Coil spring, pouch coil spring assembly and mattress comprising same

Abstract

A coil spring includes a continuous wire forming a lowermost coil, an uppermost coil, and a plurality of helical intermediate coils. The coil spring is divided into an upper portion and a lower portion. The diameter of the intermediate coils of the lower portion is greater than or equal to a lower minimum diameter, and the pitch between each of the coils of the lower portion is greater than or equal to a lower minimum pitch. The diameter of the intermediate coils of the upper portion is greater than or equal to an upper minimum diameter, and the pitch between each of the coils of the upper portion is less than or equal to an upper maximum pitch. The upper minimum diameter is greater than, less than, or equal to the lower minimum diameter, and the upper maximum pitch is less than the lower minimum pitch to provide a non-linear and variable response.

Description

[0001] Related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 530,429, filed August 2, 2023, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This invention relates to coil springs, pocketed coil spring assemblies, and mattresses including the same. In particular, this invention relates to pocketed coil spring assemblies comprising coil springs exhibiting a non-linear and variable response. Background Technology

[0004] Typically, when a uniaxial load is applied to a spring, it exhibits linear compressibility. That is, the force required to compress a typical spring two inches is twice the force required to compress the same spring one inch. This linear response of a spring is expressed by Hooke's Law, which states that the force (F) required to stretch or compress a spring a certain distance (D) is proportional to that distance. This relationship is mathematically expressed as F = kD, where k represents the spring constant of a particular spring. A higher spring constant indicates that the spring requires more force to compress, while a lower spring constant means that the spring requires less force to compress.

[0005] Linear response springs (such as certain wire coil springs) are commonly used as internal springs in mattresses, in combination with padding and upholstery surrounding the internal springs. Most mattress internal springs consist of an array of wire coil springs, typically joined together by spirally winding the ends of the coil springs together with transverse wire. This arrangement is advantageous due to its low manufacturing cost. However, such internal springs generally provide a firm and rigid mattress surface.

[0006] An alternative to internal spring mattresses is a mattress composed of one or more layers of foam. Unlike internal spring mattresses, which consist of an array of steel coil springs, foam mattresses exhibit a non-linear response to forces applied to the mattress. In particular, foam mattresses provide more support as the load increases. For example, a typical foam mattress provides increased support after it has been compressed to approximately 60% of its maximum compression. This non-linear response of foam mattresses can provide enhanced sleep comfort for the user. However, the mechanical properties of some foams degrade over time, affecting the overall comfort of the foam mattress. Furthermore, foam mattresses are generally more expensive to manufacture than metal spring mattresses. Therefore, an improved coil spring design that provides a non-linear and variable response would be highly desirable and beneficial. Summary of the Invention

[0007] The present invention satisfies some or all of the above-mentioned needs, as will be apparent to those skilled in the art upon reading the information provided in this document.

[0008] This summary describes several embodiments of the invention and, in many cases, illustrates variations and combinations of these embodiments. The summary is merely illustrative of numerous and diverse embodiments. References to one or more representative features of a given embodiment are also merely exemplary. Such embodiments may generally exist with or without these features; similarly, those features may also be applicable to other embodiments of the subject matter of this disclosure, whether or not they are listed in this summary. To avoid excessive repetition, this summary does not list or imply all possible combinations of such features.

[0009] This invention includes a coil spring, a pocketed coil spring assembly, and a mattress including the coil spring and associated pocketed coil spring assembly, wherein the included coil spring exhibits a non-linear and variable response. In some embodiments, a coil spring is provided comprising a continuous wire forming a lowermost coil, an uppermost coil opposite the lowermost coil, and a plurality of helical intermediate coils located between the lowermost coil and the uppermost coil. The continuous wire of the coil spring defines: the pitch between the lowermost coil and the helical coil adjacent to the lowermost coil, the pitch between each coil of the plurality of intermediate coils, and the pitch between the uppermost coil and the intermediate coils adjacent to the uppermost coil.

[0010] The exemplary helical spring is a continuous wire, and thus the helical spring itself is divided into a lower portion and an upper portion. The lower portion includes a lowermost coil of the helical spring and one or more intermediate coils of the helical spring, wherein the diameter of each of the one or more intermediate coils of the lower portion is greater than or equal to the lower minimum diameter, and the pitch between the coils of the lower portion is greater than or equal to the lower minimum pitch. The upper portion of the continuous wire and the resulting helical spring includes an uppermost coil and one or more intermediate coils of the intermediate coils, wherein the diameter of each of the one or more intermediate coils of the upper portion is greater than or equal to the upper minimum diameter, and the pitch between the coils of the upper portion is less than or equal to the upper maximum pitch. Furthermore, in some embodiments of the exemplary helical spring, the upper minimum diameter is greater than or equal to the lower minimum diameter, and the upper maximum pitch is less than the lower minimum pitch, causing the exemplary helical spring to exhibit a variable and non-linear response. In other embodiments of the exemplary helical spring, the upper minimum diameter is less than or equal to the lower minimum diameter, and the upper maximum pitch is less than the lower minimum pitch, such that the exemplary helical spring still exhibits a variable and nonlinear response.

[0011] In some embodiments of the exemplary helical springs described herein, the total number of coils in the lower portion is between three and eight. In some embodiments, the total number of coils in the upper portion is between three and six. In some embodiments, the number of coils in the upper portion is less than or equal to the number of coils in the lower portion.

[0012] Regarding the diameter of the helical spring of the present invention, in some embodiments of the helical spring, the diameter is configured to provide a specific spring constant and the resulting feel and shape. For example, in some embodiments, the lower portion of the exemplary spring is given an hourglass shape by providing a helical spring in which the diameter of the lowest coil is greater than the lower minimum diameter, the diameter of the intermediate coil of the lower portion adjacent to the upper portion is greater than the lower minimum diameter, and the diameter of at least one coil of the lower portion is equal to the lower minimum diameter. In some embodiments, an hourglass shape is provided in the lower portion by making the diameter of the central coil of the lower portion equal to the lower minimum diameter, and making the diameter of each of the other coils of the lower portion greater than the lower minimum diameter. Similarly, in some embodiments, an hourglass shape can also be provided in the upper portion of the spring by providing a spring in which the diameter of the intermediate coil of the upper portion adjacent to the lower portion is greater than the upper minimum diameter, the diameter of another intermediate coil in the upper portion is greater than the upper minimum diameter, and the diameter of at least one intermediate coil located between them is equal to the upper minimum diameter. In some of these embodiments with an hourglass-shaped upper portion, the diameter of the uppermost spiral is equal to the minimum diameter of the upper portion.

[0013] In some embodiments, exemplary helical springs are also provided with alternative constructions to obtain helical springs with alternative spring constants and shapes. For example, in some embodiments, a helical spring is provided in which the diameter of each intermediate coil in the intermediate coils of the upper portion is substantially equal, and the diameter of the uppermost coil is smaller than the diameter of each intermediate coil in the intermediate coils of the upper portion, such that the upper portion has a furnace tube shape. As another example, in a further embodiment, a helical spring is provided in which the diameter of the coils in the intermediate coils of the upper portion gradually decreases from the lower portion to the uppermost coil, such that the upper portion has a tapered shape. As another example, in some embodiments, a helical spring is provided in which the diameter of the coils in the intermediate coils of the upper portion gradually increases from the lower portion to the uppermost coil, such that the upper portion has a funnel shape. As a further example, in some embodiments, a helical spring is provided in which the diameter of the intermediate coil of the upper portion adjacent to the lower portion and the diameter of the intermediate coil of the upper portion adjacent to the uppermost coil are the minimum upper diameter, and the diameter of at least one intermediate coil located between them is greater than the minimum upper diameter, such that the upper portion has a barrel shape.

[0014] In some embodiments of the invention, a bagged helical spring using the helical spring described herein is further included. In some embodiments, a bagged helical spring is provided, comprising a helical spring and a flexible closure forming a bag around the helical spring. In some exemplary embodiments of the bagged helical spring, the helical spring comprises a continuous wire forming a lowermost coil, an uppermost coil opposite the lowermost coil, and a plurality of helical intermediate coils located between the lowermost and uppermost coils. The continuous wire further defines: the pitch between the lowermost coil and the helical coil adjacent to the lowermost coil, the pitch between each of the plurality of intermediate coils, and the pitch between the uppermost coil and the intermediate coil adjacent to the uppermost coil. Thus, the continuous wire forming the helical spring included in the bagged helical spring is divided into a lower portion and an upper portion. The lower portion includes one or more intermediate coils from the lowermost coil and the intermediate coils, wherein the diameter of each intermediate coil in the lower portion is greater than or equal to the lower minimum diameter, and the pitch between the coils in the lower portion is greater than or equal to the lower minimum pitch. The upper portion includes one or more intermediate coils from the uppermost coil and the intermediate coils, wherein the diameter of each intermediate coil in the upper portion is greater than or equal to the upper minimum diameter, and the pitch between the coils in the upper portion is less than or equal to the upper maximum pitch. In some embodiments of the exemplary pocket coil spring, the upper minimum diameter is less than, greater than, or equal to the lower minimum diameter, and the upper maximum pitch is less than the lower minimum pitch. Thus, the diameter of the central coil of the lower portion is equal to the lower minimum diameter, and the diameter of each of the other coils in the lower portion is the same and greater than the lower minimum diameter, giving the lower portion an hourglass shape.

