Spring core assembly and mattress assembly

Abstract

The present invention relates to a spring core assembly for a mattress assembly. The spring core assembly comprises a bottom fabric, an upper fabric, and at least one spring pocket having at least one spring coil provided between the bottom fabric and the upper fabric. The basis weight of the bottom fabric is different from that of the upper fabric. Furthermore, a mattress assembly is also described.

Description

[Technical Field]

[0001] The present invention relates to a spring core assembly for a mattress assembly. Furthermore, the present invention relates to a mattress assembly. [Background technology]

[0002] In the latest technology, mattress assemblies with different layers are known, which provide the desired comfort to the user of the mattress assembly.

[0003] Foam mattress assemblies, in the latest technology, are known to consist only of foam layers, with at least one of the foam layers providing various lying zones (also called body zones) using, for example, notches and / or recesses. For example, the widely known Emma One Foam Mattress is a mattress assembly consisting of foam layers.

[0004] Furthermore, so-called hybrid mattress assemblies are also known, which include a spring core layer and at least one foam layer placed on top of the spring core layer. Typically, the spring core layer comprises multiple spring pockets manufactured in the same manner. These mattress assemblies may also have various lying zones, established, for example, by notches and / or recesses within the foam layer, using additional foam layers placed on top of the spring core layer. Alternatively or additionally, multiple foam layers are provided, for example, using notches and / or recesses, to provide various lying zones. For example, the Emma Hybrid Mattress provides five different lying zones, while including three foam layers and one spring core layer.

[0005] Generally, the size and / or shape of individual notches and / or recesses can be varied to establish different zones, for example, zones with varying hardness or rigidity.

[0006] In fact, the concept of providing various lying / body zones is used. The reason is that foam layers can be manufactured in a cost-effective way, and therefore it is not very expensive to provide foam layers with various properties.

[0007] However, creating notches and / or recesses can result in cutting or waste of material, which is undesirable. To overcome this drawback, it is already known that a corresponding foam layer can be provided from a foam block, thereby reducing material cutting or waste. This concept is described in German Journal No. 10 2017 117 556 A1. [Overview of the project] [Problems that the invention aims to solve]

[0008] However, there is a need for improved mattress assemblies that reduce material waste. [Means for solving the problem]

[0009] The present invention provides a spring core assembly for a mattress assembly. The spring core assembly comprises a bottom fabric, an upper fabric, and at least one spring pocket having at least one spring coil provided between the bottom fabric and the upper fabric. The basis weight of the bottom fabric is different from that of the upper fabric. Thus, the bottom fabric and the upper fabric at least partially form a spring pocket provided with at least one spring coil. The spring pocket is formed such that there is preferably direct contact between the at least one spring coil and the bottom fabric and / or the upper fabric. In particular, direct contact may be established between the upper end (part) of at least one spring coil and the upper fabric. Furthermore, direct contact may be established between the lower end (part) of at least one spring coil and the bottom fabric. Furthermore, at least one spring coil may be completely surrounded by the spring pocket. The spring core assembly comprises at least one spring pocket. In other words, the spring pocket is the smallest independent unit of the spring core assembly.

[0010] Therefore, a spring core assembly that can be used as an independent spring core layer within a mattress assembly features spring pockets with different fabrics above and below the individual spring coils. This ensures that the spring core assembly, and in particular the individual spring coils, have improved support.

[0011] For example, the bottom fabric and top fabric are polypropylene (PP) fabrics, such as textile products derived from the thermoplastic polymer polypropylene.

[0012] The spring core assembly has multiple spring pockets, for example, 448 spring pockets (90cm x 190cm) or 462 spring pockets (90cm x 200cm). Depending on the width of the spring core assembly, a different number of spring pockets may be provided.

[0013] Generally, the bottom and top fabrics are placed on either side of each individual spring pocket.

[0014] For example, the spring core assembly has a height of 195 mm.

[0015] One embodiment specifies that the basis weight of the bottom fabric is higher than that of the top fabric. Consequently, the higher basis weight of the bottom fabric ensures better support for the spring coils. In fact, this may also apply to the bottom layer of a spring core assembly or mattress assembly. The higher basis weight of the bottom fabric ensures that the mattress assembly can rest on the bed frame by the springs, i.e., by the bottom fabric, thereby providing sufficient support and durability.

[0016] For example, the ratio of the basis weight of the upper fabric to the basis weight of the bottom fabric is in the range of 0.375 to 0.8, preferably in the range of 0.4 to 0.6, and particularly 0.5. This ratio ensures optimized properties with respect to (mechanical) support and mattress characteristics, such as hardness and / or stiffness.

