Pocket coil spring assembly containing flexible foam

Abstract

The pocket coil spring assembly (10) is formed to include a coil spring (20) having an upper portion (22) and a lower portion (24) that together define an interior cavity of the coil spring. The pocket coil spring assembly further includes a fabric pocket (30) encasing the coil spring, with a top region (32) covering the upper portion of the coil spring and a bottom region (34) covering the lower portion of the coil spring. A discrete amount of flexible foam (40) is formed over the fabric pocket, with the upper surface (42) of the flexible foam extending over the coil spring. The mattress assemblies (200, 300, 400) are further formed to include flexible foam distributed as a continuous or discrete amount between the pocket coil springs.

Description

Claiming priority

[0001] This PCT patent application claims priority to and the benefit of U.S. Provisional Application No. 62 / 579,209, filed October 31, 2017, which is incorporated herein by reference in its entirety. [Technical field]

[0002] The present embodiments relate to pocket coil spring assemblies. In particular, the present embodiments relate to pocket coil spring assemblies that include a quantity of flexible foam disposed either over the coil springs or in the areas between the rows of coil springs. [Background technology]

[0003] Spring assemblies using pocket coil springs, also known as wrapped coils, encased coils, or Marshall coils, are generally recognized as providing a unique feel to mattresses when used as part of a spring assembly because each individual coil can move independently and support the body, or part thereof, of a user lying on the mattress. In particular, in a pocket coil spring assembly, each coil is encased in a fabric pocket and moves substantially independently from the other coils in the pocket coil spring assembly, thereby providing individual comfort and appearance to the user's body. Furthermore, as a result of moving substantially independently of each other, the pocket coils also do not transmit motion directly from one coil to the other coils, and the motion of one user resting on a mattress assembly using pocket coils will not disturb other users resting on the mattress assembly. In this regard, mattress assemblies made with pocket coil springs are generally recognized as providing a soft, luxurious feel and are more desirable than traditional internally sprung mattresses. Thus, a pocket coil spring assembly which improves upon the unique feel and support provided by traditional pocket coil springs would be highly desirable and beneficial. Summary of the Invention

[0004] The present embodiment includes a pocket coil spring assembly. In particular, the present embodiment includes a pocket coil spring assembly that includes a quantity of flexible foam disposed over the coil springs or between the rows of coil springs.

[0005] In one exemplary embodiment, a pocket coil spring assembly is provided that includes a coil spring having an upper portion and a lower portion that together define a height of the coil spring. A fabric pocket encases the coil spring and includes an upper region that covers the upper portion of the coil spring and a bottom region that covers the lower portion of the coil spring. A hemispherical shaped quantity of flexible foam is disposed over the upper portion of the fabric pocket.

[0006] In another embodiment, a mattress assembly is provided that includes a spring core having a first support surface and a second support surface opposite the first support surface. The spring core includes a plurality of coil springs arranged in a matrix and extending from a first end of the mattress assembly to a second end of the mattress assembly. Each coil spring included in the mattress assembly has an upper portion and a lower portion that together define a height of the respective coil spring. A fabric pocket encases each one of the coil springs, each fabric pocket including an upper region that covers an upper portion of the respective coil spring and a bottom region that covers a lower portion of the respective coil spring. A plurality of quantities of flexible foam, each having a top surface, are disposed between the rows of coil springs. In some embodiments, the quantities of flexible foam are small, discrete pieces of flexible foam, while in other embodiments, the flexible foam is a continuous piece of flexible foam that extends along the entire length of the row.

[0007] Further features and advantages of the present embodiments will become apparent to those skilled in the art upon study of the description, figures, and non-limiting examples contained herein. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a side view of an exemplary pocket coil spring assembly according to an embodiment with a portion of the fabric pocket of the pocket coil spring assembly removed to reveal the coil spring. [Diagram 2]2 is a perspective view of an exemplary mattress assembly according to the present embodiment with a portion of the mattress assembly removed to show a plurality of pocket coil spring assemblies of FIG. 1 positioned therein. [Diagram 3] FIG. 2 is a perspective view of an exemplary mattress assembly according to the present embodiment with a portion of the mattress assembly removed to show a plurality of pocket coil spring assemblies within the mattress assembly and a quantity of flexible foam disposed between the rows of pocket coil springs. [Figure 4] FIG. 2 is a perspective view of another exemplary mattress assembly according to the present embodiment with a portion of the mattress assembly removed to show a plurality of exemplary pocket coil spring assemblies within the mattress assembly and a quantity of flexible foam disposed between the rows of pocket coil springs. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] An embodiment of the present invention includes a pocket coil spring assembly. In particular, the present invention includes a pocket coil spring assembly that includes a quantity of flexible foam disposed as a quantity or multiple separate quantities over the coil springs or between the rows of coil springs in the assembly and extending from one end of the mattress to the other.