[0015] In some embodiments of the invention, a mattress assembly comprising the helical springs and / or pocketed helical springs described herein is further provided. In some embodiments, a mattress assembly is provided comprising a plurality of parallel strings of pocketed helical springs, wherein each string comprises a plurality of pocketed helical springs of the present invention arranged along the length of the string. In some embodiments of the helical springs included in an exemplary mattress assembly, the upper minimum diameter is less than, greater than, or equal to the lower minimum diameter, and the upper maximum pitch is less than the lower minimum pitch. In some embodiments, the diameter of the central coil of the lower portion is equal to the lower minimum diameter, and the diameter of each of the other coils of the lower portion is the same and greater than the lower minimum diameter, such that the lower portion has an hourglass shape. Furthermore, in some embodiments of the mattress assembly, for each of the plurality of helical springs, one of the plurality of helical springs is in a first orientation, while an adjacent helical spring is in a second orientation, the second orientation being rotated 180° relative to the first orientation about the longitudinal axis of the helical spring.

[0016] In some embodiments of a mattress assembly employing coil springs positioned in the first and second orientations described above, the coil spring in the first orientation and its adjacent coil spring in the second orientation are located in the same string of pocketed coil springs. In some embodiments, the coil spring in the first orientation and its adjacent coil spring in the second orientation are located in adjacent strings of pocketed coil springs. In some embodiments, each of the plurality of coil springs in the string of pocketed coil springs including the coil spring in the first orientation is also in the first orientation; while in some embodiments, each of the plurality of coil springs in the string of pocketed coil springs including the coil spring in the second orientation is also in the second orientation. In some embodiments, another adjacent coil spring in an adjacent string of pocketed coil springs is also in the second orientation.

[0017] In a further embodiment of the invention, a method of manufacturing a mattress assembly is also provided. In some embodiments, a method of manufacturing a mattress assembly is provided, comprising the first step of providing a plurality of helical springs of the present invention. Subsequently, a pocket is formed around each helical spring with a flexible enclosure such that each pocketed helical spring is in a string of pocketed helical springs. Next, the plurality of strings of pocketed helical springs are positioned parallel to each other to form the mattress assembly. In some embodiments of the helical springs included in the mattress assembly, the upper minimum diameter is less than, greater than, or equal to the lower minimum diameter, and the upper maximum pitch is less than the lower minimum pitch. In some embodiments, before forming a pocket around each helical spring, each helical spring is positioned in a first orientation or a second orientation, the second orientation being rotated 180° relative to the first orientation about the longitudinal axis of the helical spring.

[0018] In some embodiments of the exemplary mattress assembly manufacturing method described herein, the plurality of coil springs are provided by a spring coiling machine, and the orientation of the springs is determined by the amount of wire included in the lowermost coil of the coil spring. In some embodiments, the coil springs in a second orientation have an additional half-turn of wire in the lowermost coil of the coil spring, such that the ends of the coil springs in the first orientation and the ends of the coil springs in the second orientation are positioned substantially the same relative to the pocket surrounding each coil spring. In other embodiments, the plurality of coil springs are provided by a spring coiling machine, and the orientation of the springs is determined by a flipping mechanism after the spring coiling machine provides the springs and before the pocket is formed around the coil spring.

[0019] Further features and advantages of the present invention will become apparent to those skilled in the art after reading the contents, drawings, and non-limiting examples described in this document. Attached Figure Description

[0020] Figure 1 This is a perspective view of a helical spring manufactured according to the present invention; Figure 2A This is a side view schematic diagram of the upper portion of an exemplary helical spring, which has a furnace tube shape; Figure 2B This is a side view of the upper portion of an exemplary helical spring, which has an hourglass shape; Figure 2C This is a side view of the upper portion of an exemplary helical spring, which has a tapered shape; Figure 2D This is a side view of the upper portion of an exemplary helical spring, which has a funnel shape; Figure 2E This is a side view of the upper portion of an exemplary helical spring, which has a barrel shape; Figure 3A This is a perspective view of another helical spring made according to the present invention, which includes... Figure 2A The upper part is similar to that shown; Figure 3B This is a perspective view of another helical spring made according to the present invention, which includes... Figure 2C The upper part is similar to that shown; Figure 4 This is a perspective view of two pocketed helical springs made according to the present invention, in which the two helical springs are in the same orientation; Figure 5 This is a perspective view of two pocketed helical springs made according to the present invention, in which the two helical springs are in different orientations; Figure 6A This is a side view of a bagged coil spring string, in which the coil springs alternate between a first orientation and a second orientation; Figure 6B This is a top view of two bundles of bagged helical springs. In this diagram, the helical springs in the first bundle are in a first orientation, and the helical springs in the second bundle are in a second orientation. Figure 6C This is a top view of two bundles of bagged helical springs. In this diagram, the helical springs in the first bundle alternate between a first orientation and a second orientation, and the helical springs in the second bundle also alternate between a first orientation and a second orientation. Figure 7 This is a top view of an exemplary mattress assembly, in which the coil springs in the first set of strings are in a first orientation, and the coil springs in the second set of strings are in a second orientation; Figure 8 This is a top view of an exemplary mattress assembly, in which the coil springs in the first set of strings alternate between a first orientation and a second orientation, and the coil springs in the second set of strings also alternate between a first orientation and a second orientation; Figure 9 This is a perspective view of two helical springs. In this top view, the amount of wire included in the bottommost coil differs; and Figure 10 yes Figure 9 A perspective view of two helical springs, with the ends of the helical springs aligned. Detailed Implementation

[0021] This invention includes a coil spring, a pocketed coil spring assembly, and a mattress including the coil spring and the pocketed coil spring assembly. In particular, the invention includes a pocketed coil spring assembly comprising a coil spring exhibiting a non-linear and variable response.

[0022] First see Figure 1 In one exemplary embodiment of the invention, a helical spring 10 is provided, which is composed of a continuous wire 16 forming a plurality of coils of the helical spring 10. Each coil is composed of a portion of the continuous wire 16 that is substantially equal to about one turn of the continuous wire 16 (i.e., about 360° of the helical path of the continuous wire 16). Specifically, the continuous wire 16 of the helical spring 10 forms a lowermost coil 12, an uppermost coil 14 opposite to the lowermost coil, and a plurality of helical intermediate coils 24, 26, 28, 32, and 34 located between the lowermost coil 12 and the uppermost coil 14.

[0023] The lowermost coil 12 of the continuous wire 16 forms a substantially closed circular loop at the bottom of the helical spring 10, and similarly, the uppermost coil 14 forms a substantially closed circular loop at the top of the helical spring 10. Thus, the helical spring 10 terminates at both ends in a generally planar form, which serves as the support end structure of the helical spring 10, while the intermediate coils 24, 26, 28, 32, and 34 are spirally wound between the lowermost coil 12 and the uppermost coil 14. Therefore, the lowermost coil 12 and the uppermost coil 14 can be characterized as "non-moving" coils, while the intermediate coils 24, 26, 28, 32, and 34 can be characterized as "moving" coils.

[0024] Further regarding the continuous wire 16, the lowermost coil 12, the uppermost coil 14, and the plurality of helical intermediate coils 24, 26, 28, 32, 34 are arranged such that the helical spring 10 is generally divided into a lower portion 20 and an upper portion 30. The lower portion 20 of the helical spring 10 includes the lowermost coil 12 and one or more intermediate coils, which in this exemplary embodiment include a first intermediate coil 24, a second intermediate coil 26, and a third intermediate coil 28. Similarly, the upper portion 30 of the helical spring 10 includes the uppermost coil 14 and one or more intermediate coils, which in this exemplary embodiment include a fourth intermediate coil 32 and a fifth intermediate coil 34. Thus, the lower portion 20 of this exemplary helical spring 10 includes a total of four coils, while the upper portion 30 includes a total of three coils. However, the number of coils included in the lower and upper portions is not limited and can be adjusted according to the intended purpose of the helical spring. For example, in some embodiments, the lower portion may include a total of three to eight coils (i.e., the bottommost coil plus two to seven additional intermediate coils). Similarly, in some embodiments, the upper portion may include a total of two to six coils (i.e., the topmost coil plus one to five additional intermediate coils). Regardless of the specific number of coils, in some embodiments, the number of coils in the upper portion is less than the number of coils in the lower portion. However, in other embodiments, the number of coils may be the same, or the number of coils in the upper portion may be greater.