[0017] In particular, the basis weight of the upper fabric is 60 g / m². 2 ~80g / m 2 A range, for example, 65 g / m 2 As an alternative or addition, the basis weight of the bottom fabric is 100g / m². 2 ~160g / m 2 This range includes, for example, 130 g / m². 2 These specific basis weights ensure that the spring coil is supported in a predetermined manner, while the high basis weight of the bottom fabric provides sufficient support from the spring core assembly.

[0018] Another aspect provides that the spring core assembly comprises a first type of spring pocket and a second type of spring pocket. Both types of spring pockets have the same bottom fabric and the same top fabric. The basis weight of the bottom fabric is different from the basis weight of the top fabric. The first type of spring pocket has a first spring coil disposed between the bottom fabric and the top fabric. The second type of spring pocket has a second spring coil disposed between the bottom fabric and the top fabric. The first spring coil and the second spring coil are different. For example, the first spring coil and the second spring coil have different characteristics with respect to rigidity.

[0019] The different types of spring pockets, namely the first type of spring pocket and the second type of spring pocket, ensure that different deflection / body zones are provided by the spring core assembly, creating different zones across the mattress assembly.

[0020] The first type of spring pocket and the second type of spring pocket may be adhesively bonded to each other adjacent. This ensures that different types of spring pockets can be connected to each other even though they have different characteristics with respect to rigidity due to the various spring coils. Since the spring pockets are adhesively bonded to each other, their relative positions are fixed. The pocket adhesive vertical distance can be in the range of 65 mm to 75 mm, preferably 70 mm.

[0021] The first spring coil and the second spring coil are made of steel of grade C65 - C70. The first spring coil and the second spring coil are wound around a central axis and have a total of 4.5 to 5 turns, preferably 4.75 turns.

[0022] The distance between different windings (e.g., the center-axis distance) of an uncompressed spring coil (e.g., in its uninstalled state) varies along the length of the spring coil. For an uncompressed spring coil with a total height of approximately 250 mm, the distance between the end of the first winding of the spring coil and the plane on which the spring coil is positioned is approximately 1.15 mm. The distance between the end of the second winding and the plane may be approximately 82.5 mm. The distance between the end of the third winding and the plane may be approximately 193 mm. The distance between the end of the fourth winding and the plane may be approximately 243 mm.

[0023] Furthermore, the spring coil has two opposing ends extending downward or upward, i.e., toward the inside of the spring coil, with these ends, particularly their outer sides, facing each other. The distance between the lower end and the plane is approximately 5 mm.

[0024] Therefore, the edges that come into direct contact with individual fabrics, such as the top or bottom fabric, can be positioned at a certain distance from the corresponding edge, for example, its front side.

[0025] Preferably, the diameter of the first spring coil is variable along the length of the spring coil, and the diameters of the first and second windings are smaller than the diameter of the winding in the center of the spring coil. In particular, for an uncompressed spring coil that is not housed in a spring pocket and has a height in the range of 245 mm to 255 mm, the diameter of the first winding is approximately 61 mm, the diameters of the second and third windings are approximately 66 mm, the diameter of the fourth winding is approximately 58 mm, and the diameter of the last incomplete winding is approximately 48 mm.

[0026] According to the present invention, the first spring coil and the second spring coil may have different wire diameters. In particular, the wire diameter of the first spring coil is smaller than that of the second spring coil. The different wire diameters of the spring coils provide different hardness or rigidity. Thus, different lying / body zones can be obtained, including either the first type of spring pocket or the second type of spring pocket.

[0027] The ratio of the wire diameter of the first spring coil to the wire diameter of the second spring coil may be in the range of 0.72 to 0.95, and may even be 0.9. This ratio ensures that the user can recognize different lying / body zones while maintaining a good feel, as there is no significant difference in the hardness of the individual spring coils.

[0028] For example, the wire diameter of the first spring coil is in the range of 1.6 mm to 1.9 mm, particularly in the range of 1.6 mm to 1.8 mm, and preferably 1.7 mm.

[0029] Alternatively or as an addition, the wire diameter of the second spring coil is in the range of 1.8mm to 2.2mm, particularly 1.8mm to 2mm, and preferably 1.9mm. These wire diameters ensure sufficient stiffness and stability of the individual spring coils while providing the desired comfort in the lying / body zone.

[0030] A further embodiment specifies that a plurality of first-type spring pockets are connected in series, particularly by welding, thereby forming a row of first-type spring pockets. Alternatively or additionally, a plurality of second-type spring pockets are connected in series, particularly by welding, thereby forming a row of second-type spring pockets. Depending on the size, particularly the width, of the spring core assembly, individual rows may comprise a different number of spring pockets connected to one another by welding, thereby providing a row of first-type or second-type spring pockets. Thus, individual rows may be associated with the width of the spring coil assembly or mattress assembly. Consequently, the same type of spring pockets are used along the width dimension of the spring coil assembly or mattress assembly.

