Pocket spring mattress
Patent Information
- Application Number
- BR112015014296
- Authority / Receiving Office
- BR · BR
- Patent Type
- Patents
- Current Assignee / Owner
- Publication Date
- 2026-08-25
- Estimated Expiration
- Not applicable · inactive patent
Smart Images
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Abstract
Description
1 / 20 Pocket spring mattress TECHNICAL FIELD OF THE INVENTION
[001] The present invention relates to a pocket spring mattress comprising helical springs enclosed in pockets, as well as to a method and a device for manufacturing such a mattress. BACKGROUND OF THE INVENTION
[002] A common technique for manufacturing spring mattresses is known as the pocket technique. According to this technique, the springs are enclosed in pockets, that is, they are individually enclosed by a covering material. In this way, the springs are relatively and individually resilient, so that they can flex individually without affecting the springs next to them, and thus the comfort to the user increases, since their weight is, in this way, distributed more evenly from the surface that receives the load.
[003] One disadvantage of such a mattress is, however, that each pocket, when expanded with a coil spring, generally creates a portion of cover material that protrudes from the surface of the spring mattress, commonly known as “false bulges”. These protruding portions of cover material create an uneven surface of the pocket spring mattress and do not contribute to enhancing the comfort of the pocket spring mattress. On the contrary, this can lead to different parts of the pocket spring mattress becoming sunken to varying degrees during use, so that the surface of the spring mattress Petition 870210032630, dated 09 / 04 / 2021, page 9 / 16 2 / 20 pocket springs can become rough and less comfortable. The unevenness and deformation of the surface also give the appearance of a rather old and worn mattress, even after a very short period of use. An additional problem arising from a mattress surface with false elevations is that it can be difficult to attach an additional layer, such as a quilted layer, to the surface, as there is a risk that the additional layer will only adhere to the false elevations. The quilted layer could be, for example, a polyester sheet. In this way, the additional layer not only becomes poorly adhered to the pocket spring mattress, but there is also a significant risk of deformation, folding, and unevenness of the additional layer. Thus, attaching an additional layer to the pocket spring mattress can exacerbate the problems mentioned above.
[004] Consequently, there is a need for a mattress that alleviates or prevents the problems mentioned above. SUMMARY OF THE INVENTION
[005] Therefore, an objective of the present invention is to overcome, at least in part, these problems and provide an improved pocket spring mattress with a regular smooth surface that prevents false elevations, with transverse seams folded back.
[006] One of the objectives of the present invention, therefore, is to provide a pocket spring mattress of the type defined in the introduction, a method and a device for manufacturing said mattress, whereby the disadvantages mentioned above are completely or at least partially eliminated.
[007] This goal is achieved with a mattress 3 / 20 of a pocket spring mattress and by means of a method and device for manufacturing said pocket spring mattress in the manner defined in the appended claims. These and other objectives become evident below.
[008] According to a first aspect of the invention, a pocket spring mattress is provided comprising helical springs arranged as spring units enclosed in a covering material that forms pockets, wherein the spring units are successively arranged in elongated cords, wherein the mattress comprises a plurality of such interconnected cords arranged side by side, wherein the elongated cords have a plurality of transverse seams arranged parallel to the longitudinal direction of the helical springs to separate the pockets, wherein a middle portion of the transverse seams fixes at least one layer of covering material from both sides of the spring unit to each other, characterized in that at least some of the transverse seams are backward-folded transverse seams,in which the covering material near an end portion of the backfolded transverse seams is folded back toward the middle portion of the transverse seams, whereby each of the backfolded transverse seams has at least one end portion that secures at least twice as many layers of covering material as in a corresponding transverse seam that is not backfolded.
[009] The present invention is based on the perception that a pocket spring mattress can be provided with a regular surface and that it avoids the problems 4 / 20 with false bulges, folding the cover material back towards the elongated cord that secures the folded-back cover material with seams. It is known that, by folding back, a very smooth and flat surface of the pocket spring mattress is achievable and that it completely, or at least partially, avoids any protruding “false bulges”. In this way, improved comfort is obtained, and, moreover, the attachment of additional layers becomes simpler and better. The mattress is also less susceptible to deformation in various ways, thus maintaining a good appearance for a much longer time. Furthermore, the solution is relatively simple and allows for cost-effective production. For example, this step can be achieved with an in-line step in the manufacture of conventional automated pocket spring mattresses.
