Bed or seat product and method of disassembling a product

Abstract

A bed or chair product (10) includes a pocketed spring assembly (12) glued to a cushioning assembly (14). The product (10) can be quickly and easily separated into components of the product for recycling. The pocketed spring assembly (12) includes a plurality of parallel strings (26) of individually pocketed springs (28) and a lower sheet (38) glued to lower surfaces (50, 52) of at least some of the strings (26). The cushioning assembly (14) includes at least one cushioning layer (62, 64, 66) and a tie sheet (16) stitched together without the use of any glue. The tie sheet (16) is glued to upper surfaces (50) of the strings (26) of the pocketed spring assembly (12).

Description

Technical Field

[0001] The present invention generally relates to products for use in beds and chairs, and more particularly to products for use in beds and chairs having components that can be easily separated for recycling. Background Technology

[0002] Over the years, mattress spring core construction has been a subject of continuous improvement, with advancements in materials and machinery. A well-known form of spring core construction is known as the Marshall spring construction, in which metal coil springs are encased in individual fabric pockets, forming elongated or continuous series of individually pocketed coil springs. Because the fabric used in the pocketed spring assembly is self-welding, these pocketed spring series are manufactured by folding an elongated fabric piece longitudinally to form two layers of fabric and then thermally or ultrasonically welding the transverse and longitudinal seams to join the fabric layers, thereby defining a pocket-like structure that encloses the springs. One such fabric is a nonwoven polypropylene fabric.

[0003] Once the pocket spring connectors are constructed, they can be assembled in various ways to form pocket spring assemblies for mattresses, cushions, etc. For example, multiple or consecutive connectors can be arranged in rows corresponding to the desired size and shape of the mattress, etc., and adjacent rows of connectors can be interconnected in various ways. The result is a complete assembly of individually pocketed coil springs, referred to as a pocket spring assembly.

[0004] The current method for assembling mattresses or other bedding or seating products involves using adhesives to bond the cushioning layers to the top surface of the pocket spring assembly to form a single-sided mattress. To manufacture a double-sided mattress, adhesives are used to bond the cushioning layers to both the top and bottom surfaces of the pocket spring assembly. Each cushioning layer typically includes a foam layer, which may be made of polyurethane or any other known foam composition.

[0005] Sometimes more than one cushioning layer can be used to form a cushioning sub-assembly. The components of the cushioning sub-assembly are glued together as a sub-assembly, and the complete cushioning sub-assembly is bonded to the outer surface of the pocket spring assembly by adhesive.

[0006] Known alternative methods for assembling bedding or seating products include: using adhesive to bond a cushioning layer to a pocket spring assembly, and then using more adhesive to bond a second cushioning layer to a first cushioning layer of a cushioning subassembly. Using this method, any number of cushioning layers can be bonded to each other. Known methods for assembling bedding or seating products, including the methods described above, have the following problems.

[0007] First, adhesives are expensive, and known methods for securing one or more cushioning layers to at least one side of a pocket spring assembly require large amounts of adhesive.

[0008] Secondly, separating the various components of bedding or seating products (such as mattresses) at the end of their lifespan is difficult and costly. There is a strong desire to recycle as many bedding or seating products as possible. The adhesives used to hold the components together make separation difficult, expensive, laborious, and sometimes impossible. Depending on a number of factors, separating the materials may be economically infeasible.

[0009] Third, metal coil springs may be difficult to separate from the fabric that wraps them, making it impossible for the metal to be reused or recycled separately from the fabric.

[0010] This invention addresses each of these problems. In the bedding or seating products of this invention, the amount of adhesive is reduced because the cushioning layers are sewn or quilted together rather than glued. Quilting machines disclosed in the applicant's U.S. Patents 11,015,274, 11,015,275, 11,111,615, and 11,578,441, which can sew multiple cushioning layers together to form a cushioning sub-assembly without the use of adhesive, are all incorporated herein by reference in their entirety. However, the cushioning sub-assembly must be attached to the pocket spring assembly.