[0025] like Figure 1As shown, the helical spring 10 is formed by a continuous wire 16, with the lowermost coil 12 having a diameter, the uppermost coil 14 having a diameter, and each of the intermediate coils 24, 26, 28, 32, and 34 having a corresponding diameter. The continuous wire 16 further defines: the pitch between the lowermost coil 12 and the first helical coil 24 adjacent to the lowermost coil 12, the pitch between each of the intermediate coils 24, 26, 28, 32, and 34, and the pitch between the uppermost coil 14 and the fifth intermediate coil 34 adjacent to the uppermost coil 14.

[0026] Regarding the diameter of each coil and the pitch between coils, in most helical springs formed from continuous wire wound in a helical manner, the spring constant and the resulting feel are generally determined by a combination of factors: the diameter of the wire forming the helical spring; the total number of coils in the helical spring; the size (diameter) of each coil; and the pitch or vertical spacing (or pitch angle) between the coils. In this regard, in some cases, the pitch (or vertical spacing) between the coils of the helical spring is controlled by the rate at which the continuous wire forming the helical spring is drawn through the forming die in the helical forming machine. In other cases, the pitch and the diameter are generated by the helical forming machine using specific pitch and diameter tooling, which is cam-driven or servo-driven. The method of producing helical springs is not particularly limited, and in any case, once formed, a larger pitch generally produces a stiffer helical spring due to the increased vertical orientation of the wire, while a smaller pitch generally produces a softer helical spring and allows for a greater total number of coils to be accommodated in the helical body. Similarly, a larger diameter coil in a helical spring results in a lower spring constant compared to a smaller diameter coil, and thus a softer feel. Of course, since the wire forming a helical spring is continuous, any single coil typically does not have a definite start or end point. Furthermore, the diameter and pitch are usually gradually adjusted from one part of the spring to another. Therefore, a single coil in a helical spring may not have only a single diameter or only a single pitch, but may include, for example, a start or end portion with a variable diameter and / or pitch transitioning to an adjacent coil. Therefore, as used herein, "the diameter and pitch of the coil" will generally refer to the average diameter and average pitch, but may also include the maximum diameter and maximum pitch, or the minimum diameter and minimum pitch.

[0027] Further regarding the maximum diameter and pitch and / or minimum diameter and pitch, unless otherwise stated, references herein to the minimum diameter or pitch, or maximum diameter or pitch, observed in a coil of the upper or lower portion of the exemplary helical spring generally refer to the minimum or maximum diameter or pitch observed in the moving coil of the exemplary helical spring, and not in the non-moving coil. For example, the phrase "minimum lower diameter" as used herein refers to the minimum diameter observed in the moving coil of the lower portion of the exemplary helical spring. Similarly, the phrase "maximum upper pitch" as used herein refers to the maximum pitch observed between the moving coils of the upper portion of the exemplary helical spring.

[0028] In the exemplary helical springs of the present invention described herein, the wire diameter of the helical spring typically has a standard range of about 13 gauge (2.3 mm) to about 18 gauge (1.2 mm). However, other wire diameters are possible without departing from the spirit and scope of the invention. Furthermore, while in some embodiments the wire diameter is substantially consistent along the entire length of a continuous wire, in other embodiments the wire diameter may vary.

[0029] In embodiments where the wire diameter remains constant, a variable and non-linear loading response can be provided by changing the diameter, pitch, or both, simultaneously. This is achieved by a first spring constant providing a softer feel when the spring is initially compressed, and a second spring constant providing a firmer feel as the compression of the helical spring increases.

[0030] Refer again Figure 1In the exemplary helical spring 10, the diameter of each movable coil in the lower portion 20 (i.e., the three lower intermediate coils 24, 26, 28) is greater than or equal to the minimum lower diameter, or in other words, the minimum diameter of the movable coils included in the lower portion 20. The pitch between each coil in the lower portion 20 is greater than or equal to the minimum lower pitch, or in other words, the minimum pitch between the movable coils in the lower portion 20. Furthermore, the diameter of each movable coil in the upper portion 30 (i.e., the two upper intermediate coils 32, 34) is less than or equal to the maximum upper diameter (i.e., the maximum diameter of the movable coils in the upper portion 30), and the pitch between each coil in the upper portion 30 is less than the maximum upper pitch (i.e., the maximum pitch between the movable coils in the upper portion 30). In this exemplary helical spring 10, the maximum upper diameter is less than or equal to the minimum lower diameter, and the maximum upper pitch is less than the minimum lower pitch. In other words, the diameter of each movable coil in the upper portion 30 is less than or equal to the diameter of each movable coil in the lower portion 20. Similarly, the pitch between the movable coils in the upper portion 30 is less than or equal to the pitch between the movable coils in the lower portion 20. However, in other embodiments, the diameter of one or more movable coils in the upper portion may be greater than the diameter of one or more movable coils in the lower portion. In still some additional embodiments, the pitch between one or more movable coils in the upper portion may be greater than the pitch between one or more movable coils in the lower portion. In embodiments of the invention that include inactive spirals (e.g., the lowermost spiral and / or the uppermost spiral), the diameter of these inactive spirals and the pitch between these inactive spirals and the immediately adjacent active spirals may vary without departing from the spirit and scope of the invention, regardless of the diameter and / or pitch of the active spirals.

[0031] like Figure 1As shown, particularly with respect to the lower portion 20, the diameter of the lowermost spiral 12 is greater than the minimum lower diameter, the diameter of the intermediate spiral 28 of the lower portion 20 adjacent to the upper portion 30 is greater than the minimum lower diameter, and at least one of the other spirals of the lower portion 20 has a diameter equal to the minimum lower diameter, giving the lower portion an hourglass shape. Specifically, the diameter of the second intermediate spiral 26 is equal to the minimum lower diameter, while the diameter of each of the other spirals 12, 24, and 28 of the lower portion 20 is greater than the minimum lower diameter. In this exemplary embodiment, the diameters of the lowermost spiral 12, the first intermediate spiral 24, and the third intermediate spiral 28 are all substantially equal. However, the diameters of these three spirals or the other spirals in the lower portion 20 can also be varied without departing from the spirit and scope of the invention. In particular, since the lowermost coil 12 is a non-movable coil, its diameter does not affect the response of the helical spring 10, but is selected based on other considerations (such as ease of construction or stability). In this respect, due to its non-movable coil state, and as... Figure 1 As shown in the helical spring 10, the end of the lowermost coil 12 typically has a diameter that transitions from a smaller diameter at the end of the lowermost coil 12 to a diameter substantially equal to the diameters of the first intermediate coil 24 and the third intermediate coil 28, such that, as described above, although the lower coil appears to be smaller than the lower minimum diameter at exactly the end near the lower coil 12, the diameter of the lowermost coil 12 is generally still considered to be larger than the lower minimum diameter.

[0032] exist Figure 1 In the exemplary helical spring 10 shown, the lower portion 20 includes three intermediate coils 24, 26, and 28, with the second intermediate coil 26 being characterized as the central coil. According to some embodiments, regardless of the number of coils in the lower portion, a central coil is provided, the diameter of which is smaller than the diameters of the remaining coils, giving the lower portion an hourglass shape. That is, although in Figure 1 In the exemplary helical spring 10 shown, the central coil is a second intermediate coil 26, but in other embodiments where the lower portion includes more coils, the central coil may be, for example, a third or fourth intermediate coil. In any case, the diameter difference between the smaller central coil and the remaining active coils is not limited, but in some embodiments, this difference can range from about 0.1 mm to about 10 mm. By including the smaller central coil 26, the lower portion 20 of the invention exhibits a variable spring response, as discussed further below.

[0033] Regardless of the specific diameter of the movable spiral in the lower portion, in some embodiments of the invention, the diameter of each movable spiral in the upper portion is greater than or equal to the diameter of the smaller central spiral in the lower portion. Referring again... Figure 1 Specifically, regarding the upper portion 30, the diameters of the fourth intermediate spiral 32 and the fifth intermediate spiral 34 are substantially equal to each other, and also substantially equal to the diameters of the first intermediate spiral 24 and the third intermediate spiral 28. However, the diameters of the fourth intermediate spiral 32 and the fifth intermediate spiral 34 are greater than the diameter of the second intermediate spiral 26 (i.e., the minimum lower diameter). Since the two movable spirals of the upper portion 30 (i.e., the fourth intermediate spiral 32 and the fifth intermediate spiral 34) have the same diameter, these spiral diameters are the minimum upper diameter. Therefore, and as mentioned above, the minimum upper diameter (i.e., the diameter of the uppermost spiral 14) is greater than or equal to the minimum lower diameter (i.e., the diameter of the second intermediate spiral 26). It is noteworthy that the diameter of the uppermost spiral 14 is smaller than the diameters of the fourth intermediate spiral 32 and the fifth intermediate spiral 34. However, similar to the lowermost spiral coil 12, the uppermost spiral coil 14 is a non-movable spiral coil, and therefore the diameter of the uppermost spiral coil 14 does not affect the response of the helical spring 10, but is selected based on other considerations (such as ease of manufacture or stability).

