Pocket coil spring assembly including flexible foam

Patent metadata

Field	Value
Publication number	US-9936815-B2
Application number	US-201514717245-A
Country	US
Kind code	B2
Filing date	May 20, 2015
Priority date	May 30, 2014
Publication date	Apr 10, 2018
Grant date	Apr 10, 2018

Abstract

A pocket coil spring assembly is provided that includes a coil spring having an upper portion and a lower portion collectively defining an interior cavity of the coil spring. The pocket coil spring assembly further includes a fabric pocket encasing the coil spring with a top area covering the upper portion of the coil spring and a bottom area covering the lower portion of the coil spring. An amount of flexible foam is positioned in the interior cavity of the coil spring such that a top surface of the flexible foam extends above the coil spring. A mattress assembly is further provided that includes a plurality of the pocket coil spring assemblies.

First claim

What is claimed is:

1. A pocket coil spring assembly, comprising:
a coil spring having an upper portion and a lower portion, the upper portion and the lower portion collectively defining an interior cavity of the coil spring;
a fabric pocket encasing the coil spring, the fabric pocket including a top area covering the upper portion of the coil spring and a bottom area covering the lower portion of the coil spring; and
an amount of flexible foam positioned in the interior cavity of the coil spring and having a top surface that extends above the coil spring, wherein a portion of fabric of the fabric pocket is disposed between the flexible foam and the coil spring.

2. The pocket coil spring assembly of claim 1 , wherein the top area of the fabric pocket defines a recess extending into the interior cavity of the coil spring, and wherein the flexible foam is positioned in the recess.

3. The pocket coil spring assembly of claim 2 , wherein the top area of the fabric pocket is connected to the bottom area of the fabric pocket within the interior cavity of the coil spring to thereby define the recess.

4. The pocket coil spring assembly of claim 3 , wherein the coil spring has a height and the recess extends into the interior cavity of the coil spring to about half of the height of the coil spring.

5. The pocket coil spring assembly of claim 1 , wherein the top surface of the flexible foam has a convex shape.

6. The pocket coil spring assembly of claim 1 , wherein the fabric pocket further encases the flexible foam.

7. The pocket coil spring assembly of claim 6 , wherein the amount of flexible foam is sufficient to fill substantially all of the interior cavity of the coil spring.

8. The pocket coil spring assembly of claim 1 , wherein the fabric pocket is comprised of a non-woven textile.

9. The pocket coil spring assembly of claim 1 , wherein the flexible foam is comprised of a visco-elastic foam.

10. The pocket coil spring assembly of claim 1 , wherein the flexible foam is comprised of a gel.

11. The pocket coil spring assembly of claim 1 , wherein the flexible foam is bonded to the fabric pocket.

12. A spring core, comprising:
a plurality of coil springs, each coil spring defining an interior cavity;
a continuous sheet covering each coil spring; and
an amount of flexible foam positioned in the interior cavity of each coil spring, and having a top surface that extends above each coil spring, wherein at least a portion of said continuous sheet is disposed between the flexible foam and the coil spring.

13. The spring core of claim 12 , wherein the continuous sheet defines a recess extending into the interior cavity of each coil spring, and wherein the flexible foam is positioned in each recess.

14. A mattress assembly, comprising:
a spring core having a first support surface and a second support surface opposite the first support surface, the spring core including
a plurality of coil springs, each coil spring having an upper portion and a lower portion, the upper portion and the lower portion collectively defining an interior cavity of each coil spring,
a plurality of fabric pockets, each fabric pocket encasing one of the coil springs, and including a top area covering the upper portion of each coil spring and a bottom area covering the lower portion of each coil spring, wherein the top area of the fabric pocket defines a recess extending into the interior cavity of the coil spring, and
further wherein the top area of the fabric pocket is connected to the bottom area of the fabric pocket within the interior cavity of the coil spring;
an amount of flexible foam positioned in the recess in the interior cavity of each coil spring and having a top surface that extends above each coil spring;

an upper body supporting layer positioned adjacent to the first support surface of the spring core; and
a lower foundation layer positioned adjacent to the second support surface of the spring core.

15. The mattress assembly of claim 14 , wherein the top area of each fabric pocket defines a recess extending into the interior cavity of each coil spring, and wherein the flexible foam is positioned in each recess.

16. The mattress assembly of claim 14 , wherein the top surface of the flexible foam has a convex shape.

17. The mattress assembly of claim 14 , further comprising a continuous sheet covering the upper portion of each coil spring.

18. The mattress assembly of claim 17 , wherein the flexible foam is positioned atop the continuous sheet.

19. The mattress assembly of claim 17 , wherein for each fabric pocket, a portion of the continuous sheet forms the top area of the fabric pocket.

Assignees

• Sealy Technology Llc

Inventors

• Demoss Larry K
• Thomas Darin T
• Manuszak Brian M
• Wallace Stephen

Classifications

• A47C27/064

  Pocketed springs · CPC title

• A47C27/056

  with different layers of foamed material · CPC title

• A47C27/20 Primary

  with springs moulded in, or situated in openings in foamed material · CPC title

• A47C27/0456

  Use of stiffening sheets, lattices or grids in, on, or under, spring inlays · CPC title

• A47C23/04

  using springs in compression, e.g. coiled · CPC title