Pocketed spring assembly having dimensionally stabilizing substrate

Patent metadata

Field	Value
Publication number	US-11013340-B2
Application number	US-201815987185-A
Country	US
Kind code	B2
Filing date	May 23, 2018
Priority date	May 23, 2018
Publication date	May 25, 2021
Grant date	May 25, 2021

Abstract

A pocketed spring assembly comprises a plurality of parallel strings of individually pocketed springs. A dimensionally stabilizing substrate is secured to at least some of the strings on one of the top and bottom surfaces of the strings. A scrim sleet is secured to at least some of the strings on an opposed surface of the strings to maintain the positions of the strings. The dimensionally stabilizing substrate is laterally rigid enough to maintain length and width dimensions of the coil spring assembly. However, the dimensionally stabilizing substrate is flexible enough to allow the pocketed spring assembly to be roll packed for shipping.

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 to form a pocketed spring assembly core, each of said strings comprising a plurality of individually pocketed springs, each of said strings 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 by transverse seams joining said first and second plies, at least one spring being positioned in each said pocket;
a dimensionally stabilizing substrate secured to one of top and bottom surfaces of at least some of the strings of the pocketed spring assembly core to create a pocketed spring assembly, said dimensionally stabilizing substrate comprising a sheet having a weight of at least two ounces per square yard and being made from a continuous filament, needled polyester with a resin binder;
a scrim sheet secured to the other of the top and bottom surfaces of said at least some of the strings of the pocketed spring assembly, wherein said dimensionally stabilizing substrate is at least twice as thick as the scrim sheet and more rigid than the scrim sheet;
cushioning materials; and
an upholstered covering encasing said pocketed spring assembly and cushioning materials.

2. A bedding or seating product comprising:
a pocketed spring assembly comprising a plurality of parallel strings of springs joined together to form a pocketed spring assembly core, each of said strings comprising a plurality of individually pocketed springs, each of said strings 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 by transverse seams joining said first and second plies, at least one spring being positioned in each said pocket;
a dimensionally stabilizing substrate secured to one of top and bottom surfaces of at least some of the strings of the pocketed spring assembly core to create a pocketed spring assembly, said dimensionally stabilizing substrate comprising a sheet having a weight of at least two ounces per square yard;
a scrim sheet secured to the other of the top and bottom surfaces of said at least some of the strings of the pocketed spring assembly;
wherein said dimensionally stabilizing substrate is at least twice as thick as the scrim sheet and more rigid than the scrim sheet and the dimensionally stabilizing substrate is flexible enough in the height of the pocketed spring assembly to allow the pocketed spring assembly to be roll packed.

3. The product of claim 2 wherein said scrim sheet is made of a non-woven polypropylene fabric.

4. The product of claim 2 wherein said scrim sheet is flexible in the X, Y and Z axis directions.

5. The product of claim 2 wherein the dimensionally stabilizing substrate resists being shorted in the Y axis direction when subject to a compressive force in the direction of the Y axis.

6. The product of claim 2 wherein the dimensionally stabilizing substrate is made from a continuous filament, needled polyester with a resin binder.

7. The product of claim 6 wherein the scrim sheet is made of a non-woven polypropylene fabric.

8. The product of claim 2 wherein the dimensionally stabilizing substrate comprising a sheet having a weight of at least 3.4 ounces per square yard.

9. The product of claim 2 wherein some of the individually pocketed springs are different than other individually pocketed springs of the pocketed spring assembly.

10. A pocketed spring assembly comprising:
a pocketed spring assembly core comprising parallel strings of springs joined together, each of said strings comprising a plurality of individually pocketed springs, each of said strings 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 by transverse seams joining said first and second plies, at least one spring being positioned in each said pocket;
a dimensionally stabilizing substrate made from a continuous filament, needled polyester with a resin binder and being secured to a portion of pocketed spring assembly core with adhesive, said dimensionally stabilizing substrate having a weight of at least two ounces per square yard; and
a scrim sheet secured to another portion of the pocketed spring assembly core with adhesive to facilitate handling of the pocketed spring assembly, the dimensionally stabilizing substrate being at least twice as thick as the scrim sheet and more rigid than the scrim sheet, but bendable for purposes of roll packing the pocketed spring assembly.

11. The pocketed spring assembly of claim 10 wherein said dimensionally stabilizing substrate is flexible in the direction of the Z axis only.

12. The pocketed spring assembly of claim 10 wherein said resin is corn starch.

13. The pocketed spring assembly of claim 10 wherein the scrim sheet is made of a non-woven polypropylene fabric.

14. The pocketed spring assembly of claim 10 wherein said springs are coil springs.

15. A pocketed spring assembly having a length, width and height, said 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 said strings 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 by transverse seams joining said first and second plies, at least one spring being positioned in each said pocket;
a dimensionally stabilizing substrate secured directly to either a top surface or a bottom surface of at least some of the strings, said dimensionally stabilizing substrate having a weight of at least two ounces per square yard;
a scrim sheet secured directly to the other surface of the top and bottom surfaces of said at least some of the strings,
said dimensionally stabilizing substrate being at least twice as thick as the scrim sheet, wherein said dimensionally stabilizing substrate does not bunch upwardly and form an irregular pattern as the scrim sheet does when subjected to the same force.

16. The pocketed spring assembly of claim 15 wherein the dimensionally stabilizing substrate is made from a continuous filament, needled polyester with a resin binder.

17. The pocketed spring assembly of claim 16 wherein said resin is corn starch.

18. The pocketed spring assembly of claim 15 wherein said dimensionally stabilizing substrate has a weight of 3.5 ounces per square yard.

19. The pocketed spring assembly of claim 15 wherein the scrim sheet is flexible in the direction of the length and width of the coil spring assembly.

20. The pocketed spring assembly of claim 15 wherein the scrim sheet is made of non-woven polypropylene fabric;
the fabric of the string of springs is made of non-woven polypropylene.

Assignees

• L&P Property Man Co

Inventors

• Jewett Jason V
• Nyhues Carsten
• Reading Scott D

Classifications

• A47C27/066

  Edge stiffeners · CPC title

• A47C27/062

  of different resiliencies · CPC title

• A47C27/05

  with {padding material, e.g.} foamed material, in top, bottom, or side layers · CPC title

• A47C27/07

  Attaching, or interconnecting of, springs in spring inlays · CPC title

• A47C7/35

  Combinations of different types of springs; Adjustable springs; Attachment of springs to other springs or to {the base} frame {; Springs for seat parts not provided for in other groups of this subclass} · CPC title