[0011] Secondly, when the product reaches the end of its service life, the cushioning layer above the bottom sheet of the cushioning sub-assembly can be quickly and easily separated from each other for recycling at low cost. After the stitching is removed from the cushioning sub-assembly, the lower sheet of the cushioning sub-assembly can remain adhesively attached to the pocket spring assembly. Therefore, the lower sheet of the cushioning sub-assembly can be recycled together with the material of the connecting parts of the pocket spring assembly. Preferably, both are made of the same material.

[0012] The bedding or chair products described in this article also allow for easy separation of the metal coil spring from the fabric of the pocket spring assembly. The fabric of the pocket spring assembly can be perforated, allowing a person to open the pocket of the pocket spring assembly to remove the metal coil spring from the fabric pocket. The lower sheet of the pocket spring assembly provides a gripping surface, allowing the user to tear the perforated fabric of the pocket spring connector to open the pocket and allow for removal and recycling of the metal coil spring.

[0013] Upon disassembly, three components are obtained: 1) a fabric skeleton consisting of an adhesive material; 2) at least one comfort layer, each typically a foam layer; and 3) a metal coil spring. Each component can be individually recycled or reused.

[0014] Therefore, this invention enables mattresses or other bedding or seating products to be separated into multiple materials that can be recycled individually. The entire mattress can be recycled without any waste, thereby saving landfill space, time, and money. The disassembly method described herein optimizes the efficiency of the recycling process and reduces the environmental impact of processing used mattresses or other bedding or seating products. Summary of the Invention

[0015] In one aspect, products for bedding or seating include pocket spring assemblies and cushioning assemblies joined together by adhesive. The pocket spring assembly includes multiple pocket springs joined to a lower sheet. Each pocket spring includes a metal spring located within a fabric pocket. The fabric pocket has perforations that at least partially surround the fabric pocket.

[0016] The lower sheet is attached to the lower surface of the pocket spring assembly. The lower sheet extends outward from the pocket spring core to form a frame-like perimeter that can be easily gripped by the user to manipulate the pocket spring assembly.

[0017] The lower sheet of the pocket spring assembly can be made of the same material or fabric as the fabric pocket. The lower sheet of the pocket spring assembly can also be made of the same material or fabric as the connecting sheet described below. In some embodiments, each of these fabrics can be nonwoven polypropylene.

[0018] Products for bedding or seating also include a cushioning assembly comprising at least one foam layer stitched together and a connecting sheet. The connecting sheet may be made of nonwoven polypropylene.

[0019] Decorative coverings may surround the pocket spring assembly and cushioning assembly, which, for the purposes of this article, can be considered together as the interior of the product.

[0020] On the other hand, products for bedding or seating include pocket spring assemblies comprising a plurality of parallel spring connectors joined together. Each connector includes a plurality of individually pocketed springs. Each connector includes a fabric piece joined together along a longitudinal seam and having opposing first and second fabric layers on opposite sides of the springs. The plurality of pocket pieces are formed along the length of the connector by a transverse seam joining the first and second layers. At least one spring is positioned in each pocket piece. A lower sheet is attached to the lower surface of at least some of the connectors in the connector. The connectors have perforations at least partially surrounding the connector.

[0021] A cushioning assembly comprising multiple cushioning layers and connecting sheets is sewn together. The connecting sheets of the cushioning assembly are attached to at least some of the connecting elements in the pocket spring assembly.

[0022] On the other hand, a method of disassembling a pocket spring assembly includes removing threads from the cushioning assembly to separate the cushioning layers from each other. The cushioning assembly includes a connecting sheet glued to the pocket spring assembly. The method also includes tearing the fabric along perforations in the connectors of the individually pocketed springs of the pocket spring assembly by pulling the lower sheet of the pocket spring assembly away from the connecting sheet of the cushioning assembly. The pocket spring assembly includes a plurality of parallel spring connectors joined together. Each connector includes a plurality of individually pocketed springs. Each connector also includes a piece of fabric joined together along a longitudinal seam, with opposite first and second fabric layers located on opposite sides of the springs. The plurality of pockets are formed along the length of the connector by a transverse seam joining the first and second layers. At least one spring is positioned in each pocket. The method also includes removing the springs from the pockets of the connectors. Preferably, the lower sheet of the pocket spring assembly is thicker than the connecting sheet of the cushioning assembly; however, the lower sheet of the pocket spring assembly and the connecting sheet of the cushioning assembly may be of the same thickness. Preferably, the lower sheet of the pocket spring assembly and the connecting sheet of the cushioning assembly are made of the same material. However, the lower sheet of the pocket spring assembly may be made of a different material than the connecting sheet of the cushioning assembly. Preferably, the adhesive / gluoride used to join the connectors together in the pocket spring assembly and to join the connecting sheet to the pocket spring assembly is at least partially made of the same material as the connecting sheet of the cushioning assembly, the lower sheet of the pocket spring assembly, and the connector fabric of the pocket spring assembly.