[0034] Due to the aforementioned construction of the lower portion 20 and upper portion 30, the spring response of the upper portion 30 is expected to differ from that of the lower portion 20. More specifically, the helical spring made according to the invention exhibits a variable response: initially softer, then increasing in stiffness at a non-linear rate. For example, according to some embodiments, an exemplary helical spring has an uncompressed height of approximately 2.5 inches (6.35 cm) to approximately 12 inches (30.5 cm). During the initial compression of the helical spring (e.g., the first 1-inch compression), the exemplary helical spring is approximately 10%–60% softer than a linear spring. During the second amount of compression (e.g., the second 1-inch compression), the exemplary helical spring is approximately 10%–40% softer than a linear spring. During the third amount of compression (e.g., the third 1-inch compression), the exemplary helical spring is approximately 0%–50% stiffer than a linear spring.

[0035] Table 1 below provides data on the compression response of an exemplary helical spring made according to the present invention.

[0036]

[0037] Table 1

[0038] To give the helical spring 10 a different spring response between its upper portion 30 and lower portion 20, a half-turn of continuous wire between the third intermediate coil 28 and the fourth intermediate coil is typically considered a transition coil, or in other words, the portion of the helical spring 10 from the softer upper portion 30 to the stiffer lower portion 20. Thus, once all the coils in the upper portion 30 are compressed and deactivated, the stiffer lower portion 20 is fully activated. Therefore, in some embodiments, and not intended to be limited by any particular theory or mechanism, it is contemplated that by adjusting parameters such as the location, pitch, and diameter of this transition coil, the degree of compression and deactivation of the upper and lower portions of the exemplary spring can be further adjusted, thereby controlling the timing of the transition from a soft touch to a firm touch.

[0039] Apart from the changing transition coil, the specific shape of the upper portion is not limited and can be selected to provide a specific spring constant and tactile feel for the upper portion of the helical spring. As a non-limiting example of possible shapes, and now referred to... Figures 2A to 2E The upper portion of an exemplary helical spring made according to the present invention may have a furnace tube shape or a cylindrical shape. Figure 2A ), hourglass shape ( Figure 2B ), cone shape ( Figure 2C ), funnel shape ( Figure 2D ) or barrel shape ( Figure 2E ).

[0040] Now, especially when referring to Figure 2A ,and Figure 1 Similar to the upper portion shown, in the exemplary furnace tube-shaped upper portion 130a, each of the intermediate spiral coils in the upper portion has a substantially identical diameter, while the diameter of the uppermost spiral coil is smaller than the diameter of each of the intermediate spiral coils in the upper portion. More specifically, this exemplary upper portion 130a includes three intermediate spiral coils 131a, 132a, and 133a in addition to the uppermost spiral coil 114a. The diameters of these three intermediate spiral coils 131a, 132a, and 133a are all substantially equal, and therefore the diameter of these movable spiral coils is the minimum upper diameter of this exemplary upper portion 130a. To reiterate, although the diameter of the uppermost spiral coil 114a is smaller than the diameters of the three intermediate spiral coils 131a, 132a, and 133a, since the uppermost spiral coil 114a is not a movable spiral coil, its diameter does not affect the response of the upper portion 130a. Therefore, the diameter of the uppermost spiral 114a is not limited and can be modified without departing from the spirit and scope of the invention.

[0041] Now, especially when referring to Figure 2BIn the exemplary hourglass-shaped upper portion 130b, the diameter of the intermediate spiral coil of the upper portion adjacent to the lower portion is greater than the minimum upper diameter, the diameter of another intermediate spiral coil of the upper portion is greater than the minimum upper diameter, and the diameter of at least one intermediate spiral coil located between the two is equal to the minimum upper diameter. More specifically, the exemplary upper portion 130b includes four intermediate spiral coils 131b, 132b, 133b, and 134b in addition to the uppermost spiral coil 114b. The diameter of the first intermediate spiral coil 131b (i.e., the intermediate spiral coil of the upper portion 130b adjacent to the lower portion (not shown)) is greater than the diameter of the second intermediate spiral coil 132b. The diameter of the second intermediate spiral coil 132b is also greater than the diameter of the third intermediate spiral coil 133b. However, the diameter of the fourth intermediate spiral coil 134b is greater than the diameter of the third intermediate spiral coil 133b. Therefore, the diameter of the third intermediate spiral coil 133b is the minimum upper diameter. The smallest third intermediate coil 133b is located between two larger intermediate coils (e.g., the first intermediate coil 131b and the fourth intermediate coil 134b), giving the upper portion 130b an hourglass shape. It is noteworthy that the diameter of the uppermost coil 114b is also substantially equal to the smallest diameter of the upper portion (e.g., the diameter of the third intermediate coil 133b). However, since the uppermost coil 114b is not a movable coil, its diameter does not affect the response of the upper portion 130b, and therefore the diameter of the uppermost coil 114b is not limited and can be modified without departing from the spirit and scope of the invention.

[0042] Now, especially when referring to Figure 2C In the exemplary conical upper portion 130c, the diameter of the spiral coils in the intermediate spiral coils of the upper portion gradually decreases from the lower portion to the uppermost spiral coil. More specifically, the exemplary upper portion 130c includes three intermediate spiral coils 131c, 132c, and 133c in addition to the uppermost spiral coil 114c. The diameter of the first intermediate spiral coil 131c (i.e., the intermediate spiral coil of the upper portion 130c adjacent to the lower portion (not shown)) is larger than the diameter of the second intermediate spiral coil 132c. The diameter of the second intermediate spiral coil 132c is also larger than the diameter of the third intermediate spiral coil 133c. Furthermore, the diameter of the third intermediate spiral coil 133c is larger than the diameter of the uppermost spiral coil 114c. However, since the uppermost spiral coil 114c is not a movable spiral coil, its diameter does not affect the response of the upper portion 130c; therefore, the diameter of the uppermost spiral coil 114c is not limited and can be modified without departing from the spirit and scope of the invention.

[0043] Now, especially when referring to Figure 2DIn the exemplary funnel-shaped upper portion 130d, the diameter of the spiral coils in the intermediate spiral coils of the upper portion gradually increases from the lower portion to the uppermost spiral coil. More specifically, the exemplary upper portion 130d includes three intermediate spiral coils 131d, 132d, and 133d in addition to the uppermost spiral coil 114d. The diameter of the first intermediate spiral coil 131d (i.e., the intermediate spiral coil of the upper portion 130d adjacent to the lower portion (not shown)) is smaller than the diameter of the second intermediate spiral coil 132d. The diameter of the second intermediate spiral coil 132d is also smaller than the diameter of the third intermediate spiral coil 133d. Furthermore, the diameter of the third intermediate spiral coil 133d is smaller than the diameter of the uppermost spiral coil 114d. However, since the uppermost spiral coil 114d is not a movable spiral coil, its diameter does not affect the response of the upper portion 130d; therefore, the diameter of the uppermost spiral coil 114d is not limited and can be modified without departing from the spirit and scope of the invention.

[0044] Now, especially when referring to Figure 2E In the exemplary barrel-shaped upper portion 130e, the diameters of the intermediate spiral coils of the upper portion adjacent to the lower portion and the intermediate spiral coils of the upper portion adjacent to the uppermost spiral coil are the minimum upper diameter, and the diameter of at least one intermediate spiral coil located between them is greater than the minimum upper diameter. More specifically, the exemplary upper portion 130e includes four intermediate spiral coils 131e, 132e, 133e, and 134e in addition to the uppermost spiral coil 114e. The diameter of the first intermediate spiral coil 131e (i.e., the intermediate spiral coil of the upper portion 130e adjacent to the lower portion (not shown)) is smaller than the diameter of the second intermediate spiral coil 132e. The diameter of the third intermediate spiral coil 133e is substantially the same as the diameter of the second intermediate spiral coil 132e. The diameter of the fourth intermediate spiral coil 134e is smaller than the diameter of the third intermediate spiral coil 133e. Therefore, the diameters of the first intermediate spiral coil 131e and the fourth intermediate spiral coil 134e are the minimum upper diameter. Two larger intermediate spiral coils (e.g., a second intermediate spiral coil 132e and a third intermediate spiral coil 133e) are arranged between the two smaller spiral coils, giving the upper portion 130e a barrel shape. It is noteworthy that the diameter of the uppermost spiral coil 114e is illustrated as being smaller than the minimum diameter of the upper portion. However, since the uppermost spiral coil 114e is not a movable spiral coil, its diameter does not affect the response of the upper portion 130e; therefore, the diameter of the uppermost spiral coil 114e is not limited and can be modified without departing from the spirit and scope of the invention.