[0031] Furthermore, at least two rows of the first type of spring pockets are installed adjacent to each other, and the spring pockets of adjacent rows are bonded to each other. Alternatively or additionally, at least two rows of the second type of spring pockets are installed adjacent to each other, and the spring pockets of adjacent rows are bonded to each other. Individual zones of the same type of spring pockets can be established by providing two or more rows of the same type of pocket springs. However, a particular zone may be realized by only a single row, in particular a single row of the first type of spring pocket. Zones established by the second type of spring pockets may always include at least two rows of the second type of spring pockets.

[0032] In general, adjacent rows of spring pockets, regardless of their type, may be bonded to each other, thereby establishing a spring core assembly.

[0033] Pocket springs in adjacent rows may be glued together, while pocket springs in the same row may be welded together.

[0034] Generally, a spring core assembly may be symmetrical with respect to two lines of symmetry that intersect each other at the center of the spring core assembly. In particular, the lines of symmetry are orthogonal to each other. Thus, the spring core assembly has a symmetrical design, thereby ensuring that the same spring core assembly can be used in two different directions, i.e., rotated 180 degrees around its center in a plane, without, for example, inverting the spring core assembly. In other words, since the opposing edges are interchangeable, the spring core assembly has neither an upper edge nor a lower edge. To put it another way, the bottom fabric is always oriented toward the floor, for example, toward the frame of a bed when in use.

[0035] The present invention further provides a mattress assembly comprising the spring core assembly described above. The mattress assembly further comprises at least one additional layer provided on top of the spring core assembly.

[0036] As described above, the spring core assembly may also be related to the bottom layer of the mattress assembly, and at least one additional layer may be located on top of the spring core assembly. For example, the additional layer located on top of the spring core assembly may be a foam layer. The additional layer may be directly bonded to the spring core assembly to interconnect both. Hot melt adhesive may be used to bond the additional layer to the spring core assembly.

[0037] Alternatively, the at least one additional layer may be zippered to the spring core assembly by a zip fastener. Thus, the spring core assembly, preferably the upper fabric of the spring core assembly, includes a first portion of the chain of the zip fastener, and the additional layer includes a second portion of the corresponding chain. Preferably, the additional layer includes a fabric cover, the cover having a chain for the zip fastener corresponding to the chain of the zip fastener in the spring core assembly.

[0038] In a preferred embodiment, the chain of the zip fastener extends over the length of at least one side of the spring core assembly and / or additional layer, preferably the chain extends around the entire circumference of the spring core assembly and / or additional layer. In other words, at least one additional layer can be attached to the mattress assembly by a zipperable cover on the spring core assembly. More preferably, there is a separation layer for separating the spring core assembly from at least one additional layer, so that the mattress assembly has two chambers, namely one chamber for the spring core assembly and a second chamber for at least one additional layer.

[0039] One embodiment specifies that the mattress assembly is a stack assembly comprising a spring core assembly, a first additional layer, and a second additional layer, wherein the first and second additional layers are made of different materials, in particular different foams. Thus, the mattress assembly has at least three different layers stacked on top of each other, thereby providing a mattress assembly stack. The three different layers, namely the mattress assembly, the first additional layer, and the second additional layer, each have different properties, e.g., different minimum net densities and / or different hardnesses. Furthermore, the different layers may be made of different materials, e.g., different foams.

[0040] Generally, hardness can be measured according to ISO 3386.

[0041] In certain embodiments, the spring core assembly is the bottom layer of the mattress assembly, and the third layer is bonded to the spring core assembly. The second layer is bonded to the third layer. The first layer is bonded to the second layer. All layers have different properties, e.g., different minimum densities and / or different hardnesses. Thus, three additional layers are provided that are stacked on top of each other and placed on top of the mattress assembly. Furthermore, different types of adhesives may be used to bond the individual layers to each other. As described above, the spring core assembly may be connected to the third layer using a hot melt adhesive or a water-based adhesive, while the second layer is connected to the third layer using a water-based adhesive. Furthermore, the first layer is connected to the second layer using a water-based adhesive. However, different adhesives may be used; for example, a water-based adhesive may be used to connect the spring core assembly to the third layer, and / or a hot melt adhesive or a water-based adhesive may be used to connect the second layer to the third layer, or the first layer to the second layer. As described above, it is also possible to zip the additional layers to the spring core assembly by zippers.