[0023] On the other hand, a method for disassembling a pocket spring assembly includes removing threads from the cushioning assembly to separate the cushioning layers from each other. The cushioning assembly includes a connecting sheet glued to the pocket spring assembly. The method further includes tearing the fabric along perforations in the connecting members of the individually pocketed springs of the pocket spring assembly using the lower sheet of the pocket spring assembly. The method finally includes removing the springs from the pockets of the connecting members that have been opened due to the tearing step.

[0024] The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the above-described invention and the detailed embodiments given below, explain the principles of the invention. Attached Figure Description

[0025] Figure 1 This is a partially cutaway perspective view of a bed or chair product incorporating a pocket spring assembly joined to a cushioning component, according to the principles of the present invention.

[0026] Figure 2 yes Figure 1 A three-dimensional cutaway view of the cushioning components of a mattress.

[0027] Figure 3 yes Figure 2 A partial cross-sectional view of the buffer component.

[0028] Figure 4 This is a cross-sectional view of the cushioning assembly that is fixed to the pocket spring assembly.

[0029] Figure 4A This is a longitudinal cross-sectional view of the cushioning assembly that is fixed to the pocket spring assembly.

[0030] Figure 4B This is a cross-sectional view of the portion of the cushioning assembly that is fixed to the pocket spring assembly.

[0031] Figure 5 yes Figure 4B A three-dimensional view of a pocket spring assembly being torn to separate the spring from the fabric.

[0032] Figure 6A This is a cross-sectional view showing the bag spring assembly torn and the lines connecting the cushioning layer removed.

[0033] Figure 6B This is a cross-sectional view of the separate components of a mattress. Detailed Implementation

[0034] Reference Figure 1 This illustration shows a bedding product in the form of a single-sided mattress 10, incorporating the principles of the present invention. The product or mattress 10 includes a pocket spring assembly 12 glued to a cushioning assembly 14 to form a product assembly 15. A decorative covering 20 surrounds the product assembly 15, which includes the pocket spring assembly 12 and the cushioning assembly 14 glued together.

[0035] like Figure 1 As shown, the fully assembled product 10 has a length "L", which is defined as the linear distance between opposite end surfaces 22. Figure 1 (Only one is shown in the image). Similarly, the assembled product 10 has a width "W", which is defined as the linear distance between the opposite side surfaces 24. Figure 1 Only one is shown in the image. Figure 1 In the products shown, the length is depicted as greater than the width. However, the length and width can be the same (as in the case of a square product) and this is also within the scope of the invention.

[0036] like Figure 1 As shown, the pocket spring assembly 12 includes a pocket spring assembly core 34 and a lower sheet 38. The pocket spring assembly core 34 is manufactured from a plurality of tandem pieces 26 of pocket springs 28 joined together in any known manner (e.g., by gluing). Although the pocket springs 28 are typically metal coil springs 18 (such as...) Figure 4 (As shown), but the spring can be any elastic component, including, for example, foam. Although a configuration of a metal helical spring 18 is shown, any known spring configuration can be used. The invention is not limited to helical springs.

[0037] Although the connecting elements 26 of the pocket springs 28 are typically arranged in laterally extending rows 30 and longitudinally extending columns 32, such as Figure 1 As shown, however, the cascade 26 of the pocket spring 28 may be offset, as is known in the art. This invention is not intended to limit the configuration or type of the pocket spring assembly core 34 to the configuration or type shown.

[0038] like Figure 1 As best shown, each cascade 26 extends longitudinally or from head to toe along the entire length of the pocket spring assembly core 34. Although the cascade 26 is... Figure 1 The pocket spring assembly 12 is shown extending longitudinally or from head to toe, but the connector 26 may extend laterally or from side to side as is known in the art. In any of the embodiments shown or described herein, the connector may extend longitudinally (from one end to the other) or laterally (from side to side).

