pocketed coil springs 20a, 20b up to a node 73 that is positioned on the seam 60 at a height less than that of the height of the total height of the seam 60, as discussed further below.
  • the second weld 74 then extends from the node 73 up to the upper end 22 of one of the pocketed coil springs 20a and a third weld 76 extends from the node 73 to the upper end 22 of the adjacent one of the pocketed coil springs 20b.
  • the separation 66 defined by the second weld 74 and the third weld 76 of the seam 60 thus extends downward from the uppermost end of the seam 60 substantially all of the way to the node 73, such that the seam 60 has a Y-shaped configuration.
  • Such a Y-shaped configuration then, in turn, allows the upper end 22 of one of the pocketed coil springs 20a to move independently of the upper end 22 of the adjacent one of the pocketed coil springs 20b in the particular row 12a.
  • the upper end 22 of one of the pocketed coil spring 20a, 20b, 20c moving independently of the upper end 22 of the adjacent one of pocketed coil springs 20a, 20b, 20c in a particular one of the rows 12a, 12b, 12c, by arranging the rows 12a, 12b, 12c of the pocketed coil springs 20a, 20b, 20c in a matrix, the upper ends 22 of each of the pocketed coil springs 20a, 20b, 20c in a particular one of the rows 12a, 12b, 12c are further capable of moving independently of the upper ends 22 of each of the pocketed coil springs in an adjacent one of the rows 12a, 12b, 12c.
  • an adhesive 80 is applied to the flexible enclosures 50 of each of the pocketed coils springs 20a, 20b, 20c in the particular row 12a and in the adjacent row 12b.
  • the adhesive 80 is generally positioned on the flexible enclosure 50 of the pocketed coil spring 20a below the upper end 22 of the pocketed coil spring and at a height substantially equal to or less than the height of the node 73 to allow the upper ends 22 of the pocketed coil spring 20a in each of the adjacent rows 12a, 12b to move independent of one another.
  • pocketed coils springs 20a, 20b, 20c in the rows 12a, 12b not only causes less interaction between the upper ends 22 of the pocketed coil springs 20a, 20b, 20c in the particular row 12a and the adjacent row 12b, but such an arrangement also provides a user resting on the mattress 10 with an increased amount of conformance to his or her body and less motion transfer across the entirety of the mattress 10.
  • adhesives are used in the exemplary
  • the flexible enclosures 50 and the seams 60 are typically made of a non- woven fabric that can be joined or welded together by heat and pressure (e.g., via ultrasonic welding or similar thermal welding procedure) to form a generally cylindrical construction for each flexible enclosure 50 and a generally planar construction for each seam 60.
  • suitable fabrics that can be used for the flexible enclosures 50 and the seams 60 can include one of various thermoplastic fibers known in the art, such as non- woven polymer-based fabric, non- woven polypropylene material, or non-woven polyester material.
  • the welds 72, 74, 76 of the seams 60 are typically formed via ultrasonic welding or other similar thermal welding procedures.
  • both the flexible enclosures and the seams of the support cushions described herein can be made of other flexible fabrics as well including both woven and non-woven textiles, thin flexible elastomers, paper, or other materials that offer a flexible structure.
  • the exemplary welds can then be formed by making use of an adhesive, stitching, metal staples, snaps, buttons, hook and loop fasteners, or other such means.
  • welding is inclusive of any suitable means of securely joining together two overlapping fabric layers either permanently or temporarily.
  • the coil spring 30 of each of the pocketed coil springs 20a, 20b, 20c is typically made of a continuous wire having a length and forming a plurality of convolutions 41, 42, 43, 44, 45, 46, 47, 48 that are each made up of a portion of the continuous wire substantially equal to about one turn of the continuous wire (i.e., about 360° of the helical path of the continuous wire).
  • the continuous wire of each coil spring 30 forms an upper end convolution 48, a lower end convolution 41 opposite the upper end convolution 48, and six intermediate helical convolutions 42, 43, 44, 45, 46, 47 that helically spiral between the lower end convolution 41 and the upper end convolution 48.