[0042] According to one embodiment, the three additional layers are bonded together and covered by a cover including a chain for a zip fastener, and the cover is connected to a spring core assembly, thereby forming a chamber for the three additional layers.

[0043] According to another embodiment, the three additional layers are simply stacked on top of each other and are not glued together. The stacked additional layers are covered with a cover having a zip fastener, which connects to the spring core assembly and forms a common chamber for the three additional layers. Since the three additional layers are not glued together, this design allows for the replacement of at least one of the three additional layers, while the other one or two additional layers remain.

[0044] In a further embodiment, each of the three additional layers is covered by a cover having a chain of zip fasteners and separated from another additional layer, so that the cover of the first additional layer is zippered to the cover of the second additional layer, the cover of the second additional layer is zippered to the cover of the third additional layer, and the cover of the third additional layer is zippered to the spring core assembly. In other words, each of the three additional layers is positioned between two covers, or between a cover and the spring core assembly, so that each of the three additional layers is in direct contact with at least one cover. The two covers, or the covers and the spring core assembly, form a zipperable layer pocket for the additional layer.

[0045] In each embodiment, at least one of the three additional layers is interchangeable and / or rotatable, so that, for example, the hardness can be adjusted individually for each mattress assembly. Furthermore, it is also possible to form a separation chamber for the additional layer by having an additional separation layer that separates the additional layer from the spring core layer.

[0046] Generally, the forms used for the additional layer may be related to comfort foam, visco memory foam, and / or hypersoft foam.

[0047] The comfort foam is associated with a third layer that is directly adhered or zippered to the spring core assembly. For example, the third layer has a minimum net density of 30 kg / m 3 and / or a hardness of 3 kPa. Alternatively, the third layer has a minimum net density of 31 kg / m 3 and / or a hardness of 2.8 kPa.

[0048] Typically, the third layer has the highest hardness and the lowest minimum net density among all the foam layers.

[0049] The second layer may be made of comfort foam or visco memory foam. For example, the second layer has a minimum net density of 50 kg / m 3 and / or a hardness of 1.8 kPa. Alternatively, the second layer has a minimum net density of 34 kg / m 3 and / or a hardness of 2.5 kPa.

[0050] The first layer associated with the upper layer of the mattress assembly may be made of visco memory foam or hypersoft foam. For example, the first layer has a minimum net density of 32 kg / m 3 and / or a hardness of 1.5 kPa. Alternatively, the first layer has a minimum net density of 40 kg / m 3 and / or a hardness of 1.6 kPa.

[0051] Generally, the spring core assembly and the mattress assembly may have a length of 2 m or 1.9 m, and thus 33 rows or 32 rows of spring pockets are used respectively. All rows can be established by two different types of spring pockets, particularly rows of spring pockets.

[0052] In a particular embodiment, for example, with a width of 90 cm, the spring core assembly has 14 spring pockets per row, welded together. However, the number of spring pockets per row depends on the width of the spring core assembly or mattress assembly. Therefore, a spring core assembly or mattress assembly with a width greater than 90 cm may have more than 14 spring pockets per row.

[0053] The first embodiment may comprise 11 zones.

[0054] In fact, the first zone, starting from the first edge, may include two rows of a particular type of spring pocket, for example, a second type of spring pocket. The second zone is adjacent to the first zone and includes six rows of a particular type of spring pocket, for example, a first type of spring pocket. The third zone is adjacent to the second zone and includes five rows of a particular type of spring pocket, for example, a second type of spring pocket. The fourth zone is adjacent to the third zone and includes only one row of a particular type of spring pocket, for example, a first type of spring pocket. The fifth zone is adjacent to the fourth zone and includes two rows of a particular type of spring pocket, for example, a second type of spring pocket. The sixth zone is adjacent to the fifth zone and includes only one row of a particular type of spring pocket, for example, a first type of spring pocket. The seventh zone is adjacent to the sixth zone and includes two rows of a particular type of spring pocket, for example, a second type of spring pocket. The eighth zone is adjacent to the seventh zone and includes only one row of a particular type of spring pocket, for example, a first type of spring pocket. Zone 9 is adjacent to Zone 8 and contains five rows of a specific type of spring pocket, for example, Type 2 spring pockets. Zone 10 is adjacent to Zone 9 and contains six rows of a specific type of spring pocket, for example, Type 1 spring pockets. Zone 11 is adjacent to Zone 10 and contains two rows of a specific type of spring pocket, for example, Type 2 spring pockets. Zone 11 ends at the second edge opposite the first edge.

[0055] The symmetry line of the spring core assembly extends along the sixth zone, for example, along a single row provided by the sixth zone. Another symmetry line extends perpendicularly to it and intersects all zones, for example, all rows. Both symmetry lines intersect each other at the center of the spring core assembly.