[010] “False ridges” should be understood herein as a covering material that projects from the surface of the pocket spring mattress and / or the pocket cords, thus creating an uneven surface that can cause a reduction in comfort and a less pleasing visual appearance. By making a pocket spring mattress with a regular surface, the pocket spring mattress is more comfortable and lasts longer during use without the pocket spring mattress becoming unevenly sunken across the surface, which creates a rough appearance. In addition, the pocket spring mattress also enhances the perception of a well-made pocket spring mattress.
[011] In the context of the present application, “back-folded transverse seams” should be understood as transverse seams that fasten twice 5 / 20 more layers of cover material are secured at the end portion(s) than at a corresponding cross seam that does not have such a backfold. In most cases, this also means that backfolded cross seams at the backfolded end portion(s) essentially secure twice as many layers of cover material as at a middle portion of the cross seams. Backfolded cross seams thus reduce protruding cover material. The double layer of cover material is a result of backfolded cover material being folded back near the end portions of successive springs in the longitudinal direction of the coil springs. Whereas at the point where the cross seam secures, generally two layers of cover material, backfolded cross seams can secure at least four layers of cover material.
[012] The middle portion of the transverse seams should be understood as a portion of the transverse seams close to a centerline along the longitudinal direction of the elongated cord. Back-folded cover material, when not folded back towards a centerline of the elongated cord, can create false bulges. False bulges can arise by enclosing the helical springs in rectangular pockets.
[013] The backfold in the backfolded transverse seams may be arranged on one or both end portions of the elongated cord in the transverse direction. The longitudinal direction of the springs should be understood, hereinafter, as the direction of compression of the 6 / 20 springs. The springs, when enclosed in the elongated cord, are arranged so that the longitudinal direction of the spring coincides with the transverse direction of the transverse seams of the elongated cord.
[014] The backward-folded cover material may preferably be folded between the layers of cover material enclosing the coil springs. However, the backward-folded cover material may also be folded to an outer side of the cover material.
[015] The elongated cord should be understood, hereinafter, as a strip of covering material arranged to cover the springs in the pocket, so that the springs are arranged in succession. The elongated cord may comprise a strip or sheet of folded covering material. However, the elongated cord may also be composed of two assembled strips / sheets, a tubular covering material, or any other covering shape that may have the capacity to cover the springs in the pockets in succession.
[016] Transverse seams and backfolded transverse seams may be formed by any form of adhesive bonding, welding, staple fastening, stitching, or any combination thereof. In a preferred embodiment, welding is used.
[017] According to an exemplary embodiment of the invention, at least one of the backfolded transverse seams may have a first end portion and a second end portion that secure at least twice as many layers of covering material as in a corresponding transverse seam that is not backfolded. The backfolding of the covering material 7 / 20 near the first and second end portions of the transverse seams folded back facilitates the creation of a pocket spring mattress with two smooth and regular surfaces. This, for example, is advantageous when the mattress is intended to be used with both sides facing up, i.e., a mattress that can be flipped.
[018] According to an exemplary embodiment of the invention, the elongated cords can be made of a covering material with a constant width. By having the ability to use a covering material with a constant width, for example, in the form of rectangular strips of covering material, for the elongated cords, the mattress becomes easier and less expensive to manufacture.
[019] The elongated cord may additionally include a longitudinal seam arranged to seal the covering material that covers successive springs in spring units. The longitudinal seam may be located near the centerline of the elongated cord or at the transverse end portion of the elongated cord or anywhere in between. In the case where longitudinal seams are arranged at an end portion of the cords, it is preferable that the back fold be arranged at the opposite end.
[020] According to an exemplary embodiment of the invention, the pocket spring mattress may additionally comprise a layer attached to a surface of the pocket spring mattress having transverse seams folded backwards. One of the advantages of having a regular surface is that additional layers can be attached. 8 / 20 directly to the surface of the pocket spring mattress, which reduces the risk of deformation and / or displacement of the layer, which can occur when a layer is attached to false elevations. The layer can be attached by any type of fastening means, such as adhesives, staples, welding, stitching or any combination thereof. The layer can be made of any type, such as a quilted layer that includes foam-like material, such as a sheet of polyester, latex, felt or any other upholstery material. The layer can also be a thin protective sheet or similar.