  • each coil spring 30 forms a substantially closed circular loop at the topmost portion of the coil spring 30, while the lower end convolution 41 similarly forms a substantially closed circular loop at the lowermost portion of the coil spring 30.
  • the coil spring 30 thus terminates at either end in a generally planar form that serves as the supporting end structures of the exemplary pocketed coil springs 20a, 20b, 20c.
  • the upper end convolution 48, the six intermediate helical convolutions 42, 43, 44, 45, 46, 47, and the lower end convolution 41 of each coil spring 30 are generally arranged such that the coil spring 30 has a lower section 32 and an upper section 34.
  • the lower section 32 of the coil spring 30 includes the lower end convolution 41, the first intermediate helical convolution 42, the second intermediate helical convolution 43, and the third intermediate helical convolution 44 (i.e., the three lower helical convolutions) and the upper section 34 of the coil spring 30 includes the fourth helical intermediate convolution 45, the fifth helical intermediate convolution 46, the sixth intermediate convolution 47 (i.e., the three upper helical convolutions), and the upper end convolution 48.
  • the continuous wire also defines a pitch between the lower end convolution 41 and the first intermediate helical convolution 42, a pitch between each one of the plurality of intermediate helical convolutions 42, 43, 44, 45, 46, 47, and a pitch between the sixth intermediate helical convolution 47 and the upper end convolution 48.
  • the spring constant and resultant feel of the coil spring are typically determined by the gauge of the wire forming the coil spring, the total number of convolutions in the coil spring, the size of the convolutions (diameter), and the pitch or vertical spacing (or pitch angle) between the convolutions.
  • the pitch (or vertical spacing) between each convolution of a coil spring is typically controlled by the rate at which the continuous wire, which forms the coil spring, is drawn through a forming die in a coil-forming machine.
  • a larger pitch will typically produce a stiffer coil spring due to the increased vertical orientation of the wire, while a smaller pitch will typically produce a softer coil spring and allow for a larger number of total convolutions in the coil body.
  • larger diameter convolutions in a coil spring also contribute to a lower spring constant and
  • the wire forming the coil spring is continuous, there is generally no defined beginning point or ending point of any single convolution.
  • the diameter and pitch is typically adjusted gradually between one portion of the spring to another.
  • a single convolution of a coil spring may not have just one single diameter or just one single pitch, but may include, for example, a beginning or end portion with a variable diameter and/or pitch that transitions to the adjacent convolution. Therefore, as used herein, the diameter and pitch of a convolution will typically refer to an average diameter and pitch, but can also be inclusive of a maximum diameter and pitch or a minimum diameter and pitch.
  • the wire gauge of the coil springs generally has a range of about 10 awg to about 20 awg, which includes, in some embodiments, a range of about 11 awg to about 17 awg, and, in other embodiments, a range of about 12 awg to about 16 awg.
  • a variable and non-linear loading response is provided in some embodiments where a first spring constant provides a softer feel as the spring is initially compressed and a second spring constant provides a firmer feel as the compression of the coil spring increases.
  • an exemplary pocketed coil spring can be configured to provide a nonlinear response to loading (i.e., where increased support is observed after the spring has been compressed an initial predetermined distance).
  • the diameters of the intermediate helical convolutions 42, 43, 44, 45, 46, 47, the lower end convolution 41, and the upper end convolution 48 are substantially equal to one another.
  • the pitch between certain of the intermediate helical convolutions 42, 43, 44, 45, 46, 47 is varied.
  • the pitch between the first intermediate helical convolution 42 and the second intermediate helical convolution 43 is greater than the pitch between the second intermediate helical convolution 43 and the third intermediate helical convolution 44
  • the pitch between the second intermediate helical convolution 43 and the third intermediate helical convolution 44 is greater than the pitch between the third intermediate helical convolution 44 and the fourth intermediate helical convolution 45.