[0039] like Figure 1 and Figure 5 As best shown, each connector 26 of the pocket spring assembly core 34 includes a fabric piece joined along a longitudinal seam 40. Figure 1 and Figure 4B As best shown, opposite first fabric layers 42 and second fabric layers 44 are located on opposite sides of spring 18, and a plurality of pockets 46 are formed along the length of the connector 26 by a transverse seam 48 joining the first fabric layers 42 and the second fabric layers 44. At least one spring 18 is positioned in each pocket 46. Although one type of spring 18 is shown, any spring may be incorporated into any pocket 46.

[0040] like Figure 4 As best shown, each connector 26 of the pocket spring assembly core 34 has an upper surface 50 and a lower surface 52. (As illustrated...) Figure 4A As shown, the upper surfaces 50 of the connectors 26 of the pocket spring assembly core 34 are substantially coplanar in the upper plane P1, and the lower surfaces 52 of the connectors 26 of the pocket spring assembly core 34 are substantially coplanar in the lower plane P2. The linear distance between the upper surfaces 50 and the lower surfaces 52 of the connectors 26 of the pocket spring assembly core 34 is defined as the height "H" of the pocket spring assembly core 34, since all connectors 26 are of the same height.

[0041] like Figure 4As best shown, the lower sheet 38 is secured to the lower surface 52 of at least some of the connectors 26 in the core of the pocket spring assembly using adhesive / glue beads 36. The adhesive beads 36 securing the connectors 26 of the core of the pocket spring assembly 34 to the lower sheet 38 can be beads, wires, or segments of a glue or adhesive.

[0042] like Figure 1 As best shown, the lower sheet 38 has a length "L", the length of which is defined as the linear distance between opposite end edges 54. Figure 1 (Only one is shown). Similarly, the lower sheet 38 has a width "W", which is defined as the linear distance between the opposite side edges 56. In the pocket spring assembly 12 shown, the length is shown as greater than the width. However, the length and width can be the same (as in the square pocket spring assembly) and this is also within the scope of the invention. Figure 4 As shown, the lower sheet 38 has a thickness "T1", which is defined as the linear distance between the opposite top surface 58 and bottom surface 60. In one embodiment, the thickness T1 of the lower sheet 38 is 0.032 inches, but it can be any desired thickness.

[0043] The lower sheet 38 is preferably made of nonwoven polypropylene fabric, which is the material commonly used to manufacture the connector 26 of the core 34 of a pocket spring assembly. The lower sheet 38 may be a dimensionally stable substrate as defined in U.S. Patent Applications Nos. 18 / 469,644, 17 / 244,021, 18 / 313,470, or U.S. Patents Nos. 11,013,340 and 11,771,235, each of which is incorporated herein by reference.

[0044] like Figure 4 As shown, the lower sheet 38 extends outward from the pocket spring core 34 by a distance "D", thereby forming a picture frame-shaped peripheral portion 110, which can be easily grasped by the user to manipulate the pocket spring assembly 12. In order to disassemble the product 10 as described below, the user grasps the peripheral portion 110 to tear open the pocket 46 of the connector 26, thereby separating the metal coil spring 18 from the fabric of the connector 26.

[0045] The tandem connector 26 described or shown herein, as well as any other spring tandem connectors, can be connected in a side-by-side relationship, for example, by gluing the sides of the tandem connectors together in an assembly machine, thereby forming a spring assembly or spring array of pocket springs 28 having multiple rows and columns, which pocket springs are joined together by gluing, welding, or any other conventional assembly process typically used to form pocket spring cores or assemblies.

[0046] Figure 2 and Figure 3 The buffer assembly 14 is shown in detail. The buffer assembly 14 includes a connecting sheet 16 at its bottom and includes three buffer layers: a bottom buffer layer 62, a middle buffer layer 64 and an upper buffer layer 66.

[0047] Although the accompanying drawings show three buffer layers 62, 64, 66 and connecting sheet 16 stitched together, any number of buffer layers can be stitched together with connecting sheet 16.