[021] According to another aspect of the invention, a device is provided for making a spring mattress comprising means for providing a covering material that forms an elongated cord, means for arranging helical springs in succession so that they are enclosed by the covering material, means for providing a transverse seam that separates each helical spring into enclosed pockets, and means for interconnecting a plurality of parallel cords side by side by surface fastening between the contiguous surfaces, wherein it further comprises means for providing at least some of the transverse seams as backward-folded transverse seams, folding the covering material backward near at least an end portion of each backward-folded transverse seam towards a middle portion of the transverse seams.The covering material is folded back toward the centerline of the elongated cord in the transverse direction of the elongated cord.
[022] The device for making a cord of 9 / 20 pocket includes advantages that are equal to or similar to the first aspects discussed above.
[023] Furthermore, in an exemplary embodiment of the invention, the means for providing backfolded transverse seams may include a guide plate arranged to fit the cover material towards a centerline of the elongated cord, when the cover material is guided along the guide plate. The guide may have the ability to press the cover material backwards, so that the cover material is folded backwards, creating double layers. The guide plate has the ability to fit the cover material, having both sides overlapped by the cover material. Thus, the backfold can be achieved in a relatively simple manner, which is also easy to integrate as an in-line step in conventional pocket spring mattress manufacturing equipment.
[024] In an exemplary embodiment of the invention, the means for providing backfolded transverse seams may further include a receiving plate having a recess with the corresponding shape of the guide plate, wherein the recess of the receiving plate is arranged to at least partially cover the guide plate, so that the covering material, when oriented along the guide plate, is folded into the recess of the receiving plate.
[025] The receiving plate can be placed between the layers of the elongated cord. The receiving plate has a recess corresponding to the shape of the guide plate. When the guide plate teeth the material 10 / 20 of the covering, the covering material is pushed into the recess of the receiving plate, which creates a backward-folded covering material. The covering material is arranged to be oriented between the guide plate and the receiving plate, forming a backward-folded covering material in at least one end portion of the elongated cord along the longitudinal direction of the cord.
[026] In addition, the guide plate may be arranged with rounded corners in the orientation direction to enhance the ability of the covering material to be oriented along the guide plate. The orientation direction of the guide plate is the corner that first encounters the covering material. Thus, the movement of the covering material beyond the guide plate is facilitated.
[027] According to one aspect of the invention, a method is provided for manufacturing a pocket cord comprising the steps of providing a covering material that forms an elongated cord configured to enclose a plurality of helical springs arranged in succession; arranging helical springs so that they are enclosed by the covering material; providing a plurality of transverse seams through the elongated cord so that successive pockets are formed and directed so that a longitudinal geometric axis of the helical springs is parallel to the transverse seams; and providing backward-folded transverse seams, before, simultaneously with, or after the step of providing a plurality of transverse seams, by backward-folding the covering material near at least a portion of 11 / 20 end of said transverse seams folded back towards a middle portion of the transverse seams.
[028] The method for making a pocket cord has equal or similar advantages in relation to other aspects discussed above.
[029] The helical spring arrangement step may occur after the step of providing a plurality of transverse seams or the step of providing a plurality of transverse seams folded back.
[030] According to one embodiment of the invention, the step of supplying material for backfolded cross seams may further comprise the step of fitting the cover material, overlapping at least part of a first and a second side of a backfold guide plate.
[031] According to one embodiment of the invention, the helical spring arrangement step can occur after the backfolding step of the covering material.
[032] According to one embodiment of the invention, the steps of arranging helical springs and providing a plurality of transverse seams can be performed simultaneously.
[033] According to one embodiment of the invention, the method further comprises the step of providing a longitudinal seam along the open ends of the elongated cord in a longitudinal direction of the elongated cord.
[034] According to one embodiment of the invention, 12 / 20 The method for manufacturing a pocket spring mattress may further comprise the steps of supplying a plurality of pocket cords; and of interconnecting a plurality of pocket cords side by side by surface fastening between adjacent surfaces.