  • the pitch between the fourth intermediate helical convolution 45 and the fifth intermediate helical convolution 46 as and the pitch between the fifth intermediate helical convolution 46 and the sixth intermediate helical convolution 47 are substantially equal to one another, with the pitch between the fourth intermediate helical convolution 45 and the fifth intermediate helical convolution 46 and the pitch between the fifth intermediate helical convolution 46 and the sixth intermediate helical convolution 47 being smaller than the pitch between the first intermediate helical convolution 42 and the second intermediate helical convolution 43, the pitch between the second intermediate helical convolution 43 and the third intermediate helical convolution 44, as well as the pitch between the third intermediate helical convolution 44 and the fourth intermediate helical convolution 45.
  • the pitches around the intermediate helical convolutions 42, 43, 44 that form the lower section 32 of the coil spring 30 are larger pitches that can, to a certain degree, be considered substantially equal to one another, such that the intermediate helical convolutions 42, 43, 44 that form the lower section 32 of each coil spring 30 exhibit a first spring constant.
  • the pitches around the intermediate helical convolutions 45, 46, 47 that form the upper section 34 of each coil spring 30 are substantially equal to one another, such that the intermediate helical convolutions 45, 46, 47 that form the upper section 34 exhibit a second spring constant.
  • each coil spring 30 has a diameter of about 60 mm and a total height of about 235 mm, with the continuous wire forming the coil spring 30 having a diameter of about 2 mm (i.e., a wire gauge of about 12 awg).
  • the pitch between first intermediate helical convolution 42 and the second intermediate helical convolution 43 is about 60 mm
  • the pitch between the second intermediate helical convolution 43 and the third intermediate helical convolution 44 is about 55 mm
  • the pitch between the third intermediate helical convolution 44 and the fourth intermediate helical convolution 45 is about 40 mm
  • the pitch between the fourth intermediate helical convolution 45 and the fifth intermediate helical convolution 46 is about 14 mm
  • the pitch between the fifth intermediate helical convolution 46 and the sixth intermediate helical convolution 47 is about 14 mm
  • the pitch between the sixth intermediate helical convolution 47 and the upper end convolution 48 is about 14 mm.
  • the seams 60 of the exemplary mattress 10 are configured such that the bottom portion 64 of each seam 60 is positioned adjacent to the lower end 24 of the pocketed coil springs 20a, 20b, 20c and, consequently, each seam 60 is also positioned adjacent to the lower section 32 of each coil spring 30.
  • the top portion 62 of the seam 60 i.e., where the separation 66 is defined
  • the separation 66 defined by each seam 60 is also positioned adjacent to the upper section 34 of each coil spring 30.
  • the adhesive 80 is also generally positioned on the flexible enclosure 50 of each of the pocketed coil springs 20a, 20b, 20c below the upper end 22 of the pocketed coil springs 20a, 20b, 20c and at a height substantially equal to or less than the height of the node 73. Consequently, the adhesive 80 is further generally positioned adjacent to the lower section 32 of each coil spring 30.
  • the lower section 32 of each coil spring 30 is thus generally secured in the lower end 24 of each of the pocketed coil springs 20a, 20b, 20c, while the upper section 34 of each coil spring 30 is configured to move more independently.
  • each coil spring 30 able to partially compress without necessarily causing any compression in other coil springs 30, but because of the different spring constants between the upper section 34 and the lower section 32 of each coil spring 30, the lack of connection between each upper section 34 of each coil spring 30 provides for additional freedom of movement and thus a greater degree of comfort to a user during the initial compression.
  • a separation can also be defined by the bottom portion of the seam or at both the top portion of the seam and the bottom portion of the seam.
  • a support cushion assembly can be provided similar to the embodiments described in FIGS. 1 and 2 above, but where the separation and the Y-shaped configuration of the seam or welds is positioned at the bottom portion of the seam instead of the top portion.
  • a seam can be provided that generally has an X- shaped configuration where two welds define a separation at the top portion of the seam and two additional welds define a separation at the bottom portion of the seam.