[0048] Similarly, such as Figure 4A and Figure 4B As best shown, the dimensions of the connecting sheet 16 are approximately the same as the lower sheet 38 of the pocket spring assembly 12. Figure 2 As best shown, the connecting sheet 16 has a length "L1", which is defined as the linear distance between opposite end edges 68. Similarly, the connecting sheet 16 has a width "W1", which is defined as the linear distance between opposite side edges 70. Figure 2 Only one is shown in the image. Figure 2 In the illustrated buffer assembly 14, the length is shown to be greater than the width. However, the length and width can be the same (as in a square buffer assembly) and this is also within the scope of the invention. Figure 4 As shown, the connecting sheet 16 has a thickness "T2", which is defined as the linear distance between the opposite top surface 72 and bottom surface 74. In one embodiment, the thickness T2 of the connecting sheet 16 is 0.009 inches, but it can be any desired thickness.

[0049] Although the connecting sheet 16 is shown as thinner than the lower sheet 38 of the pocket spring assembly 12, they can be of the same thickness. In most embodiments, the lower sheet 38 of the pocket spring assembly 12 is thicker than the connecting sheet 16 of the cushioning assembly 14.

[0050] Each of the three buffer layers is shown to have a different thickness than the other two. For example... Figure 6B As shown, the lower buffer layer 62 has a thickness "TL", which is defined as the linear distance between the generally flat upper surface 76 and the generally flat lower surface 78. Figure 6B As shown, the intermediate buffer layer 64 has a thickness "TM", which is defined as the linear distance between the generally flat upper surface 80 and the generally flat lower surface 82. Figure 6B As shown, the upper buffer layer 66 has a thickness “TU”, which is defined as the linear distance between the generally flat upper surface 84 and the generally flat lower surface 86. Figure 4 These thicknesses are also shown.

[0051] The lower buffer layer 62 is shown as thinner than the middle buffer layer 64 and the upper buffer layer 66. The upper buffer layer 66 is shown as thicker than the middle buffer layer 64 and the lower buffer layer 62. The middle buffer layer 64 is shown as thicker than the lower buffer layer 62 and thinner than the upper buffer layer 66. The thickness of any buffer layer may differ from that of any other buffer layer. The figures are not intended to be limiting. Any number of buffer layers—including all buffer layers—may be of the same thickness.

[0052] Although cushioning layers 62, 64, and 66 are shown as different types of foam, any number of cushioning layers can be the same type of foam. Instead of foam, one or more cushioning layers can be made at least partially of fibers, gels, bagged spring blankets, or any other suitable material or any combination thereof.

[0053] Although the upper and lower surfaces of each foam component are shown as generally flat, the cushioning layer does not necessarily have to have a generally flat surface. For example, the foam component may have interlocking surfaces, such as a corrugated or ribbed surface.

[0054] like Figure 3 , Figure 4 , Figure 4A and Figure 4B As shown, the buffer layers 62, 64, and 66 are not glued together with the connecting sheet 16. Figure 3 As best shown, the cushioning layers 62, 64, and 66 are sewn together with the connecting sheet 16 using a chain stitch 88, which includes needle thread 90 and looper thread 92, as disclosed in U.S. Patents 11,015,274, 11,015,275, 11,111,615, and 11,578,441, all of which are incorporated herein by reference in their entirety. The quilting machine used to manufacture this chain stitch 88 without compressing the cushioning layers is the XT9, sold by Global Systems Group, a subsidiary of Leggett & Platt Incorporated. See www.gsgcompanies.com. Any known type of stitching can be used to secure the cushioning layers to the connecting sheet.

[0055] like Figure 4 , Figure 4A and Figure 4BAs shown, the connecting sheet 16 extends outward from the cushioning layers 66, 64, 62 by a distance "DD", thereby forming a frame-like peripheral portion 112, which can be easily grasped by the user to manipulate the cushioning assembly 14. In order to disassemble the product 10 as described below, the user can grasp the peripheral portion 112 to help separate the cushioning layers 62, 64, 66 or assist in disassembling any part of the bedding or seating product.

