Pocketed spring comfort layer and method of making same

Patent metadata

Field	Value
Publication number	US-9943173-B2
Application number	US-201514879672-A
Country	US
Kind code	B2
Filing date	Oct 9, 2015
Priority date	Feb 13, 2015
Publication date	Apr 17, 2018
Grant date	Apr 17, 2018

Abstract

A comfort layer for a bedding or seating product has slow-acting pockets characterized by the individual springs of the comfort layer being pocketed with either semi-impermeable or non-permeable fabric. Each seam joining opposed plies of fabric around each of the coil springs of the comfort layer may be segmented, allowing air to flow between the segments, thereby increasing the luxury “feel” of the comfort layer. The method of making the comfort layer includes compressing the springs and creating pockets with a welding horn and an anvil.

First claim

We claim:

1. A comfort layer configured to overlay a spring core of a bedding or seating product, said comfort layer comprising:
a matrix of interconnected mini pocketed springs, each mini coil spring of which is contained within a pocket, said pocket being semi-impermeable to airflow through said pocket and having a rectangular weld seam around the pocket joining first and second pieces of fabric of the pocket, each rectangular weld seam having four side seams, each side seam comprising multiple linear weld segments;
said comfort layer being characterized, when a load is placed upon the comfort layer, by the rate of compression of at least some of the mini coil springs inside some of the pockets of the comfort layer being at least partially retarded by the rate at which air escapes through the fabric of the pocket and through gaps between the linear weld segments joining the first and second pieces of fabric along each side seam of each rectangular weld seam, the rate of compression of the mini coil springs being slowed by the size of the gaps between the linear weld segments.

2. The comfort layer of claim 1 wherein the linear weld segments of the pocket are the same size.

3. The comfort layer of claim 1 wherein the rate of return of the mini coil springs in the pockets is slowed by the piece of fabric and the size of the gaps between the linear weld segments of the rectangular weld seams.

4. The comfort layer of claim 1 wherein linear weld segments of said segmented seams of said pockets are evenly spaced from each other.

5. A comfort layer configured to overlay a spring core of a bedding or seating product, said comfort layer comprising:
a matrix of mini coil springs;
a first piece of fabric semi-impermeable to airflow through the fabric on one side of the matrix of mini coil springs;
a second piece of fabric semi-impermeable to airflow through the fabric on another side of the matrix of mini coil springs, the first and second pieces of fabric being joined with rectangular weld seams comprising linear weld segments around each of the mini coil springs to create gaps between the first and second pieces of fabric and individual pockets which contain the mini coil springs,
said comfort layer being characterized, when at least some of the mini coil springs in at least some of the pockets are subjected to a load air moves between the pockets through the gaps between the linear weld segments of the rectangular weld seams and exits perimeter pockets into the atmosphere, the rate of compression of the mini coil springs being slowed by the size of the gaps between the linear weld segments of the rectangular weld seams and the fabric semi-impermeable to airflow through the fabric.

6. The comfort layer of claim 5 wherein said linear weld segments are the same size.

7. The comfort layer of claim 5 wherein the rate of return of the mini coil springs in the pockets is slowed by the pieces of fabric and the size of the gaps between the linear weld segments of the rectangular weld seams.

8. The comfort layer of claim 5 wherein at least one of said pieces of fabric comprises multiple layers.

9. The comfort layer of claim 5 wherein each of said pieces of fabric comprises multiple layers.

10. A comfort layer configured to overlay a spring core of a bedding or seating product, said comfort layer comprising:
mini coil springs;
a first piece of fabric on one side of the mini coil springs;
a second piece of fabric on another side of the mini coil springs, the first and second pieces of fabric being joined with rectangular weld seams comprising linear weld segments around each of the mini coil springs to create gaps of the same size between the linear weld segments and individual pockets which contain the mini coil springs, at least one of the pieces of fabric being semi-impermeable to airflow through the fabric,
said comfort layer being characterized, when at least some of the pockets are subjected to a load air moves between the pockets through the gaps between the segments of the seams and exits perimeter pockets into the atmosphere, the rate of compression of the mini coil springs being slowed by the size of the gaps between the linear weld segments of the rectangular weld seams and the fabric semi-impermeable to airflow through the fabric.

11. The comfort layer of claim 10 wherein at least one of said pieces of fabric comprises multiple layers.

12. The comfort layer of claim 10 wherein each of said first and second pieces of fabric comprises multiple layers.

13. The comfort layer of claim 10 wherein at least one of said pieces of fabric comprises at least one layer of woven fabric material.

14. The comfort layer of claim 10 wherein at least one of said first and second pieces of fabric has a coating.

15. The comfort layer of claim 10 wherein said mini coil springs in a relaxed condition are approximately two inches tall.

16. The comfort layer of claim 10 wherein at least some of said mini coil springs have a barrel shape.

Assignees

• L&P Property Man Co

Inventors

• Krtek Richard A
• Long Austin G
• Rhea Eric
• Richmond Darrell A

Classifications

• B21F27/16

  for spring mattresses · CPC title

• A47C27/064 Primary

  Pocketed springs · CPC title

• B68G9/00

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

• A47C27/05

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

• A47C21/046

  without active means, e.g. with openings or heat conductors · CPC title