[0056] The second embodiment may have nine zones.

[0057] In fact, the first zone, starting from the first edge, may include two rows of a particular type of spring pocket, for example, a second type of spring pocket. The second zone is adjacent to the first zone and includes six rows of a particular type of spring pocket, for example, a first type of spring pocket. The third zone is adjacent to the second zone and includes six rows of a particular type of spring pocket, for example, a second type of spring pocket. The fourth zone is adjacent to the third zone and includes only one row of a particular type of spring pocket, for example, a first type of spring pocket. The fifth zone is adjacent to the fourth zone and includes two rows of a particular type of spring pocket, for example, a second type of spring pocket. The sixth zone is adjacent to the fifth zone and includes only one row of a particular type of spring pocket, for example, a first type of spring pocket. The seventh zone is adjacent to the sixth zone and includes six rows of a particular type of spring pocket, for example, a second type of spring pocket. The eighth zone is adjacent to the seventh zone and includes six rows of a particular type of spring pocket, for example, a first type of spring pocket. Zone 9 is adjacent to Zone 8 and contains two rows of a specific type of spring pocket, for example, a Type 2 spring pocket. Zone 9 ends at the second edge, which is opposite the first edge.

[0058] The symmetry line of the spring core assembly extends along the fifth zone, for example, between the two rows provided by the fifth zone. Another symmetry line extends perpendicular to it and intersects all zones, for example, all rows. Both symmetry lines intersect each other at the center of the spring core assembly.

[0059] When a user lies down on the mattress assembly, various zones are used to provide different levels of support to the user.

[0060] Generally, the distribution of different spring coils, especially those with different diameters, ensures the zoning of a spring core assembly or mattress assembly. Zoning means providing support and relief to various areas of the body. In fact, the various zones of the body are the head, shoulders, hips, pelvis, thighs, calves, and feet. A spring core assembly provides appropriate support and comfort to people of various body types, regardless of their sleeping position.

[0061] When combined with a mattress assembly, the additional layer, namely the foam layer, ensures pressure relief and comfort, and makes the mattress assembly more durable.

[0062] Generally, additional layers, i.e., foam layers, are fabricated as, for example, complete material layers without notches and / or recesses.

[0063] The additional layer may have the same height, for example, 15 mm.

[0064] The spring core assembly may have a height of 200 mm.

[0065] The entire mattress assembly may have a height of 245 mm. [Brief explanation of the drawing]

[0066] The aforementioned aspects of the claimed subject matter and the methods of the associated advantages will be more readily understood by referring to the following description in conjunction with the attached drawings. In the drawings,

[0067] [Figure 1] A schematic diagram of the entire mattress assembly according to the first embodiment of the present invention, using the spring core assembly according to the first embodiment of the present invention, is shown. [Figure 2] A schematic diagram of the entire mattress assembly according to the second embodiment of the present invention, using the spring core assembly according to the second embodiment of the present invention, is shown. [Figure 3] A schematic diagram of the entire mattress assembly according to the third embodiment of the present invention, using the spring core assembly according to the third embodiment of the present invention, is shown. [Figure 4] A schematic diagram of the entire mattress assembly according to the fourth embodiment of the present invention, using the spring core assembly according to the fourth embodiment of the present invention, is shown. [Modes for carrying out the invention]

[0068] Figure 1 shows a mattress assembly 10 including a spring core assembly 12, and a top view thereof is also shown in Figure 1. As shown in the overview of the mattress assembly 10, the spring core assembly 12 corresponds to the bottom layer of the mattress assembly 10.

[0069] Furthermore, the mattress assembly 10 includes a first additional layer 14 corresponding to the upper layer of the mattress assembly 10. Between the first additional layer 14 and the spring core assembly 12, the mattress assembly 10 further includes a second additional layer 16 and a third additional layer 18.

[0070] Therefore, the mattress assembly 10 is related to the stack assembly, because various layers 12-18 are stacked on top of each other to form the mattress assembly stack.

[0071] In contrast to the spring core assembly 12, the additional layers 14-18 are made of foam.

[0072] In particular, the various layers 12-18 are interconnected using adhesive. Different adhesives may be used depending on the type of layer being interconnected.

[0073] For example, the first layer 14 is bonded to the second layer 16 using a water-based adhesive. The second layer 16 is similarly bonded to the third layer 18 using a water-based adhesive, while a hot-melt adhesive is provided between the spring core assembly 12 and the third layer 18.

[0074] Therefore, the connection between the foam layer, i.e., the third layer 18 and the spring core assembly 12, is established using a hot-melt adhesive, while a water-based adhesive is used to interconnect the foam layers.