[0056] Figure 4 , Figure 4A and Figure 4B A method of assembling product component 15 according to the invention is shown. Cushioning component 14 is glued to pocket spring component 12 to form product component 15, which is surrounded by decorative cover 20. Decorative cover 20 may have flame retardant on its inner side.

[0057] like Figure 4 As best shown, the cushioning assembly 14 descends in the direction of arrow 91 until the connecting sheet 16 of the cushioning assembly 14 is secured to the upper surface 50 of at least some of the connectors 26 of the pocket spring assembly core 34 using bead-like pieces 71 of adhesive / glue. Instead of bead-like pieces, the adhesive used to secure the connecting sheet 16 of the cushioning assembly 14 to the upper surface 50 of the connectors 26 of the pocket spring assembly core 34 can be a linear or segmental piece of adhesive. Figure 4A A cushioning assembly 14 is shown, which is secured to the pocket spring assembly 12 by means of a connecting sheet 16 of the cushioning assembly 14.

[0058] like Figure 4B As best shown, adjacent connecting pieces 26 are glued together with bead-like pieces 81 of adhesive. Instead of bead-like pieces, the adhesive used to secure adjacent connecting pieces 26 of the pocket spring assembly core 34 can be linear or segmental pieces of adhesive. Although Figure 4B A three-layer adhesive bead 81 is shown, but any number of adhesive layers can be used to hold adjacent connectors 26 together.

[0059] like Figure 4 , Figure 4A and Figure 4B As shown in the best embodiment, each cascade 26 has a continuous ring 94 of perforations 96 surrounding the entire cascade 26. Figure 4A A side section 100 of the continuous ring 94 of the perforation 96 is shown, which extends through the fabric piece used to form each tandem 26. Figure 4B An end segment 98 of the continuous loop 94 of the perforation 96 is shown, which extends through one of the layers 42, 44 of the fabric piece for forming the connector 26. The continuous loop 94 of the perforation 96 extends around the entire connector 26, thereby facilitating tearing of the fabric as described herein.

[0060] The pocket spring assembly 12 has a continuous ring 94 with perforations 96 near the lower sheet 38 at the lower third of the pocket spring assembly 12.

[0061] Figure 5 , Figure 6A and Figure 6B Methods for disassembling bedding or seating products, such as a single-sided mattress 10, are shown. Figure 6A As shown, the needle thread 90 and looper thread 92 are removed from the rest of the cushioning assembly 14 to allow the cushioning layers to separate from each other. Figure 6B As shown, the connecting sheet 16 holds at least some of the connectors 26 of the pocket spring assembly 12 on the upper surface 50. Preferably, the connecting sheet 16 is made of the same fabric or material as the fabric of the connectors 26 of the pocket spring assembly 12, so that they can be recycled together without attempting to separate the connecting sheet 16 from the fabric of the connectors 26. In some embodiments, this fabric is nonwoven polypropylene.

[0062] The disassembly method also includes tearing the fabric of the connector 26 along the perforation 96 in the connector 26 of the pocket spring assembly 12. This tearing is achieved by pulling the lower sheet 38 of the pocket spring assembly 12 away from the connecting sheet 16 of the cushioning assembly 14. With the lower section 106 of the pocket spring assembly 12, including the lower sheet 38, separated from the upper fabric section 108 of the pocket spring assembly 12, the metal coil spring 18 can be removed from the pocket 46 of the upper fabric section 108 of the pocket spring assembly 12. The metal coil spring 18 can then pass downwards through the opening created in the pocket 46 of the upper fabric section 108 of the pocket spring assembly 12 by the tearing step.

[0063] like Figure 5 and Figure 6A As shown, the lower sheet 38 of the bag spring assembly 12 can be grasped by a person or machine and along... Figure 5 The metal coil spring 18 is separated from the fabric of the pocket spring assembly 12 by pulling downwards in the direction of arrow 102. Force generated by a person or machine causes the connecting piece 26 of the pocket spring assembly 12 to tear along the continuous ring 94 of the perforation 96. After the pocket 46 of the connecting piece 26 opens due to the tear in the fabric, the coil spring 18 can be removed from inside the pocket 46 by gravity, machine, or manually. See Figure 6A Arrow 104.