[0045] To reiterate, regardless of the specific shape of the upper portion, it is contemplated that in certain exemplary helical springs made according to the present invention, the minimum diameter of the upper portion will generally be equal to or greater than the diameter of the smaller central coil of the lower portion, or in other words, equal to or greater than the minimum diameter of the lower portion. Therefore, it is contemplated that during the initial compression of the helical spring, the upper portion will be more easily compressed than the lower portion. Although in the exemplary embodiments described above, the uppermost coil is not a movable coil, it is also contemplated that in some embodiments, the uppermost coil may also be a movable coil or a partially movable coil, and thus the diameter of the uppermost coil can be selected according to the present invention to contribute to the overall response of the upper portion.

[0046] exist Figures 2A to 2E In the exemplary embodiments shown, the diameters of the coils vary to provide a specific spring constant and tactile feedback to the upper portion of the helical spring, while the pitch between the coils in the upper portion is substantially the same. However, it is contemplated that, in order to provide a specific spring constant and tactile feedback, the pitch between the coils in the upper portion may also vary, in addition to varying the diameters of one or more coils in the upper portion. However, as previously stated, in at least some exemplary embodiments, the maximum pitch in the upper portion is less than the minimum pitch in the lower portion. That is, regardless of whether the pitch in the upper and / or lower portion varies, the pitch between the coils in the upper portion is less than the pitch between the coils in the lower portion. Therefore, it is contemplated that, during the initial compression of the helical spring, the upper portion will be more easily compressed than the lower portion.

[0047] As a further improvement to the exemplary helical spring of the present invention, in some embodiments, the diameter of each movable coil in the upper portion of the spring is not necessarily greater than or equal to the diameter of the smaller central coil in the lower portion of the spring, in order to provide a variable and nonlinear loading response. Rather, and now referring to... Figure 3A In another embodiment, an exemplary helical spring 110a is provided, wherein the minimum diameter of the upper portion is less than or equal to the minimum diameter of the lower portion, and wherein the helical spring 110a also employs one of the aforementioned alternative upper portions. Specifically, in the helical spring 110a, the helical spring 110a is divided into a lower portion 120 and an upper portion 130a, wherein the lower portion 120 has an hourglass shape and includes a lowermost coil 112, a first intermediate coil 124, a second intermediate coil 126, and a third intermediate coil 128. The second intermediate coil 126 and... Figure 1 The intermediate coil 26 shown is similar, also characterized as the central coil of the lower portion 120, and its diameter is equal to the minimum lower diameter of the helical spring 110a. The upper portion 130a of the helical spring 110a is similar to... Figure 2AThe furnace tube configuration shown includes a fourth intermediate coil 131a, a fifth intermediate coil 132a, a sixth intermediate coil 133a, and an uppermost coil 114a. Therefore, the lower portion 120 of the exemplary helical spring 110a includes a total of four coils, and the upper portion 130a of the exemplary helical spring 110a also includes a total of four coils.

[0048] like Figure 3A As shown, in the exemplary helical spring 110a, the diameter of each movable coil in the lower portion 120 (i.e., the three lower intermediate coils 124, 126, 128) is greater than or equal to the minimum lower diameter, which is also the diameter of the second intermediate coil 126. The pitch between the coils 112, 124, 126, 128 in the lower portion 120 is greater than or equal to the minimum lower pitch. Furthermore, the diameter of each movable coil in the upper portion 130a (i.e., the three upper intermediate coils 131a, 132a, 133a) is less than or equal to the maximum upper diameter, and the pitch between the coils 131a, 132a, 133a, 114a in the upper portion 130a is less than or equal to the maximum upper pitch. However, in this exemplary helical spring 110a, the diameter of each movable coil in the upper portion 130a (i.e., the three upper intermediate coils 131a, 132a, 133a, 114a) is less than or equal to the maximum upper pitch. Figure 1 Unlike the helical spring 10 shown, the minimum diameter of the upper portion is less than or equal to the minimum diameter of the lower portion because the diameters of the fifth intermediate coil 132a and the sixth intermediate coil 133a are smaller than the diameter of the second intermediate coil 126. In the helical spring 110a, the pitch between the movable coils in the upper portion 130a remains less than or equal to the pitch between the movable coils in the lower portion 120, so that the helical spring 110a maintains and exhibits a variable and nonlinear loading response.

[0049] As a further improvement and another example of a helical spring made according to the present invention, and now referred to... Figure 3B A helical spring 110c is provided, which is also similar to Figure 3A The helical spring 110a shown has a lower portion 120 and an upper portion 130c. The lower portion 120 is connected to... Figure 3A The basic structure is the same as shown above, except that the lower portion 120 includes a lowermost spiral coil 112, a first intermediate spiral coil 124, a second intermediate spiral coil 126, and a third intermediate spiral coil 128, the pitch and diameter of which are the same as those described above. Figure 3A The same as described. However, with Figure 3A Unlike the coil spring 110a shown, the upper portion 130c of the coil spring 110c is similar to... Figure 2CThe conical structure shown includes a fourth intermediate spiral coil 131c, a fifth intermediate spiral coil 132c, a sixth intermediate spiral coil 133c, and an uppermost spiral coil 114c. The diameter of the fourth intermediate spiral coil 131c is larger than the diameter of the fifth intermediate spiral coil 132c, and the diameter of the fifth intermediate spiral coil 132c is also larger than the diameter of the sixth intermediate spiral coil 133c. Similarly, in the helical spring 110c, the minimum upper diameter is less than or equal to the minimum lower diameter because the diameters of the fifth intermediate spiral coil 132c and the sixth intermediate spiral coil 133c are smaller than the diameter of the second intermediate spiral coil 126. In the helical spring 110c, the pitch between the movable spiral coils in the upper portion 130c is also kept less than or equal to the pitch between the movable spiral coils in the lower portion 120, thus maintaining a variable and non-linear loading response for the helical spring 110c.

[0050] Further regarding the exemplary embodiments of the helical springs described herein, wherein the minimum upper diameter is less than or equal to the minimum lower diameter, it is, of course, expected that such embodiments are not limited to... Figure 3A The upper portion of the furnace tube and conical structure shown is not an isolated example; such embodiments can also be extended to other structures for the upper portion of the exemplary spring. For example, in a further embodiment where the minimum diameter of the upper portion is less than or equal to the minimum diameter of the lower portion, it is contemplated that a design could be employed. Figure 2B The upper portion shown, where coil 133b will be the minimum diameter of the exemplary helical spring; alternatively, it can also be... Figure 2D The upper portion shown, where the coil 131d will be the minimum diameter of the exemplary helical spring; or it can be adopted Figure 2E The upper portion shown, in which coils 131e and 134e will be the minimum diameters of the exemplary helical spring.

[0051] Now refer to Figure 4 In another exemplary embodiment of the invention, a first bagged helical spring 200a is provided, which includes a helical spring 210a, as referred to above. Figure 1 The aforementioned helical spring 10 is substantially similar. However, the first bagged helical spring 200a further includes a flexible enclosure 260a that forms a bag around the helical spring 210a. The flexible enclosure 260a includes: a bottom wall 262a adjacent to the lowermost spiral coil 212a of the helical spring 210a, a top wall 264a adjacent to the uppermost spiral coil 214a of the helical spring 210a, and a continuous side wall 266a extending from the bottom wall 262a to the top wall 264a, such that the continuous side wall 266a surrounds the helical spring 210a.

[0052] like Figure 4As shown, a second pouched helical spring 200b is also provided, disposed adjacent to the first pouched helical spring 200a. This second pouched helical spring 200b is substantially identical to the first pouched helical spring 200a, comprising both a helical spring 210b and a flexible sealing member 260b forming a pouch around the helical spring 210b. Figure 4 As shown, the first pocketed helical spring 200a and the second pocketed helical spring 200b are interconnected along their respective sidewalls 266a, 266b. The method of connecting adjacent pocketed helical springs is not limited and may include bonding or otherwise joining separately manufactured pocketed helical springs together, or alternatively, the manufacture of adjacent pocketed helical springs may be substantially simultaneous so that they have already been connected. For example, a flexible fabric may be provided, and flexible enclosures 260a, 260b may be formed from this flexible fabric to surround each of the individual helical springs 210a, 210b, thereby obtaining… Figure 4 The adjacent first pocketed helical spring 200a and second pocketed helical spring 200b are shown. For this purpose, the flexible fabric is preferably a nonwoven fabric that can be joined or welded by heat and pressure (e.g., by ultrasonic welding or similar thermal welding processes). Suitable fabrics may include, for example, one of the various thermoplastic fibers known in the art, such as nonwoven polymer-based fabrics, nonwoven polypropylene materials, or nonwoven polyester materials. In this regard, in some embodiments, suitable nonwoven fabrics may include elastic materials, such as spandex (i.e., spandex fiber), which can return to their original shape after stretching. In short, a wide variety of fabrics or similar materials can therefore be used to manufacture the flexible enclosure according to the invention, and of course, such nonwoven fabrics can also be joined together by sewing, metal studs, welding, or other suitable methods. Thus, adjacent pocketed helical springs are connected to each other, for example, by welding or bonding. However, alternatively, such interconnections can also be performed by means of clamps or hook-and-loop fasteners, or in other convenient ways.