[035] These and other advantages of the present invention become evident from the detailed description of the specific embodiments that follow. BRIEF DESCRIPTION OF THE DRAWINGS
[036] These and other aspects of the present invention are now described in greater detail and in relation to the accompanying drawings which show exemplary embodiments of the invention, in which:
[037] Figure 1 is a side view of an example of a pocket spring mattress part, according to the prior art;
[038] Figures 2a and 2b are side views of alternative embodiments of a pocket cord to be used in a pocket spring mattress according to the present invention;
[039] Figure 3 is a perspective view of the pocket cord of Figure 2a;
[040] Figure 4 is a perspective view of a part of a pocket spring mattress, according to an embodiment of the present invention;
[041] Figure 5 is a perspective view of a pocket spring mattress, according to an embodiment of the present invention;
[042] Figure 6 is a schematic perspective view of an exemplary embodiment of a 13 / 20 production device and a method for producing pocket cords, according to an embodiment of the present invention; and
[043] Figure 7 is a cross-sectional view of the middle to fold-back covering material of Figure 6. DETAILED DESCRIPTION
[044] The invention is described below to exemplify its purposes by means of embodiments and in relation to the accompanying drawings.
[045] Figure 1 illustrates a pocket cord 1, according to the prior art, which has false elevations 6. The pocket cord 1 has helical springs 2 that are enclosed in pockets 3, as spring units in succession, by a covering material 4. The pockets 3 are separated by transverse seams 5 arranged parallel to the longitudinal direction of the helical springs 2 between each helical spring. Furthermore, the pocket cord 1 is made of a strip of folded covering material that is sealed by a longitudinal seam arranged along the longitudinal direction of the pocket cord 1. Thus, rectangular pockets are formed by the transverse and longitudinal seams and when an object, such as a helical spring 2, is inserted into the pocket 3, the covering material 4 near the transverse seams 5 protrudes and creates an irregular surface comprising false elevations 6.
[046] Next, in relation to Figure 2 to Figure 7, different aspects of the invention are illustrated. In Figure 2a, a pocket cord 1 is illustrated, as described above in Figure 1, which separates each helical spring into pockets 3. 14 / 20 However, part of the cover material 4, in Figure 2a, is folded back to create backward-folded transverse seams 7 to prevent false protruding elevations 6. The cover material 4 arranged to be folded back is situated between the end portions of successive helical springs 2, in the longitudinal direction of the helical springs 2. The backward-folded cover material 4 is folded towards a middle portion 8 of the transverse seams 5. The pocket cord 1, in this example, is made of a single layer of folded cover material arranged to enclose the springs, such that the backward-folded transverse seams 7 secure four layers of cover material 4 while the transverse seams 5 secure two layers of cover material 4. Suitably, the cover material 4 is preferably made of a weldable fabric, but other materials, such as various types of plastic materials, may be equally well used.Similarly, it is possible to use non-weldable fabrics, such as cotton fabrics. Typically, elongated cords of helical springs enclosed in interconnected covered pockets 2 are manufactured automatically, the cords are then cut to suitable lengths and joined side by side to form the mattress.
[047] In the embodiment shown in Figure 2a, the cord further comprises a longitudinal seam disposed at the lower end of the cord and directed parallel to the length direction of the cord and perpendicular to the direction of the transverse seams and in the axial direction of the enclosed springs. In such an embodiment, as also illustrated in Figure 2a, it is preferable to provide 15 / 20 fold back on the end portions positioned opposite to the longitudinal seam.
[048] The embodiment shown in Figure 2b is similar to the embodiment discussed above in relation to Figure 2a. However, in this embodiment, the longitudinal seam is not located at the lower end of the cord, but on one side in the middle of the cord. The longitudinal seam may, for example, be located near the centerline of the cord. In such an embodiment, the back fold can be easily provided in end portions on both sides of the cord, as also illustrated in Figure 2b.