[0064] Because the tensile strength of the fabric component of connector 26 is less than that of the lower sheet 38, tearing is possible. In some applications, the tensile strength of the lower sheet 38 is at least twice that of the fabric component of connector 26. In most embodiments, the tensile strength of the lower sheet 38 of pocket spring assembly 12 is greater than the tensile strength of the fabric component of connector 26 of pocket spring assembly 12.

[0065] After the metal coil spring 12 is separated from the fabric by tearing along the perforation 96, the fabric of the pocket spring assembly 12 is separated into a first or lower fabric segment 106 having a lower sheet 38 and a second or upper fabric segment 108 having the attached cushioning assembly 14. Although the perforation 96 is shown as a continuous loop 94 surrounding the connector 26, the perforation 96 may be arranged around the connector 26 in other configurations. This is true for any of the embodiments shown or described herein. U.S. Patent Application No. 18 / 313,470 discloses such a method of tearing a connector along a perforation, and that patent application is incorporated herein by reference in its entirety.

[0066] Figure 6B The disassembled product assembly components are shown. After the needle thread 90 and looper thread 92 of the cushioning assembly 14 are removed, the upper cushioning layer 66 can be separated from the middle cushioning layer 64 and the lower cushioning layer 62. Each cushioning layer can be recycled along with other similar products from other mattresses or bedding / seat products.

[0067] Similarly, after the fabric of the connector 26 in the core 34 of the pocket spring assembly has been torn along the perforation 96, and after the metal coil spring 18 has been separated for recycling, the lower section 106 of the fabric can be separated from the upper section 108 of the fabric. Since the connecting sheet 16 of the cushioning assembly 14 is made of the same material as the fabric of the upper section 108 of the pocket spring assembly 12, the connecting sheet 16 of the cushioning assembly 14 can remain glued to the upper section 108 of the pocket spring assembly 12 and be recycled together. Typically, this fabric is nonwoven polypropylene. A pocket spring assembly having a different sheet made of the same material as the fabric used to manufacture the connector (including nonwoven polypropylene fabric) is disclosed by reference in its entirety in U.S. Patent Application No. 18 / 469,644, which has been made by reference in its entirety.

[0068] To facilitate recycling at the end of the lifespan of bedding or seating products such as mattresses, the adhesive can be made of polypropylene, the fabric of the loosely woven sheet can be made of polypropylene, the fabric of the dimensionally stable substrate can be made of polypropylene, and the fabric used to form the connecting parts can be made of polypropylene. Therefore, after the metal of the pocket spring assembly separates from the fabric, all the fabric can be made of polypropylene and can be recycled quickly and easily.

[0069] The various embodiments shown and described in this invention are for illustrative purposes only, as the drawings and description are not intended to limit or restrict the scope of the claims in any way. Various changes, modifications, and improvements that can be made to this invention will be apparent to those skilled in the art without departing from the spirit or scope of the invention. Therefore, the invention is not limited in its broader aspects to the specific details and representative apparatuses and methods shown and described. Thus, changes can be made from these details without departing from the spirit or scope of the overall inventive concept. The invention resides in each individual feature described herein, as well as in any and all combinations of these features. Therefore, the scope of the invention should be defined only by the appended claims and their equivalents.

Claims

1. A product for use on a bed or chair, the product comprising: A pocket spring assembly comprising a plurality of pocket springs engaged to a lower sheet, each pocket spring comprising a metal spring located within a fabric pocket, wherein the fabric pocket has at least partially perforations surrounding the fabric pocket. A cushioning assembly comprising at least one foam layer and a connecting sheet, wherein the at least one foam layer and the connecting sheet are stitched together. The connecting sheet of the cushioning assembly is joined to at least some of the fabric pouches of the pocket spring assembly.

2. The product according to claim 1, wherein, The connecting sheet is made of the same material as the fabric bag-like piece.

3. The product according to claim 1, wherein, The lower sheet of the pocket spring assembly is made of the same material as the connecting sheet of the cushioning assembly.

4. The product according to claim 1, wherein, The lower sheet of the pocket spring assembly and the connecting sheet of the cushioning assembly are made of nonwoven polypropylene.