[0053] Still refer to Figure 4 In this exemplary embodiment, the helical spring 210a of the first pocketed helical spring 200a is in a first orientation relative to rotation about the longitudinal axis of the helical spring 210a. The helical spring 210b of the second pocketed helical spring 200b is also in a first orientation. Therefore, the continuous wires 216a, 216b follow substantially parallel helical paths. In other words, at any given height of the helical springs 210a, 210b, the distance between the continuous wires 216a and 216b is substantially equal. However, one problem that may exist with this arrangement (i.e., both adjacent helical springs are in the first orientation) is that the helical springs are more likely to nest with each other.

[0054] In contrast, now refer to Figure 5In another exemplary embodiment, the helical spring 310a of the first bagged helical spring 300a is in a first orientation, while the helical spring 310b of the second bagged helical spring 300b is in a second orientation, which is rotated 180° relative to the first orientation about the longitudinal axis of the helical spring 310b. For example, in Figure 4 In the middle, the end 313a of the lowest coil 312a of the first bagged helical spring 300a faces towards Figure 4 Positioned on the left, while the end 313b of the lowest coil 312b of the second bagged helical spring 300b faces towards... Figure 4 The right side is positioned. More importantly, due to the 180° rotation, the continuous wires 316a and 316b no longer follow a parallel helical path, and therefore, the distance between the continuous wires 316a and 316b changes along the height of the helical springs 310a and 310b. Accordingly, the helical springs can no longer nest with each other. For example, in Figure 5 In the first pocketed coil spring 300a, the rightmost portion of the third coil 326a is adjacent to the leftmost portion of the third coil 326b of the adjacent second pocketed coil spring 300b. Therefore, the proximity of these portions of the adjacent springs will reduce or even completely prevent any tendency for the two adjacent coil springs to nest with each other.

[0055] Now refer to Figure 6A In some exemplary embodiments of the present invention, a plurality of adjacent bagged helical springs 400a–400f are connected along a line to form a bagged helical spring string 402, wherein the bagged helical springs 400a–400f are arranged along the length of the string 402. Figure 6A In the exemplary string 402 shown, the adjacent pocketed coil springs 400a–400f within string 402 include coil springs in the aforementioned combination. Figure 5The first orientation and the second orientation alternate. For example, the coil springs included in the first pocketed coil spring 400a are in the first orientation, the coil springs included in the second pocketed coil spring 400b are in the second orientation, the coil springs included in the third pocketed coil spring 400c are in the first orientation, the coil springs included in the fourth pocketed coil spring 400d are in the second orientation, the coil springs included in the fifth pocketed coil spring 400e are in the first orientation, and the coil springs included in the sixth pocketed coil spring 400f are in the second orientation. Therefore, within the pocketed coil springs of the same string 402, for each coil spring in the first orientation (i.e., the first, third, and fifth pocketed coil springs 400a, 400c, 400e), the adjacent coil springs are in the second orientation (i.e., the second, fourth, and sixth pocketed coil springs 400b, 400d, 400f). Of course, it is not required that the orientation of the coil springs must alternate between each adjacent spring. Depending on the specific form and function required for the bagged helical spring string, other configurations, such as 3-3, 2-2-2, or 1-2-1-2, are also possible.

[0056] Furthermore, and now refer to Figure 6B In some other exemplary embodiments of the invention, two adjacent strings 404 and 405 of pocketed helical springs are provided. In the first string 404, all pocketed helical springs 400a–400f are in a first orientation. In the second string 405, all pocketed helical springs 400g–400l are in a second orientation. As shown, for each pocketed helical spring 400a–400f in the first string 404, there is an adjacent pocketed helical spring 400g–400l in the second string 405. In other words, for each of the plurality of helical springs in the first string 404 in the first orientation, there is an adjacent helical spring in the second orientation in the adjacent second string 405. As previously stated, the plurality of pocketed helical springs 400a–400f in the first string 404 have helical springs in the first orientation, while the plurality of pocketed helical springs 400g–400l in the second string 405 have helical springs in the second orientation. However, it is not required that every helical spring in a string be in the same orientation. Instead, one or more helical springs in each string can be in alternating orientations without departing from the spirit and scope of the invention.

[0057] Now refer to Figure 6C In yet another exemplary embodiment of the invention, two adjacent strings of 406, 407 of pocketed helical springs are again provided. However, in this exemplary embodiment, and in conjunction with the above... Figure 6ASimilarly, in the first string 406, adjacent pocketed helical springs 400a–400f alternate between a first orientation and a second orientation, and similarly, adjacent pocketed helical springs 400g–400l alternate between a first orientation and a second orientation in the second string 407. Therefore, in the pocketed helical springs of the first string 406, for each helical spring in the first orientation (i.e., the first, third, and fifth pocketed helical springs 400a, 400c, 400e), an adjacent helical spring is in the second orientation (i.e., the second, fourth, and sixth pocketed helical springs 400b, 400d, 400f). Furthermore, in the second string 407, there is another adjacent helical spring in the second orientation (i.e., the first, third, and fifth pocketed helical springs 400g, 400i, 400k).

[0058] It is worth noting that multiple bags of helical springs positioned in parallel (e.g.) Figure 6B and Figure 6C The strings shown can form mattress components. See now. Figure 7 An exemplary mattress assembly 500 includes multiple coil spring strings 504, 505, wherein the coil springs are oriented in a manner similar to... Figure 6B In other words, in the first string 504, all the pocketed coil springs included in the string are in a first orientation. In the second string 505, which alternates with the first string 504, all the pocketed coil springs included in the string are in a second orientation. As shown in the figure, for each pocketed coil spring in the first string 504 that is in the first orientation, there is an adjacent pocketed coil spring in the adjacent second string 505 that is in the second orientation.

[0059] Now refer to Figure 8 Another exemplary mattress assembly 600 includes a plurality of coil spring strings 606, 607, wherein the coil springs are oriented in a manner similar to Figure 6C In other words, within each string of strings 606 and 607, the pocketed helical springs alternate between a first orientation and a second orientation. Therefore, in the first group of strings 606, for each helical spring in the first orientation, the adjacent helical spring is in the second orientation. Furthermore, in the adjacent second group of strings 607, there is another adjacent helical spring in the second orientation. This arrangement can be called a checkerboard pattern.

[0060] As a further improvement, the mattress assembly made according to the present invention may include coil springs in different patterns employing a first orientation and a second orientation in different zones (or sections) of the mattress assembly. To provide a list of non-limiting examples, the mattress assembly may include: a perimeter zone and a non-perimeter zone; a head zone and a foot zone; a left side zone and a right side zone; or any combination of the above zones. Each of these zones may have oriented coil springs with different patterns according to the desired function and feel of that zone. For example, coil springs all in the same orientation may provide a desired feel when compressed, while coil springs with alternating orientations may provide a different desired feel. Furthermore, in some embodiments, the pattern may vary between different zones to provide a smoother transition between them. For example, a first zone may have all coil springs in the first orientation, and a second zone may provide a checkerboard arrangement alternating between the first and second orientations (e.g., Figure 6C and Figure 8 (as shown in the pattern), and in the transition zone between the first and second zones, some adjacent helical springs may be in the same orientation, and other adjacent helical springs may be in alternating orientations.

[0061] However, although the figures shown and discussed above describe a 180° rotation, different amounts of rotation (e.g., 30°, 60°, 90°, 120°, and 150°) are possible without departing from the spirit and scope of the invention. Different amounts of rotation can also be used within different zones and / or for transitions between these zones.

[0062] As a further improvement to the invention, the helical spring within the bag-type helical spring is prevented from changing its orientation after assembly. In some embodiments, the fabric used to form the bag is sufficient to prevent the helical spring from rotating about its longitudinal axis. In other embodiments, additional means are provided to prevent the helical spring from rotating about its longitudinal axis. For example, in some embodiments, the cut end of the thread (e.g., the starting / ending end of the helical spring) can be positioned outside the final coil to provide a pushback force on the fabric. In other embodiments, the helical spring can be preloaded (e.g., partially compressed) before forming the bag, such that the helical spring applies sufficient force at the top and bottom to prevent rotation. In still other embodiments, the bag can be welded closed in some way at the top and / or bottom of the helical spring, such that the weld itself prevents rotation, including, but not limited to, using specially designed forming weld heads to form a weld that engages with the helical spring and prevents rotation. Furthermore, in some embodiments, mechanical connections, such as adhesives, fasteners, straps, stitching, etc., can be used to physically attach the helical spring to the bag to prevent rotation.