[049] In the backfolded end portions, at least twice as many layers of covering material are secured by the transverse seam in the backfolded end portions, relative to corresponding transverse seam end portions without such a backfold. In the embodiment of Figure 2a, this also means that at least twice as many layers of covering material are secured by the transverse seam in the backfolded end portions, relative to the middle portion of the transverse seam. This also applies to the embodiment of Figure 2b, except for the overlap of covering material obtained at the location of the longitudinal seam.
[050] Helical springs 2 of many different sizes can be used together with the present invention and, in principle, any desirable spring size, large or small, can be used. Preferably, however, the helical springs 2 used have a diameter in the range of 2 to 10 cm and, preferably, in the range of 4 to 8 cm, such as 6 cm. Furthermore, the helical springs 2 are preferably 16 / 20 manufactured from helically wound wires. The springs preferably comprise at least three turns and preferably less than 10 turns. Furthermore, they are advantageously made of spiral wire with a thickness in the range of 0.5 to 3.0 mm, preferably a wire thickness in the range of 1.25 to 2.50 mm. Preferably, the springs have a slightly cylindrical shape with smaller turns at the top and bottom.
[051] The transverse seams 5 and the back-folded transverse seams 7 can be arranged as a continuous line or in smaller sections or at single points forming, for example, a dashed line or a dotted line, respectively. The seams are preferably formed by welding, but other connection methods can also be used.
[052] Furthermore, Figure 3 illustrates a perspective view of the pocket cord 1. The backfolded transverse seams 7 can thus be illustrated by the double layer fastened by the seams in relation to the middle portion 8 of the transverse seams 5. The cover material 4, close to the backfolded transverse seams 7 which are folded back, is disposed between the remainder of the cover material 4 which encloses the helical springs 2. By folding back the cover material of the end portion of the pocket cord 1 in the longitudinal direction of the springs, the top end of the pocket cord 1 has a smooth and regular surface without false protruding elevations. The backfolded cover material fastened with a backfolded transverse seam may have the shape of an X when viewed from above. 17 / 20
[053] In Figure 4, a part of a pocket spring mattress 10 illustrates parts of pocket cords 1 shown in Figure 3 joined side by side in successive rows. Surface fixation between pocket cords 1 can be achieved by welding, gluing, suturing and / or staple fixation. Preferably, an adhesive is used for this fixation.
[054] Each of the pocket cords has transverse seams 5, of which at least some and preferably all are backward-folded transverse seams 7. The backward folds of the backward-folded transverse seams 7 are arranged on the top surface of the pocket spring mattress, but may also be additionally arranged on the opposite surface.
[055] Figure 5 illustrates a pocket spring mattress 10 which has a plurality of pocket cords 1 arranged side by side and fastened together. The plurality of pocket cords 1 used in the pocket spring mattress 10 is shown previously in Figure 3. In addition, Figure 4 illustrates the side-by-side fastening. The surface fastening of the rows of pocket cords 1 can also be done by Velcro tape or some other suitable surface fastening method, as known in the art.
[056] Figure 5 illustrates the smooth and regular surface of the pocket spring mattress 10. The regular surface allows an additional layer, such as a polyester sheet, to be easily attached to the cover material 4 on the surface of the pocket spring mattress.
[057] Figure 6 illustrates an example of a 18 / 20 Production device and a method for manufacturing pocket cords 1 with backfolded transverse seams 7. An elongated cord of cover material 4 is arranged in two layers. The receiving plate 11 can be positioned so that it is encircled by the elongated cord, as illustrated by the dashed lines. The guide plate 9 is placed on the outside of the elongated cord arranged in the recess of the receiving plate 11. The guide plate 9 is used to fit the cover material 4 that forms the backfolded cover material in the recess of the receiving plate 11. The backfolded cover material comprises four layers of cover material 4. The layers of cover material 4 are then fastened with transverse seams 5 in the middle portion 8 of the cord and backfolded transverse seams 7 through the backfolded cover material.When the pockets 3 are formed, the helical springs 2 can be inserted, which expands the pockets 3 and creates a smooth, regular surface. However, the steps illustrated in Figure 6 can be done in a different order. For example, the steps of arranging the springs in the pocket material can be performed before the step of providing backfolding of the backfolded cross seams 7.