[0075] In the illustrated embodiment, the first to third additional layers 14 to 18 have the same height, i.e., 15 mm, while the spring core assembly 12 has a height of 195 mm, resulting in an overall height of 240 mm.

[0076] As mentioned above, the first to third additional layers 14-18 are made of different forms. Therefore, the individual characteristics of the additional layers 14-18 may differ.

[0077] For example, the first layer 14 is 32 kg / m³ 3 It is made from hypersoft foam with a minimum net density and a hardness of 1.5 kPa.

[0078] The second additional layer 16 has a density of 50 kg / m³. 3 It may also be made from viscomemory foam having a minimum net density and a hardness of 1.5 kPa.

[0079] The third additional layer 18 has a density of 30 kg / m³. 3 It may be made from comfort foam having a minimum net density and a hardness of 3 kPa.

[0080] The spring core assembly 12 comprises a plurality of spring pockets 20, schematically shown in Figure 1. Each spring pocket 20 includes a bottom fabric 22 and an upper fabric 24, and the spring pockets 20 are bonded to a third additional layer 18 via the upper fabric 24.

[0081] Each spring pocket 20 has a spring coil 26 positioned between the bottom fabric 22 and the top fabric 24. The spring coil 26 is made of metal wire.

[0082] Each fabric, i.e., the bottom fabric 22 and the top fabric 24, has a different grammage. For example, the grammage of the bottom fabric 22 is higher than that of the top fabric 24. Several spring pockets 20 may each have their own bottom fabric 22 and / or top fabric 24. Alternatively, several spring pockets 20 may share a common bottom fabric 22 and / or a common top fabric 24.

[0083] For example, the ratio of the basis weight of the upper fabric 24 to the basis weight of the bottom fabric 22 is in the range of 0.4 to 0.6, particularly 0.5.

[0084] Specifically, the basis weight of the upper fabric 24 is 60 g / m². 3 ~80g / m 3 The range, especially 65g / m 3 However, the basis weight of the bottom fabric 22 is 100g / m². 3 ~160g / m 3 The range, especially 130g / m² 3 That is the case.

[0085] In fact, the bottom fabric 22 provides a support surface for the entire mattress assembly 10, as shown in Figure 1.

[0086] Therefore, these different basis weights of the fabrics 22 and 24 ensure proper support for the spring coils 26 installed within the spring pockets 20, and ensure proper support for the user of the entire mattress assembly 10.

[0087] For example, the bottom fabric 22 and the top fabric 26 are made of polypropylene (PP) fabric, such as a textile product derived from the thermoplastic polymer polypropylene.

[0088] A top view of the spring core assembly 12 is also shown in Figure 1 and is referred to below.

[0089] The top view shows that the spring core assembly 12 is established by two different types of spring pockets 20, namely, a first type spring pocket 28 and a second type spring pocket 30.

[0090] Different types of spring pockets 28,30 are distinguished from one another by the individual spring coils 26, particularly by the wire diameter of the individual spring coils 26.

[0091] In fact, the first type of spring pocket 36 has a first spring coil 42 with a wire diameter in the range of 1.6 mm to 1.9 mm, particularly in the range of 1.6 mm to 1.8 mm, preferably 1.7 mm, while the wire diameter of the second spring coil 42 is in the range of 1.8 mm to 2.2 mm, particularly in the range of 1.8 mm to 2 mm, preferably 1.9 mm.

[0092] For example, the ratio of the wire diameter of the first spring coil 40 to the wire diameter of the second spring coil 42 is in the range of 0.72 to 0.95, and in particular 0.9.

[0093] In the illustrated embodiment, the spring core assembly 12 comprises several different zones A to I, i.e., a total of nine different zones. The zone is established by the region defined by different types of spring pockets 20.

[0094] Each zone A to I is provided with only one type of spring pocket 20, namely either a first type spring pocket 28 or a second type spring pocket 30.

[0095] Each of the nine distinct zones comprises at least one row of a specific type of spring pocket 20.

[0096] Generally, a row of a particular type of spring pocket 20 means that individual spring pockets 20 are manufactured of the same type and interconnected with one another by welding. The row of spring pockets 20 has a length corresponding to the width W of the spring core assembly 12 or mattress assembly 10.

[0097] In the illustrated embodiment, regardless of the specific type of spring pocket 20, one row comprises 14 spring pockets 20.