[0010] 1, in one exemplary embodiment, a pocket coil spring assembly 10 is provided that includes a coil spring 20 having an upper portion 22 and a lower portion 24 that together define a height of the coil spring 20. The pocket coil spring assembly 10 further includes a fabric pocket 30 that encases the coil spring 20. In particular, the fabric pocket 30 includes an upper region 32 that covers the upper portion 22 of the coil spring 20 and a bottom region 34 that covers the lower portion 24 of the coil spring 20. Further included within the pocket coil spring assembly 10 is a quantity of flexible foam disposed over the upper region 32 of the coil spring 20 and having an upper surface 42 that extends above the coil spring 20.

[0011] With respect to the coil spring 20, in the exemplary pocket coil spring assembly 10 shown in Figure 1, the coil spring 20 is formed from a continuous wire that extends from an upper end spiral 23 in an upper portion 22 of the coil spring 20 to a lower end spiral 25 opposite the upper end spiral 23 in a lower portion 24 of the coil spring 20. In the coil spring 20, there are seven intermediate spirals that are helical between the upper end spiral 23 and the lower end spiral 25, making the coil spring 20 comprised of nine total spirals or turns. Of course, various other coils, such as coil springs 20 having different numbers of spirals, may also be used in the exemplary pocket coil spring assembly without departing from the spirit and scope of the present claims.

[0012] With respect to the fabric pocket 30, in the exemplary pocket coil spring assembly 10 shown in FIG. 1, a top region 32 and a bottom region 34 of the fabric pocket 30 extend along the outside of the coil spring 20 to form a generally cylindrical (or tubular) side 36 of the fabric pocket 30. In this case, the fabric pocket 30 is preferably formed from inelastic fabrics that are bonded or welded together with heat or pressure (e.g., using ultrasonic welding or similar heat welding techniques) to form such a cylindrical structure. For example, fabrics suitable for use in the fabric pocket 30 include one of a variety of thermoplastic fabrics known to those skilled in the art, such as, for example, a nonwoven polymer-based fabric, a nonwoven polypropylene material, or a nonwoven polyester material.

[0013] 1, the flexible foam 40 included in the pocket coil spring assembly 10 generally includes a type of foam having a density suitable for supporting and distributing pressure from a user's body or portion thereof and resting on the pocket coil spring assembly 10. Such flexible foams include, but are not limited to, latex foam, reticulated or non-reticulated viscoelastic foam (also referred to as memory foam or low resilience foam), reticulated or non-reticulated non-viscoelastic foam, high resilience polyurethane foam, expanded polymer foam (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene or polyethylene), and the like. In the exemplary embodiment shown in FIG. 1, the flexible foam 40 includes a two-part polyurethane foam. The polyurethane foam is dispensed as a liquid directly onto the upper region 32 of the fabric pocket 30 to form small hemispheres (i.e., half of a sphere) that react and bond with the fabric pocket 30 itself, including a top surface 42 having a convex shape and a flat bottom surface (not shown). Of course, it will be understood that varying the composition of the liquid will result in different shapes of the flexible foam 40. The amount of liquid dispensed, and thus the resulting amount of foam, may vary.

[0014] In terms of hardness, the flexible foam 40 included in the pocket coil spring assembly 10 has a hardness of at least about 10 N to about 80 N in some embodiments. Measurements are taken at about room temperature (e.g., 21° C. to 23° C.) by applying pressure from a plate against a sample material until at least 40% of the original thickness of the material is compressed, and holding the 40% compression for a predetermined period of time, as defined by the International Organization for Standardization (ISO) 2439 hardness measurement standard. In some embodiments, the flexible foam 40 included in the pocket coil spring assembly 10 has a hardness of about 10N, about 20N, about 30N, about 40N, about 50N, about 60N, about 70N, about 80N, about 90N, about 100N, about 110N, about 120N, about 130N, about 140N, about 150N, about 160N, about 170N, about 180N, about 190N, about 200N to provide a desired degree of comfort and body conforming or support qualities.

[0015] With respect to density, the flexible foam 40 included in the pocket coil spring assembly 10 also has a density that helps provide a desired degree of comfort and body conforming qualities, as well as high material durability, in some embodiments. In some embodiments, the flexible foam 40 included in the pocket coil spring assembly 10 has a density of at least about 30 kg / m 3 to about 150 kg / m 3 In some embodiments, the flexible foam 40 included in the pocket coil spring assembly 10 has a density of about 10 kg / m 3 , about 15kg / m 3 , about 20kg / m 3 , about 25kg / m 3 , about 30kg / m 3 , about 40kg / m 3 , about 50kg / m 3 , about 60kg / m 3 , about 70kg / m 3 , about 80kg / m 3 , about 90kg / m 3 , about 100kg / m 3 , about 110kg / m 3 , about 120kg / m 3 , about 130kg / m3 , about 140kg / m 3 , about 150kg / m 3 Of course, the selection of a flexible foam having a particular density will affect the characteristics of the foam, including its firmness, how the foam responds to pressure, and the overall feel of the foam, but it should be appreciated that a flexible foam having a desired density and firmness can be readily selected for a particular pocket coil spring assembly or desired application. With regard to the special properties of the flexible foam 40, a user's body or a portion thereof resting on the pocket coil spring assembly 10 is supported by both the flexible foam 40 and the coil spring 20, but because the upper surface 42 of the flexible foam 40 is located above the coil spring 20, a user's body or a portion thereof resting on the pocket coil spring assembly 10 contacts only the flexible foam 40 and not the coil spring 20. In this manner, the exemplary pocket coil spring assembly 10 advantageously combines the tactile feel of a foam with the durability and support of a spring.

