Dual-layered fabric for use in pocketed spring assembly

Patent metadata

Field	Value
Publication number	US-10722044-B2
Application number	US-201816003809-A
Country	US
Kind code	B2
Filing date	Jun 8, 2018
Priority date	Jun 27, 2017
Publication date	Jul 28, 2020
Grant date	Jul 28, 2020

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 seams joining the plies. At least one spring is positioned in each of the pockets. The double-layered fabric used to make at least some strings comprises two layers of non-woven spunbonded polypropylene fabric to reduce noise. The layers may be ultrasonically welded or point bonded together.

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 the strings of springs comprising a plurality of individually pocketed springs, each of the strings of springs comprising a dual layered combination of fabric, the dual layered combination of fabric being joined to itself along a longitudinal seam joining four plies, the dual layered combination of fabric having first and second opposed sides covering opposite surfaces of the springs, two plies being on each of the opposed sides, a plurality of pockets being formed along a length of the string of springs by transverse seams joining the first and second sides, at least one spring being positioned in each said pocket, wherein the dual layered combination of fabric comprises only two layers of non-woven fabric;
cushioning materials; and
a covering encasing the 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 pocketed spring assembly comprising a plurality of parallel strings of springs joined together, each of the strings of springs comprising a plurality of individually pocketed springs, each of the strings of springs comprising a dual layered combination of fabric, the dual layered combination of fabric being joined to itself along a longitudinal seam joining four plies, the dual layered combination of fabric having first and second opposed sides covering opposite surfaces of the springs, two plies being on each of the opposed sides, a plurality of pockets being formed along a length of the string of springs by transverse seams joining the first and second sides, at least one spring being positioned in each said pocket, wherein the dual layered combination of fabric comprises only two layers of non-woven fabric.

3. The pocketed spring assembly of claim 2 wherein the two layers of non-woven fabric are identical.

4. The pocketed spring assembly of claim 2 wherein at least one of the layers comprises non-woven spunbonded polypropylene fabric.

5. The pocketed spring assembly of claim 2 wherein the layers of non- woven fabric are joined together at multiple locations.

6. The pocketed spring assembly of claim 2 wherein the layers of non- woven fabric are ultrasonically welded together at multiple locations.

7. The pocketed spring assembly of claim 2 wherein each of the layers of non-woven fabric has a weight of 0.5 to 1.5 ounces per square yard.

8. The pocketed spring assembly of claim 2 wherein each of the layers of non-woven fabric has the same weight.

9. The pocketed spring assembly of claim 2 wherein the layers of non- woven fabric have different weights.

10. 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 comprising a plurality of individually pocketed springs, each of the strings being formed from a set of aligned non-woven spunbonded polypropylene fabric pieces, said aligned set of fabric pieces being joined to itself along a longitudinal seam joining four plies and having first and second opposed sides of fabric covering opposite surfaces of the springs, two plies being on each of the first and second opposed sides, a plurality of pockets being formed along a length of the string by transverse seams joining the first and second sides of the fabric, at least one spring being positioned in each of the pockets, wherein the longitudinal seam and each of the transverse seams joins four pieces of fabric together.

11. The pocketed spring assembly of claim 10 wherein the set comprises two pieces of non-woven spunbonded polypropylene fabric ultrasonically welded together along opposed side edges of the pieces of fabric.

12. The pocketed spring assembly of claim 11 wherein the two pieces of non-woven spunbonded polypropylene fabric are identical.

13. The pocketed spring assembly of claim 10 wherein each of the pieces of non-woven spunbonded polypropylene fabric has a weight of 0.5 to 1.5 ounces per square yard.

14. The pocketed spring assembly of claim 11 wherein the two pieces of non-woven spunbonded polypropylene fabric are ultrasonically welded together only along opposed side edges of the pieces of fabric.

15. The pocketed spring assembly of claim 10 wherein at least one of the pieces of non-woven spunbonded polypropylene fabric has a weight of 0.5 to 1.5 ounces per square yard.

16. The pocketed spring assembly of claim 10 wherein each of the pieces of non-woven spunbonded polypropylene fabric has the same weight.

17. The pocketed spring assembly of claim 10 wherein the pieces of non- woven spunbonded polypropylene fabric have different weights.

18. A method of making a fabric for use in a pocketed spring assembly, said method comprising:
creating a web of double-layered non-woven spunbonded polypropylene fabric from two rolls of single-layered non-woven spunbonded polypropylene fabric;
passing the web of double-layered non-woven spunbonded polypropylene fabric through an apparatus to create a finished non-woven spunbonded polypropylene fabric; and
using the finished non-woven spunbonded polypropylene fabric to create a string of springs, the string having at least one seam joining four plies of fabric and having two plies on each of opposite sides of the string of springs.

19. The method of claim 18 wherein the finished non-woven spunbonded polypropylene fabric is point bonded.

20. The method of claim 18 wherein the apparatus creates welds along edges of the web of double-layered non-woven spunbonded polypropylene fabric.

21. The method of claim 18 wherein the apparatus creates continuous welds along edges of the web of double-layered non-woven spunbonded polypropylene fabric.

22. A string of springs for use in a pocketed spring assembly, the string of springs comprising:
a plurality of individually pocketed springs, said string of springs comprising a dual layered combination of fabric joined to itself along a longitudinal seam joining four plies of the dual layered combination of fabric, first and second opposed sides of the dual layered combination of fabric being on opposite sides of the springs, two plies being on each of the opposed sides of the springs, a plurality of pockets being formed along a length of the string by transverse seams joining four plies of the dual layered combination of fabric, at least one spring being positioned in each of the pockets, wherein the dual layered combination of fabric comprises two layers of non-woven spunbonded polypropylene fabric.

23. The string of springs of claim 22 wherein the two layers are ultrasonically welded together.

24. The string of springs of claim 22 wherein the two layers are made of the same fabric.

25. A method of making a fabric for use in a pocketed spring assembly, said method comprising:
unrolling a web of double-layered fabric from a roll of double-layered fabric, each of the layers comprising non-woven spunbonded polypropylene fabric;
passing the web of double-layered fabric through a welder to create a finished fabric;
creating a string of springs with the finished fabric, the string having a longitudinal seam and transverse seams, each of the seams joining four plies of fabric and the finished fabric having two pli

Assignees

• L&P Property Man Co

Inventors

• Jewett Jason
• Richmond Darrell A

Classifications

• A47C27/063

  wrapped or otherwise protected · CPC title

• B32B37/0084

  Point bonding · CPC title

• B29C66/133

  Fin-type joints, the parts to be joined being flexible (the parts to be joined being rigid B29C66/1312) · CPC title

• B29C66/836

  Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table (B29C66/65 takes precedence) · CPC title

• B32B2310/028

  using vibration, e.g. sonic or ultrasonic · CPC title