[0063] According to some exemplary embodiments of the present invention, a mattress assembly is manufactured by first providing a plurality of helical springs, for example, in conjunction with the above. Figure 1 and Figure 4 –5. The exemplary helical springs described in the example helical springs are then surrounded by a flexible enclosure to form a bag, such that each bagged helical spring is located within a string of bagged helical springs, for example, as described above. Figure 6A –6C describes a series of strings. Multiple strings of pocketed helical springs are positioned in parallel to form a mattress assembly, such as those described above. Figure 7 –8. The mattress assembly described in the mattress assembly. According to some exemplary embodiments of the invention, the coil springs are configured with a first orientation or a second orientation before forming a pocket around each coil spring, as described above. Figure 6A -6C and Figure 7 As discussed in –8.

[0064] In some exemplary embodiments, a coiling machine is used to produce helical springs, and the orientation of the spring is determined by the amount of wire included in the lowest coil of the helical spring. Now, in particular, reference is made to... Figure 9 and Figure 10 According to one exemplary embodiment, a first helical spring 710a (representing a helical spring intended to employ a first orientation) manufactured and supplied by a spring coiling machine is combined with the above. Figure 1 and Figure 4 The second helical spring 710b (representing a helical spring intended for a second orientation) is manufactured in a substantially similar manner, except that an additional half-turn of wire is included in the lowermost coil 712b of the helical spring 710b. Therefore, and as... Figure 10 As shown, when the ends 713a and 713b of the helical springs 710a and 710b are aligned, the second helical spring 710b, with an additional half-turn, has rotated 180° relative to the first helical spring 710a. Although not explicitly shown in the figure, when a pouch is formed around the first and second helical springs 710a and 710b, the ends 713a and 713b will be in substantially the same position relative to the pouch surrounding the helical springs 710a and 710b.

[0065] Rather than including the additional half-turn of wire, it is contemplated that the amount of wire included in the lowest spiral coil can be reduced by half a turn to achieve a similar change in orientation. Similarly, wire can be added or removed at the highest spiral coil to achieve a similar change in orientation. Of course, in all cases, the change in the amount of wire is not limited to half a turn, but can be less than half a turn or more than half a turn without departing from the spirit and scope of the invention.

[0066] In embodiments where the helical spring is manufactured and produced by a spring coiling machine and includes different amounts of coil in the lowermost and / or uppermost coils, it is anticipated that, since the cutting point position on the spring coiling machine remains constant, the amount of wire included in the lowermost and / or uppermost coils of the helical spring determines the orientation of the spring.

[0067] Of course, the same coil spring can also be oriented using any number of auxiliary mechanical devices (such as a flipping mechanism) after the coil spring has been supplied but before it is bagged.

[0068] Those skilled in the art will recognize that other embodiments are possible without departing from the teachings of this invention or the scope of the appended claims. The specific details of this detailed description, particularly the exemplary embodiments disclosed herein, are provided primarily for clarity of understanding and should not be construed as limiting in any way. Various modifications will be readily apparent to those skilled in the art upon reading this disclosure, and these modifications can be made without departing from the spirit or scope of the claimed invention.

Claims

1. A helical spring, comprising: A continuous wire, the continuous wire forming a lowermost spiral coil, an uppermost spiral coil opposite to the lowermost spiral coil, and a plurality of helical intermediate spiral coils located between the lowermost spiral coil and the uppermost spiral coil, the continuous wire defining: the pitch between the lowermost spiral coil and the helical spiral coil adjacent to the lowermost spiral coil, the pitch between each spiral coil in the plurality of intermediate spiral coils, and the pitch between the uppermost spiral coil and the intermediate spiral coil adjacent to the uppermost spiral coil, and the continuous wire is divided into: The lower portion includes one or more intermediate spiral coils among the lowermost spiral coil and the intermediate spiral coils, wherein the diameter of each intermediate spiral coil in the lower portion is greater than or equal to the minimum lower diameter, and the pitch between the spiral coils in the lower portion is greater than or equal to the minimum lower pitch; and The upper portion includes the uppermost spiral coil and one or more intermediate spiral coils, wherein the diameter of each intermediate spiral coil in the upper portion is greater than or equal to the minimum diameter of the upper portion, and the pitch between the spiral coils in the upper portion is less than or equal to the maximum pitch of the upper portion. Wherein, the minimum diameter of the upper part is greater than or equal to the minimum diameter of the lower part, and Wherein, the maximum pitch of the upper part is less than the minimum pitch of the lower part.

2. The helical spring according to claim 1, wherein the total number of coils in the lower portion is between three and eight coils.

3. The helical spring according to claim 1, wherein the total number of coils in the upper portion is between three and six coils.

4. The helical spring according to claim 1, wherein the number of coils in the upper portion is less than or equal to the number of coils in the lower portion.

5. The helical spring according to claim 1, wherein the diameter of the lowermost coil is greater than the lower minimum diameter, the diameter of the intermediate coil of the lower portion adjacent to the upper portion is greater than the lower minimum diameter, and the diameter of at least one coil of the lower portion is equal to the lower minimum diameter, such that the lower portion has an hourglass shape.

6. The helical spring of claim 1, wherein the diameter of the central coil of the lower portion is equal to the minimum diameter of the lower portion, and the diameter of each of the other coils of the lower portion is greater than the minimum diameter of the lower portion, such that the lower portion has an hourglass shape.

7. The helical spring according to claim 1, wherein the diameter of each intermediate coil in the upper portion is substantially equal, and the diameter of the uppermost coil is smaller than the diameter of each intermediate coil in the upper portion, such that the upper portion has a furnace tube shape.

8. The helical spring of claim 1, wherein the diameter of the intermediate coil of the upper portion adjacent to the lower portion is greater than the upper minimum diameter, the diameter of another intermediate coil of the upper portion is greater than the upper minimum diameter, and the diameter of at least one intermediate coil located between the two is equal to the upper minimum diameter, such that the upper portion has an hourglass shape.

9. The helical spring according to claim 8, wherein the diameter of the uppermost coil is equal to the minimum diameter of the upper portion.

10. The helical spring according to claim 1, wherein the diameter of the coil in the intermediate coil of the upper portion gradually decreases from the lower portion to the uppermost coil, such that the upper portion has a tapered shape.

11. The helical spring according to claim 1, wherein the diameter of the coil in the intermediate coil of the upper portion gradually increases from the lower portion to the uppermost coil, such that the upper portion has a funnel shape.

12. The helical spring of claim 1, wherein the diameter of the intermediate coil of the upper portion adjacent to the lower portion and the diameter of the intermediate coil of the upper portion adjacent to the uppermost coil are the minimum upper diameter, and at least one intermediate coil located between them has a diameter greater than the minimum upper diameter, such that the upper portion has a barrel shape.

13. A pocket-sized helical spring, comprising: A helical spring, the helical spring comprising A continuous wire, the continuous wire forming a lowermost spiral coil, an uppermost spiral coil opposite to the lowermost spiral coil, and a plurality of helical intermediate spiral coils located between the lowermost spiral coil and the uppermost spiral coil, the continuous wire defining: the pitch between the lowermost spiral coil and the helical spiral coil adjacent to the lowermost spiral coil, the pitch between each of the plurality of intermediate spiral coils, and the pitch between the uppermost spiral coil and the intermediate spiral coil adjacent to the uppermost spiral coil; the continuous wire is divided into: The lower portion includes the lowermost spiral coil and one or more intermediate spiral coils, wherein the diameter of each intermediate spiral coil in the lower portion is greater than or equal to the minimum lower diameter, and the pitch between the spiral coils in the lower portion is greater than or equal to the minimum lower pitch; and The upper portion includes one or more intermediate spirals among the uppermost spiral and the intermediate spirals, wherein the diameter of each intermediate spiral in the upper portion is greater than or equal to the minimum upper diameter, and the pitch between the spirals in the upper portion is less than or equal to the maximum upper pitch. as well as A flexible enclosure forming a bag around the helical spring. Wherein, the minimum diameter of the upper part is greater than or equal to the minimum diameter of the lower part, and the maximum pitch of the upper part is less than the minimum pitch of the lower part, and The diameter of the central spiral of the lower portion is equal to the minimum diameter of the lower portion, and the diameter of each of the other intermediate spirals of the lower portion is the same and greater than the minimum diameter of the lower portion, so that the lower portion has an hourglass shape.

