Multi-layered impermeable fabric for use in pocketed spring assembly

Patent metadata

Field	Value
Publication number	US-10034553-B2
Application number	US-201615062595-A
Country	US
Kind code	B2
Filing date	Mar 7, 2016
Priority date	Mar 7, 2016
Publication date	Jul 31, 2018
Grant date	Jul 31, 2018

Abstract

A pocketed spring assembly comprises a plurality of parallel strings of individually pocketed springs. Each string is joined to at least one adjacent string. Each string has first and second opposed plies of fabric and a plurality of pockets formed along a length of the string by transverse segmented seams joining the plies. Gaps between the segments of the seams allow air to pass into and out of the pockets despite the fabric being impermeable to airflow through the fabric. The size of the gaps determines the firmness or “feel” of the pocketed spring assembly or portion thereof.

First claim

What is claimed is:

1. A bedding or seating product comprising:
a pocketed spring assembly comprising a plurality of parallel strings of springs joined together, each of said strings of springs comprising a plurality of individually pocketed springs, each of said strings of springs comprising a piece of fabric joined along a segmented longitudinal seam, first and second opposed plies of fabric being on opposite sides of the springs, a plurality of pockets being formed along a length of said string of springs by segmented transverse seams joining said first and second plies, at least one spring being positioned in each said pocket, wherein the piece of fabric is impermeable to airflow, but upon being subjected to a load, air inside the pocket exits the pocket through gaps between segments of the seams and the piece of fabric comprises a layer of non-woven material, a layer of thermoplastic film impermeable to airflow and a layer of lofted needle punch polyester fiber batting, the piece of fabric being oriented such that the layer of non-woven material is closest to the springs;
cushioning materials; and
an upholstered covering encasing said pocketed spring assembly and cushioning materials.

2. A pocketed spring assembly for use in a bedding or seating product, the pocketed spring assembly comprising:
a plurality of parallel strings of springs joined together, each of said strings of springs comprising a plurality of individually pocketed springs, each of said strings of springs comprising a piece of fabric joined along a longitudinal seam, first and second opposed plies of fabric being on opposite sides of the springs, a plurality of pockets being formed along a length of said string of springs by transverse seams joining said first and second plies, at least one spring being positioned in each said pocket, wherein the piece of fabric is impermeable to airflow, but upon the pocket being subjected to a load, air inside the pocket exits the pocket through gaps between segments of the seams and the piece of fabric comprises a layer of non-woven material, a layer of thermoplastic film impermeable to airflow and a layer of lofted needle punch polyester fiber batting, the piece of fabric being oriented such that the layer of non-woven material is closest to the springs.

3. The pocketed spring assembly of claim 2 wherein the layer of non-woven material is polypropylene.

4. The pocketed spring assembly of claim 3 wherein the piece of fabric comprises three layers.

5. The pocketed spring assembly of claim 2 wherein the layer of thermoplastic film is polyurethane.

6. The pocketed spring assembly of claim 2 wherein the layer of non-woven material protects the layer of thermoplastic film from contacting the springs.

7. The pocketed spring assembly of claim 2 wherein the layer of non-woven material acts as a protective layer.

8. The pocketed spring assembly of claim 2 wherein the layer of lofted needle punch polyester fiber batting functions as a sound attenuating layer.

9. A fabric for use in a pocketed spring assembly, said fabric comprising:
a first layer of protective material;
a second layer impermeable to airflow; and
a third layer of sound attenuating material comprising lofted needle punch polyester fiber batting secured to the second layer to prevent noise when the pocketed spring assembly is compressed and expanded.

10. The fabric of claim 9 wherein the second and third layers are glued together.

11. The fabric of claim 9 wherein the fabric forms a pocket of the pocketed spring assembly, the pocket surrounding a spring inside the pocket, the first layer being closest to the spring.

12. The fabric of claim 11 wherein the second layer is sandwiched between the first and third layers.

13. The fabric of claim 9 wherein the three layers are laminated together.

14. The fabric of claim 9 wherein the fabric forms multiple pockets of a string of springs for use in the pocketed spring assembly, each pocket surrounding at least one spring inside the pocket, the first layer of the fabric being closest to the springs.

15. A method of making a fabric for use in a pocketed spring assembly, said method comprising:
creating a stack comprising a layer of protective material, a glue layer, a middle layer impermeable to airflow and a sound attenuating layer comprising lofted needle punch polyester fiber batting;
passing the stack through a laminator to create a finished fabric;
rolling up the finished fabric.

16. The method of claim 15 wherein the glue layer melts in the laminator.

17. The method of claim 15 wherein the sound attenuating layer is secured to the middle layer by the glue to create a sound dampening layer in the finished fabric.

18. A method of making a pocketed spring assembly for use in a bedding or seating product, the method comprising:
joining a plurality of parallel strings of springs together, each of said strings of springs comprising a plurality of individually pocketed springs, each of said strings of springs comprising a piece of fabric joined along a longitudinal seam, first and second opposed plies of fabric being on opposite sides of the springs, a plurality of pockets being formed along a length of said string of springs by transverse seams joining said first and second plies, at least one spring being positioned in each said pocket, wherein the piece of fabric is impermeable to airflow, but air inside the pocket exits and enters the pocket through gaps between segments of the seams, the piece of fabric comprising a layer of polypropylene non-woven material, a layer of thermoplastic polyurethane film impermeable to airflow and a layer of lofted needle punch polyester fiber batting.

19. The method of claim 18 wherein the piece of fabric is oriented such that the layer of polypropylene non-woven material is closest to the springs.

20. The method of claim 18 wherein the piece of fabric comprises three layers.

21. A method of making a pocketed spring assembly for use in a bedding or seating product, the method comprising:
joining a plurality of parallel strings of springs together, each of said strings of springs comprising a plurality of individually pocketed springs, each of said strings of springs comprising a piece of fabric joined along a longitudinal seam, first and second opposed plies of fabric being on opposite sides of the springs, a plurality of pockets being formed along a length of said string of springs by transverse seams joining said first and second plies, at least one spring being positioned in each said pocket, wherein the piece of fabric is impermeable to airflow, but air inside the pocket exits and enters the pocket through gaps between segments of the seams and wherein the piece of fabric comprises multiple layers, including lofted needle punch polyester fiber batting and the layer of lofted needle punch polyester fiber batting is the furthest layer away from the springs.

22. A method of making a pocketed spring assembly, the method comprising:
joining a plurality of parallel strings of springs together, each of said strings of springs comprising a plurality of individually pocketed springs, each of said strings of springs comprising a piece of fabric joined along a longitudinal seam, first and second opposed plies of fabric being on opposite sides of the springs, a plurality of pockets being formed along a length of said string of springs by transverse segmented seams joining said first and second plies, at least one spring being positione

Assignees

• L&P Property Man Co

Inventors

• Long Austin G

Classifications

• A47C27/008

  protecting against wear or damage · CPC title

• A47C27/064 Primary

  Pocketed springs · CPC title

• A47C27/007

  permeable to liquid or air in a special way (A47C27/006 takes precedence) · CPC title

• B68G9/00

  Placing upholstery springs in pockets; Fitting springs in upholstery · CPC title