[0098] In fact, Zone 1A contains two rows of Type 2 spring pockets 30. The adjacent Zone 2B contains six rows of Type 1 spring pockets 28. Zone 3C contains six rows of Type 1 spring pockets 30. Zone 4D contains a single row of Type 1 spring pockets 28. Zone 5E contains two rows of Type 2 spring pockets 30. Zone 6F contains a single row of Type 1 spring pockets 28. Zone 7G contains six rows of Type 2 spring pockets 30. Zone 8H contains six rows of Type 1 spring pockets. Finally, Zone 9I contains two rows of Type 2 spring pockets 30.

[0099] In the illustrated embodiment, the spring core assembly 12 has a length L of 190 cm. Thus, the spring core assembly 12 comprises 32 rows, and these 32 rows are interconnected by adhesive.

[0100] As shown above, the individual spring pockets 20 of a row, and in particular their individual spring coils 26, are interconnected with one another by welding, thereby establishing the row.

[0101] In contrast, the spring pockets 20 in adjacent rows are connected to each other by adhesive.

[0102] Generally, the spring pockets 20, and especially the spring coils 26 thereof, are welded together along a first dimension, for example, a width W.

[0103] Furthermore, each spring pocket 20 is bonded along a second dimension, for example, length L, which is perpendicular to the first dimension, for example, width W.

[0104] Furthermore, the spring core assembly 12 is symmetric with respect to two lines of symmetry S1 and S2 that intersect each other at the center or midpoint M of the spring core assembly 12.

[0105] In fact, the second axis of symmetry S2 passes through the fifth zone E, specifically between both rows of the fifth zone E, i.e., between the 16th and 17th rows of the spring pocket 20 of the entire spring core assembly 12 along its length L.

[0106] The second axis of symmetry S2 intersects the first axis of symmetry S1 inside the fifth zone E, that is, between the seventh and eighth columns of the spring pocket 20 along the width W.

[0107] Figure 42 shows a similar embodiment, differing from the first embodiment in that the length L of the spring core assembly 12 and the mattress assembly 10 is increased to 2m. Thus, the spring core assembly 12 comprises one additional row, i.e., a total of 33 springs.

[0108] This additional row creates 11 zones A through K, resulting in a distribution of different zones.

[0109] Again, the various zones A to K are established by rows of spring pockets 20, and in the illustrated embodiment, each row contains 14 spring pockets 20.

[0110] Furthermore, various zones can be established by either two different types of spring pockets 20, namely, a first-type spring pocket 28 or a second-type spring pocket 30.

[0111] Zone 1A contains two rows of Type 2 spring pockets 30. Adjacent Zone 2B contains six rows of Type 1 spring pockets 28. Adjacent Zone 3C contains five rows. Adjacent Zone 4D contains a single row of Type 1 spring pockets 28. Adjacent Zone 5E contains two rows of Type 2 spring pockets 30. Adjacent Zone 6F contains a single row of Type 1 spring pockets 28.

[0112] The sixth zone F also includes a second symmetry axis S2 that intersects the first symmetry access at the center M, passing through a single row.

[0113] The adjacent 7th zone G contains two rows of type 2 spring pockets 30. The adjacent 8th zone H contains only one row of type 1 spring pockets 28. The adjacent 9th zone I contains five rows of type 2 spring pockets 30. The adjacent 10th zone J contains six rows of type 1 spring pockets 28. Finally, the adjacent 11th zone K contains two rows of type 2 spring pockets 30.

[0114] The additional layers 16-18 are the same as those in the first embodiment shown in Figure 1, and refer to that.

[0115] Figure 3 shows a third embodiment, which includes a mattress assembly 10 and a spring core assembly 12 having a length of 190 cm. Its size is the same as that of the first embodiment shown in Figure 1.

[0116] In fact, the spring core assembly 12 also has 32 rows of spring pockets 32. In fact, the distribution of the different types of spring pockets 20, namely the first type of spring pocket 28 and the second type of spring pocket 30, is similar to that shown in Figure 1. Therefore, refer to the above description.

[0117] However, the mattress assembly 10 differs from that shown in the first embodiment because the additional layers 14-18 are manufactured differently.

[0118] Generally, each of the additional layers 14-18 has a height of 15 mm, similar to the first embodiment. Furthermore, these additional layers 14-18 are also bonded to each other using the same adhesive.

[0119] However, the properties of the additional layers 14-18 differ from those of the first embodiment, for example, due to the different materials used in the additional layers 14-18.

[0120] In fact, the first additional layer 14 has a density of 40 kg / m³. 3 It is made of viscomemory foam having a minimum net density and a hardness of 1.6 kPa. The second additional layer 16 is 34 kg / m 3 It is made of comfort foam having a minimum net density and a hardness of 2.5 kPa. The third additional layer 18, which is directly bonded to the spring core assembly 12, is also 31 kg / m 3 It is made from comfort foam with a minimum net density and a hardness of 2.8 kPa.