14. A mattress assembly comprising: Multiple parallel strings formed by bagged helical springs, each string comprising: Multiple helical springs are arranged along the length of the string, each helical spring comprising: A continuous wire, the continuous wire forming a lowermost spiral coil, an uppermost spiral coil opposite to the lowermost spiral coil, and a plurality of helical intermediate spiral coils located between the lowermost spiral coil and the uppermost spiral coil, the continuous wire defining: the pitch between the lowermost spiral coil and the helical spiral coil adjacent to the lowermost spiral coil, the pitch between each of the plurality of intermediate spiral coils, and the pitch between the uppermost spiral coil and the intermediate spiral coil adjacent to the uppermost spiral coil; and the continuous wire is divided into: The lower portion includes one or more intermediate spirals among the lowermost spirals and intermediate spirals, wherein the diameter of each intermediate spiral in the lower portion is greater than or equal to the lower minimum diameter, and the pitch between the spirals in the lower portion is greater than or equal to the lower minimum pitch. The upper portion includes one or more intermediate spiral coils among the uppermost spiral coil and the intermediate spiral coils, wherein the diameter of each intermediate spiral coil in the upper portion is greater than or equal to the minimum upper diameter, and the pitch between the spiral coils in the upper portion is less than or equal to the maximum upper pitch; and A flexible enclosure forming a bag around each of the coil springs in the string. Wherein, the minimum diameter of the upper part is greater than or equal to the minimum diameter of the lower part, and the maximum pitch of the upper part is less than the minimum pitch of the lower part. In this configuration, the diameter of the central spiral in the lower portion is equal to the minimum diameter of the lower portion, and the diameter of each of the other intermediate spirals in the lower portion is the same and greater than the minimum diameter of the lower portion, giving the lower portion an hourglass shape. In this configuration, for each of the plurality of helical springs, the helical spring is in a first orientation, while the adjacent helical spring is in a second orientation, the second orientation being rotated 180° relative to the first orientation about the longitudinal axis of the helical spring.

15. The mattress assembly of claim 14, wherein the helical spring in the first orientation and the adjacent helical spring in the second orientation are located in the same string of pocketed helical springs.

16. The mattress assembly of claim 14, wherein the helical spring in the first orientation and the adjacent helical spring in the second orientation are located in adjacent strings of pocketed helical springs.

17. The mattress assembly of claim 16, wherein each of the plurality of pocketed coil springs in the string of the coil springs in the first orientation is also in the first orientation.

18. The mattress assembly of claim 16, wherein each of the plurality of pocketed coil springs in the string of the coil springs in the second orientation is also in the second orientation.

19. The mattress assembly of claim 15, wherein another adjacent coil spring in an adjacent string of pocketed coil springs is in the second orientation.

20. A method of manufacturing a mattress assembly, comprising: Multiple helical springs are provided, each helical spring including A continuous wire, the continuous wire forming a lowermost spiral coil, an uppermost spiral coil opposite to the lowermost spiral coil, and a plurality of helical intermediate spiral coils located between the lowermost spiral coil and the uppermost spiral coil, the continuous wire defining: the pitch between the lowermost spiral coil and the helical spiral coil adjacent to the lowermost spiral coil, the pitch between each of the plurality of intermediate spiral coils, and the pitch between the uppermost spiral coil and the intermediate spiral coil adjacent to the uppermost spiral coil, and the continuous wire is divided into: The lower portion includes one or more intermediate spiral coils among the lowermost spiral coil and the intermediate spiral coils, wherein the diameter of each intermediate spiral coil in the lower portion is greater than or equal to the minimum lower diameter, and the pitch between the spiral coils in the lower portion is greater than or equal to the minimum lower pitch; and The upper portion includes one or more intermediate spirals among the uppermost spiral and the intermediate spirals, wherein the diameter of each intermediate spiral in the upper portion is greater than or equal to the minimum diameter of the upper portion, and the pitch between the spirals in the upper portion is less than or equal to the maximum pitch of the upper portion. A flexible enclosure is used to form a bag around each helical spring, such that each bagged helical spring is in the bagged helical spring string; as well as The multiple bundles of bagged helical springs are positioned in a parallel manner. Wherein, the maximum pitch of the upper part is less than the minimum pitch of the lower part, and Prior to forming the bag around each helical spring, the helical spring is positioned in a first orientation or a second orientation, the second orientation being rotated 180° relative to the first orientation about the longitudinal axis of the helical spring.

21. The method of claim 20, wherein the upper minimum diameter is greater than or equal to the lower minimum diameter.

22. The method of claim 20, wherein the upper minimum diameter is less than or equal to the lower minimum diameter.

23. The method of claim 20, wherein the plurality of helical springs are provided by a spring coiling machine, and the orientation of the springs is determined by the amount of wire included in the lowermost coil of the helical springs.

24. The method of claim 20, wherein the helical spring in the second orientation has an additional half-turn of wire in the lowermost coil of the helical spring, such that the end of the helical spring in the first orientation and the end of the helical spring in the second orientation are located in substantially the same position relative to the bag surrounding each helical spring.

25. The method of claim 20, wherein the plurality of helical springs are provided by a spring coiling machine, and the orientation of the springs is determined by a flipping mechanism after the spring coiling machine provides the springs and before the bag is formed around the helical springs.

26. A helical spring, comprising: A continuous wire, the continuous wire forming a lowermost spiral coil, an uppermost spiral coil opposite to the lowermost spiral coil, and a plurality of helical intermediate spiral coils located between the lowermost spiral coil and the uppermost spiral coil, the continuous wire defining: the pitch between the lowermost spiral coil and the helical spiral coil adjacent to the lowermost spiral coil, the pitch between each of the plurality of intermediate spiral coils, and the pitch between the uppermost spiral coil and the intermediate spiral coil adjacent to the uppermost spiral coil, and the continuous wire is divided into: The lower portion includes one or more intermediate spiral coils among the lowermost spiral coil and the intermediate spiral coils, wherein the diameter of each intermediate spiral coil in the lower portion is greater than or equal to the minimum lower diameter, and the pitch between the spiral coils in the lower portion is greater than or equal to the minimum lower pitch; and The upper portion includes the uppermost spiral coil and one or more intermediate spiral coils, wherein the diameter of each intermediate spiral coil in the upper portion is greater than or equal to the minimum diameter of the upper portion, and the pitch between the spiral coils in the upper portion is less than or equal to the maximum pitch of the upper portion. In the lower portion, one of the spiral intermediate spirals forms a central spiral, the diameter of which is equal to the minimum diameter of the lower portion. In this configuration, each of the other intermediate spiral coils in the lower portion has the same diameter, which is larger than the minimum diameter of the lower portion, giving the lower portion an hourglass shape. Wherein, the minimum diameter of the upper part is less than or equal to the minimum diameter of the lower part, and Wherein, the maximum pitch of the upper part is less than the minimum pitch of the lower part.

27. The helical spring of claim 26, wherein the total number of coils in the lower portion is between three and eight.

28. The helical spring of claim 26, wherein the total number of coils in the upper portion is between three and six.

29. The helical spring of claim 26, wherein the number of coils in the upper portion is less than or equal to the number of coils in the lower portion.

30. The helical spring of claim 26, wherein the diameter of each of the intermediate coils in the upper portion is substantially equal, and the diameter of the uppermost coil is smaller than the diameter of each of the intermediate coils in the upper portion, such that the upper portion has a furnace tube shape.

31. The helical spring of claim 26, wherein the diameter of the intermediate coil of the upper portion adjacent to the lower portion is greater than the upper minimum diameter, the diameter of another intermediate coil of the upper portion is greater than the upper minimum diameter, and the diameter of at least one intermediate coil located between the two is equal to the upper minimum diameter, such that the upper portion has an hourglass shape.

32. The helical spring according to claim 31, wherein the diameter of the uppermost coil is equal to the minimum diameter of the upper portion.

33. The helical spring of claim 26, wherein the diameter of the coil in the intermediate coil of the upper portion gradually decreases from the lower portion to the uppermost coil, such that the upper portion has a tapered shape.

34. The helical spring of claim 26, wherein the diameter of the coil in the intermediate coil of the upper portion gradually increases from the lower portion to the uppermost coil, such that the upper portion has a funnel shape.

35. The helical spring of claim 26, wherein the diameter of the intermediate coil of the upper portion adjacent to the lower portion and the diameter of the coil in the intermediate coil of the upper portion adjacent to the uppermost coil are the minimum upper diameter, and at least one intermediate coil located between them has a diameter greater than the minimum upper diameter, such that the upper portion has a barrel shape.

36. A pocket-sized helical spring, comprising: The helical spring according to claim 26; as well as A flexible enclosure that forms a bag around the helical spring.

37. A mattress assembly comprising a plurality of parallel strings of pocketed coil springs, each string comprising: A plurality of helical springs according to claim 26, the plurality of helical springs being arranged along the length of the string; as well as A flexible enclosure that forms a bag around each of the helical springs in the string. Wherein, the minimum diameter of the upper part is greater than or equal to the minimum diameter of the lower part, and the maximum pitch of the upper part is less than the minimum pitch of the lower part. In this configuration, for each of the plurality of helical springs, each helical spring is in a first orientation, while the adjacent helical spring is in a second orientation, the second orientation being rotated 180° relative to the first orientation about the longitudinal axis of the helical spring.

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