  • the separation defined by a seam of an exemplary pocketed coil spring assembly of the present invention is not directly defined by one or more welds, but rather is positioned between various welds in a particular row of a pocketed coil spring assembly.
  • a support cushion in the form of a mattress 110 is provided that, similar to the mattress 10 shown in FIGS. 1 and 2, includes a seam 160 that is positioned between one pocketed coil spring 120a and an adjacent pocketed coil spring 120b.
  • the seam 160 likewise includes a top portion 162 and a bottom portion 164, and has a height that is substantially equal to the height of each of the pocketed coil springs 120a, 120b.
  • the seam 160 also defines a separation 166 at the top portion 162 of the seam 160.
  • the seam 160 includes a first weld 172 that is positioned adjacent to one pocketed coil spring 120a and that has a height substantially equal to the pocketed coil spring 120a.
  • a second weld 174 is then positioned adjacent to the adjacent pocketed coil spring 120b and has a height substantially equal to that of the adjacent pocketed coil spring 120b. As shown in FIG.
  • the separation 166 of the seam 160 is then defined not by the first weld 172 and the second weld 174, but is rather defined by the seam 160 itself between the first weld 172 and the second weld 174 and at the top portion 162 of the seam 160.
  • a support cushion in the form of a mattress 210 is provided, which is similar to the mattress 110 described above with reference to FIG.
  • the seam 260 further includes a third weld 276 that is positioned between the first weld 272 and the second weld 274 and that only extends to a height less than the total height of the seam 260.
  • the separation 266 defined by the seam 260 is thus further positioned above the third weld 276.
  • an exemplary support cushion can also be provided where there is no separation formed in the seam at all, but yet, because of the configuration of the adhesive positioned between the rows of pocketed coil spring assemblies, the exemplary support cushion is still capable of providing increased amounts of conformance and less motion transfer across the entirety of the support cushion. For example, and referring now to FIG.
  • a support cushion in the form of a mattress 310 is provided that includes a plurality of rows 312a, 312b, 312c of pocketed coil springs 320a, 320b, 320c, with each of the rows 312a, 312b, 312c being substantially identical to one another and arranged side -by-side to form a matrix.
  • Each of the pocketed coil springs 320a, 320b, 320c in each row 312a, 312b, 312c are also substantially identical to one another, with each of the pocketed coil springs 320a, 320b, 320c including a coil spring 330 having an upper section 334 and a lower section 332 and surrounded by a flexible enclosure 350, and with each of the pocketed coil springs 320a, 320b, 320c having an upper end 322 and a lower end 324.
  • a seam 360 is also positioned between and connects each one of the plurality of pocketed coil springs 320a, 320b, 320c in each of the rows 312a, 312b, 312c.
  • each seam 360 includes a top portion 362 and a bottom portion 364 and has a height substantially equal to the height of each of the pocketed coil springs 320a, 320b, 320c.
  • Each seam 360 further includes a weld 372 that extends from the bottom portion 364 of each seam 360 to a height substantially less than the height of the seam 360 (e.g., to a height that is 50 to 75% the height of the seam 360) and, more specifically, to a height substantially equal to or less than a height of the lower section 332 of each coil spring 330.
  • an adhesive 80 is still applied to the flexible enclosures 50 of each of the pocketed coils springs 20a, 20b, 20c in one of the particular rows 312a, 312b, 312c (e.g., the row 312a) and an adjacent one of the rows 312a, 312b, 312c (e.g., the row 312b), and is generally positioned on the flexible enclosure 50 of the pocketed coil spring 20a substantially below the upper end 322 of each of the pocketed coil springs 320a, 320b, 320c to allow the upper ends 22 of the pocketed coil springs 320a, 320b, 320c in one of the rows 312a, 312b, 312c to move independently of the upper ends 22 of the pocketed coil springs 320a, 320b, 320c in an adjacent one of the rows 312a, 312b, 312c.
  • each of the pocketed coil spring assemblies described herein are particularly suited for use in a mattress and can be combined with one or more supporting or foundation layers. For instance, and referring once again to the mattress 10 shown in FIG.