5. The product according to claim 1, wherein, At least some of the pocket springs are joined together.

6. The product according to claim 1, wherein, The connecting sheet of the cushioning assembly, the fabric bag-like component, and the lower sheet of the pocket spring assembly are made of nonwoven polypropylene, and the adhesive compound is at least partially made of polypropylene.

7. The product according to claim 1, wherein, The connecting sheet of the cushioning assembly, the fabric bag-like part, the lower sheet of the pocket spring assembly, and the adhesive are all made of the same base material.

8. A product for use in a bed or chair, said product comprising: A pocket spring assembly comprising a plurality of parallel spring connectors joined together, each connector comprising a plurality of individually pocketed springs, each connector comprising a fabric piece joined together along a longitudinal seam, opposite first and second fabric layers located on opposite sides of the springs, the plurality of pockets being formed along the length of the connectors by transverse seams joining the first and second layers, at least one spring positioned in each pocket, a lower sheet attached to the lower surface of at least some of the connectors, wherein the connectors have perforations completely surrounding the pockets; A cushioning assembly comprising multiple cushioning layers and a connecting sheet, the cushioning layers being sewn together. The connecting sheet of the cushioning assembly is attached to at least some of the connecting members of the pocket spring assembly.

9. The product according to claim 8, wherein, At least one of the buffer layers is made of foam.

10. The product according to claim 8, wherein, The tensile strength of the lower sheet of the pocket spring assembly is greater than the tensile strength of the fabric of the connecting member of the pocket spring assembly.

11. The product according to claim 8, wherein, The connecting sheet, the fabric of the connecting member, and the lower sheet are made of the same material to facilitate recycling.

12. The product according to claim 8, wherein, The connecting sheet and the ferrule fabric are made of the same material to facilitate recycling.

13. The product according to claim 8, wherein, At least some of the buffer layers are made of foam.

14. A method for disassembling a bed or chair product, the method comprising: The cushioning layers in the cushioning assembly are separated from each other, the cushioning assembly including a connecting sheet glued to the pocket spring assembly; By pulling the lower sheet of the pocket spring assembly away from the connecting sheet of the cushioning assembly, the fabric is torn along perforations in the individual pocket springs of the pocket spring assembly, which includes a plurality of parallel spring connectors joined together, each connector including a plurality of individually pocketed springs, each connector including a fabric piece joined together along a longitudinal seam, opposite first and second fabric layers located on opposite sides of the springs, the plurality of pockets being formed along the length of the connectors by transverse seams joining the first and second layers, and at least one spring positioned in each pocket.

15. The method of claim 14, further comprising removing the spring from the pocket-shaped part of the connector.

16. The method of claim 14, wherein, The lower sheet of the pocket spring assembly is thicker than the connecting sheet of the cushioning assembly to facilitate gripping of the lower sheet.

17. The method of claim 14, wherein, The connecting sheet of the cushioning assembly is made of the same material as the lower sheet of the pocket spring assembly.

18. The method according to claim 17, wherein, The adhesive bonding the connecting sheet to the pocket spring assembly is made at least in part of the same material as the connecting sheet of the cushioning assembly and the lower sheet of the pocket spring assembly.

19. The method of claim 14, wherein, The lower sheet of the pocket spring assembly and the connecting sheet of the cushioning assembly are both made of nonwoven polypropylene.

20. A method for disassembling a bedding or chair product, the method comprising: The cushioning layers of the cushioning assembly are separated from each other, the cushioning assembly including connecting sheets glued to the pocket spring assembly; Using the lower sheet of the pocket spring assembly, the fabric is torn along the perforations in the string of individually pocketed springs of the pocket spring assembly; as well as Remove the spring from the bag-shaped part of the connector.

21. The method according to claim 20, wherein, The lower sheet of the pocket spring assembly is thicker than the connecting sheet of the cushioning assembly to facilitate gripping of the lower sheet of the pocket spring assembly.

22. The method according to claim 20, wherein, The connecting sheet of the cushioning assembly is made of the same material as the lower sheet of the pocket spring assembly.

23. The method according to claim 21, wherein, The material is nonwoven polypropylene.

24. The method of claim 20, wherein, The fabric of the connecting member of the pocket spring assembly is made of the same nonwoven material as the lower sheet of the pocket spring assembly and the connecting sheet of the cushioning assembly.

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