[0121] Therefore, the same spring core assembly 12 is used, but it is used in combination with different additional layer structures, thereby providing mattress assemblies 10 with different characteristics.

[0122] Figure 4 shows a fourth embodiment, which is a combination of the second embodiment shown in Figure 2 and the third embodiment shown in Figure 3. The mattress assembly 10 and the spring core assembly 12 have a length of 2 m, similar to the second embodiment, but the mattress assembly 10 includes the same additional layers 14-18 used in the third embodiment.

[0123] Therefore, the spring core assembly 12 of the fourth embodiment includes 33 rows, as already described with respect to the second embodiment shown in Figure 2, but the additional layers 14-18 are as described with respect to the third embodiment shown in Figure 3.

[0124] Accordingly, the above description is referenced with respect to the second and third embodiments.

Claims

1. A spring core assembly for a mattress assembly, A spring core assembly comprising a bottom fabric, an upper fabric, and at least one spring coil provided between the bottom fabric and the upper fabric, characterized in that the basis weight of the bottom fabric is different from the basis weight of the upper fabric, and comprising at least one spring pocket.

2. The spring core assembly according to claim 1, wherein the basis weight of the bottom fabric is higher than the basis weight of the top fabric.

3. The spring core assembly according to claim 1 or 2, wherein the ratio of the basis weight of the upper fabric to the basis weight of the bottom fabric is in the range of 0.4 to 0.6, and particularly 0.

5.

4. The basis weight of the upper fabric is 60 g / m². ２ ~80g / m ２ This range is particularly 65 g / m ２ And / or, the basis weight of the bottom fabric is 100 g / m². ２ ~160g / m ２ This range is particularly 130 g / m². ２ The spring core assembly according to any one of claims 1 to 3.

5. The spring core assembly comprises a first type spring pocket and a second type spring pocket. Both types of spring pockets have the same bottom fabric and the same top fabric. The basis weight of the bottom fabric differs from that of the top fabric. The first type of spring pocket has a first spring coil provided between the bottom fabric and the top fabric, The second type of spring pocket has a second spring coil located between the bottom fabric and the top fabric. A spring core assembly according to any one of claims 1 to 4, wherein the first spring coil and the second spring coil are different.

6. The spring core assembly according to claim 5, wherein the first type spring pocket and the second type spring pocket are bonded adjacent to each other.

7. The spring core assembly according to claim 5 or 6, wherein the first spring coil and the second spring coil have different wire diameters, and in particular, the wire diameter of the first spring coil is smaller than the wire diameter of the second spring coil.

8. The spring core assembly according to any one of claims 5 to 7, wherein the ratio of the wire diameter of the first spring coil to the wire diameter of the second spring coil is in the range of 0.72 to 0.95, and particularly 0.

9.

9. The spring core assembly according to any one of claims 5 to 8, wherein the wire diameter of the first spring coil is in the range of 1.6 mm to 1.9 mm, particularly in the range of 1.6 mm to 1.8 mm, preferably 1.7 mm, and / or the wire diameter of the second spring coil is in the range of 1.8 mm to 2.2 mm, particularly in the range of 1.8 mm to 2 mm, preferably 1.9 mm.

10. A spring core assembly according to any one of claims 5 to 9, wherein a plurality of first type spring pockets are connected in series, particularly by welding, thereby forming a row of first type spring pockets, and / or a plurality of second type spring pockets are connected in series, particularly by welding, thereby forming a row of second type spring pockets.

11. A spring core assembly according to any one of claims 5 to 10, wherein at least two rows of first type spring pockets are installed adjacent to each other, and the spring pockets of adjacent rows are bonded to each other, and / or at least two rows of second type spring pockets are installed adjacent to each other, and the spring pockets of adjacent rows are bonded to each other.

12. The spring core assembly according to any one of claims 1 to 11, wherein the spring core assembly is symmetric with respect to two lines of symmetry that intersect each other at the center of the spring core assembly, and in particular, the lines of symmetry are perpendicular to each other.

13. A mattress assembly comprising a spring core assembly according to any one of claims 1 to 12, A mattress assembly further comprising at least one additional layer located on top of a spring core assembly.

14. The mattress assembly is a stack assembly including the spring core assembly, a first additional layer, and a second additional layer. The mattress assembly according to claim 13, wherein the first additional layer and the second additional layer are made of different materials, in particular different foams.

15. The spring core assembly is the bottom layer of the mattress assembly. The third layer is glued or zippered to the spring core assembly. The second layer is glued or zipped to the third layer. The first layer is glued or zipped to the second layer. The mattress assembly according to claim 14, wherein all layers have different properties, in particular different minimum densities and / or different hardnesses.

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