[058] Figure 7 illustrates a side view of the guide plate 9 and the receiving plate 11 that form the backfolded cover material. The guide plate 9, in Figure 7, has a wedge shape arranged to fit the cover material 4 into the recess of the receiving plate 11 which has a corresponding V shape. The backfolded cover material is thus serrated. 19 / 20 between the layers of covering material that form an M shape or a W shape, depending on the viewing direction. However, the covering material folded back can also be folded on one of the outer sides of the covering material 4.
[059] The invention has been described above by means of embodiments. Several variants of the invention, however, are conceivable. For example, it is possible to provide backfolding of the backfolded transverse seams at both ends or at only one end. It is also possible to use backfolded transverse seams on the entire mattress, whereby all transverse seams can constitute backfolded transverse seams. However, it is also possible to use a combination of backfolded transverse seams and conventional transverse seams without backfolding. For example, such conventional transverse seams can be used around the edges of the mattress or in certain areas of the mattress. It is also possible to use the pocket spring mattress without any additional top layer, for use, for example, with unattached layers, bed mattresses or the like.However, the pocket spring mattress preferably comprises at least one additional layer disposed on top of the pocket spring mattress. The additional layer may be a padded layer or a thin, unpadded layer. Furthermore, the device and method for manufacturing the pocket spring mattress may be designed in other ways different from that of the illustrated example. For example, other means of providing the back fold are possible, such as movable fingers or plates, which are movable in one. 20 / 20 direction parallel to the transverse seams that are formed or about to be formed. It is preferable that the backfolded material be fixed to the transverse seam during the formation of the transverse seam. In this way, the transverse seam can be formed in a single step, in a conventional manner. However, a dual or similar seam arrangement is also possible. In this case, it is possible, for example, to first form a first transverse seam, then provide a backfold, and subsequently add a second seam, which overlaps or nearly overlaps the first seam, to fix the backfold. Such evident variants should be considered as encompassed by the invention, as defined by the appended claims.
Claims
1 / 2 CLAIMS 1. POCKET SPRING MATTRESS (10), comprising helical springs (2) arranged as spring units enclosed in a cover material (4) forming pockets (3), wherein the spring units are successively arranged in elongated cords, wherein the mattress comprises a plurality of such interconnected cords arranged side by side, wherein the elongated cords have a plurality of transverse seams (5) arranged parallel to the longitudinal direction of the helical springs (2) to separate the pockets (3), wherein a middle portion (8) of the transverse seams (5) fixes at least one layer of cover material (4) on both sides of the spring unit to each other, characterized in that at least some of the transverse seams (5) are back-folded transverse seams (7),wherein the covering material (4) in proximity to an end portion of said backfolded transverse seams (7) is folded back towards the middle portion (8) of the transverse seams (5), whereby each of said backfolded transverse seams (7) has at least one end portion that secures at least twice as many layers of covering material (4) as in a corresponding transverse seam (5) that is not backfolded, wherein the cords further comprise longitudinal seams arranged parallel to a length direction of the cords, the longitudinal seams being arranged at either of the lower ends opposite the backfolds and lateral folds in the middle of the cords, Petition 870210032630, dated 09 / 04 / 2021, page 10 / 16 2 / 2 wherein the springs are cylindrical in shape, with smaller turns at the top and bottom,wherein the backfolded cover material is folded between layers of cover material forming the pockets, wherein essentially all transverse seams are backfolded transverse seams, and wherein the pocket spring mattress (10) further comprises a layer attached to a surface of the pocket spring mattress (10) which has backfolded transverse seams (7).
2. POCKET SPRING MATTRESS (10), according to claim 1, characterized in that at least one of the backfolded transverse seams (7) has a first end portion and a second end portion in which both secure at least twice as many layers of cover material (4) as in a corresponding transverse seam (5) that is not backfolded.
3. POCKET SPRING MATTRESS (10), according to either claim 1 or 2, characterized in that the cords are made of a covering material (4) with a constant width.
4. POCKET SPRING MATTRESS (10), according to any one of claims 1 to 3, characterized in that the transverse seams folded back are formed by welding.
5. POCKET SPRING MATTRESS (10), according to any one of claims 1 to 4, characterized in that the springs have a cylindrical shape with smaller coils at the top and bottom. Petition 870210032630, dated 09 / 04 / 2021, page 11 / 16