  • the mattress 10 further comprises an upper body supporting layer 92 positioned above the plurality of pocketed coil springs 20a, 20b, 20c in each of the rows 12a, 12b, 12c, and a lower foundation layer 94 positioned below each of the pocketed coil springs 20a, 20b, 20c in each of the rows 12a, 12b, 12c. Furthermore, a sidewall 96 extends between the upper body supporting layer 92 and the lower foundation layer 94 around the entire periphery of the two layers 92, 94, such that the pocketed coil springs 20a, 20b, 20c in each of the rows 12a, 12b, 12c are completely surrounded.
  • the upper body supporting layer 92 and the sidewall 96 are each comprised of a visco-elastic foam to support the body of a user and provide a sufficiently soft surface on which to rest.
  • the lower foundation layer 94 is typically comprised of a piece of wood or other similarly rigid material capable of supporting the pocketed coil springs 20a, 20b, 20c in each of the rows 12a, 12b, 12c.
  • the upper body supporting layer 92 and the sidewall 96, as well as the lower foundation layer 94 can also be comprised of other materials or combinations of materials known to those skilled in the art, including, but not limited to foam, upholstery, and/or other flexible materials.
  • the exemplary support cushions described herein can further include a cover that surrounds and protects the various layers and spring assemblies of the support cushions.
  • the mattress 10 shown in FIG. 1 the mattress 10 further includes a cover 98 that surrounds the upper body supporting layer 92, the sidewall 96, and the lower foundation layer 94 to protect the underlying layers of the mattress 10.
  • covers are typically comprised of one or more textiles having a sufficient amount of durability to protect the underlying layers, but are also sufficiently breathable to allow adequate airflow and comfort to a user positioned on the support cushion.
  • such covers can also be comprised of one more flame-retardant materials.
  • support cushions shown in FIGS. 1-5 are in the form of mattresses 10, 110, 210, 310 and are typically dimensionally-sized to support a user lying in a supine or prone position, it is contemplated that the features described herein are equally applicable to seat cushions, seat backs, mattress topers, overlays, and the like.
  • the phrase "support cushion” is used herein to refer to any and all such objects having any size or shape, and that are capable of or are generally used to support the body of a user or a portion thereof.

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  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

La présente invention concerne un ensemble de ressorts hélicoïdaux à poche qui comprend une pluralité de ressorts hélicoïdaux à poche agencés dans une rangée. Chacun des ressorts hélicoïdaux à poche comprend un ressort hélicoïdal entouré par une enceinte flexible. Une couture est positionnée entre chacun de la pluralité de ressorts hélicoïdaux à poche et l'un adjacent de la pluralité de ressorts hélicoïdaux à poche. Chaque couture est configurée pour permettre qu'une ou plusieurs extrémités de chacun des ressorts hélicoïdaux à poche se déplacent indépendamment de l'extrémité correspondante de l'un adjacent des ressorts hélicoïdaux à poche. L'invention concerne en outre des coussins de support, tels que des matelas, qui comprennent une pluralité de tels ensembles de ressorts hélicoïdaux à poche agencés dans une matrice.
PCT/US2015/067775 2015-12-29 2015-12-29 Ensembles de ressorts hélicoïdaux à poche ayant des coutures séparées et coussins de support comprenant ceux-ci Ceased WO2017116406A1 (fr)

Priority Applications (2)

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US16/065,483 US20190000239A1 (en) 2015-12-29 2015-12-29 Pocket Coil Spring Assemblies Having Separated Seams and Support Cushions Including the Same
PCT/US2015/067775 WO2017116406A1 (fr) 2015-12-29 2015-12-29 Ensembles de ressorts hélicoïdaux à poche ayant des coutures séparées et coussins de support comprenant ceux-ci

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PCT/US2015/067775 WO2017116406A1 (fr) 2015-12-29 2015-12-29 Ensembles de ressorts hélicoïdaux à poche ayant des coutures séparées et coussins de support comprenant ceux-ci

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