[0016] As mentioned above, the flexible foam 40 in the illustrated embodiment shown in FIG. 1 is formed from a two-part polyurethane foam, although other materials such as gels or fiber-filled materials may be used in addition to or in place of the foam. For example, in some embodiments, the flexible foam may include or be replaced with a vinyl- or silicone-based gel, or other similar materials. In other examples, in some embodiments, the flexible foam may include an elastomeric gelatinous material that may provide a cooling effect by acting as a heat dump or heat sink into which heat from the user's body or a portion thereof located above the flexible foam 40 dissipates. More particularly, in those embodiments, the flexible foam includes a polyurethane-based gel made from a combination of Hyperlast® LU1046 Polyol, Hyperlast® LP5613 isocyanate, and a thermoplastic polyurethane film, each manufactured and sold by Dow Chemical Company Corp, Midland, MI. These, combined, have a thermal conductivity of 0.1776 W / m * Thermal conductivity of K, 0.1184mm 2 / s, and a thermal diffusivity of 1.503 MJ( / m2) as specified by the International Organization for Standardization (ISO) 22007-2 volumetric ratio measurement standard. 3 The gel is then produced with a volumetric specific heat of 0.1 kPa (Hg) at 100° C. It should also be appreciated that varying "zones" or regions are created by the multiple spring coils and foam. For example, the density of the flexible foam varies in different "zones" or regions of the mattress assembly.

[0017] Additionally, it should be appreciated that the spring coil wire gauge, spring constant, preload, and overall geometry used in a particular pocket coil spring assembly may be readily varied and used to add particular feel or characteristics in the exemplary pocket coil spring assembly without departing from the spirit and scope of the present invention.

[0018] Referring to Figure 2, in another embodiment of the present embodiment, an exemplary mattress assembly 200 is provided that includes a plurality of pocket coil spring assemblies 10 as described above with reference to Figure 1. As shown in Figure 2, the pocket coil spring assemblies 10 are arranged in a matrix and collectively form a spring core 202 having a first support surface 204 (or sleep surface) and a second support surface 206 opposite the first support surface 204. In the spring core 202 shown in Figure 2, the longitudinal axes of each pocket coil spring assembly 10 are arranged parallel to one another, with the upper surface 42 of the flexible foam 40 of the pocket coil spring assembly 10 at least partially forming the first support surface 204 of the spring core 202, and the bottom region 34 of the fabric pocket 30 together with the lower portion 24 of the coil spring 20 of each pocket coil spring assembly 10 forming the second support surface 206 of the spring core 202.

[0019] Additionally, in some embodiments, the example mattress assembly 200 further includes an upper body support layer 260 positioned adjacent the first support surface 206 of the spring core 202, and a lower foundation layer 270 positioned adjacent the second support surface 206 of the spring core 202. The side panels 280 may extend between the upper body support layer and the lower foundation layer around the entirety of the spring core 202 and enclose the plurality of pocket coil spring assemblies 10.

[0020] Although the upper body support layer 260 is formed from a viscoelastic foam, it is contemplated that the upper body support layer may be formed from some combination of foam, upholstery material, and / or other soft, flexible materials as are known in the art. Additionally, the upper body support layer may be formed from multiple layers of material configured to improve the comfort and support of the upper body support layer. In contrast to the upper body support layer, the lower base layer is typically comprised of a piece of wood or other similar rigid member and is configured to support a plurality of pocket coil spring assemblies 10.

[0021] Referring now to Figure 3, in another embodiment, an exemplary mattress assembly 300 is formed having a plurality of pocket coil spring assemblies 310 that are shorter in height than the coil springs described above with reference to Figures 1-2. The exemplary mattress assembly 300 shown in Figure 3 further includes an upper continuous sheet 350 and a lower continuous sheet 352, which will be described below.

[0022] Each of the pocket coil spring assemblies 310 shown in Figure 3 includes a coil spring 320 having an upper portion 322 and a lower portion 324 that together define the height of the coil spring 320. Each of the coil springs 310 in Figure 3 is formed from a spiral wire that extends from an upper end convolution of the upper portion 322 of the coil spring 320 to an opposing lower end convolution of the lower portion 324 of the coil spring 320.

[0023] As noted, the exemplary mattress assembly 300 shown in FIG. 3 further includes an upper convoluted sheet 350 extending across an upper portion 322 of each of the plurality of coil springs 320 and a lower convoluted sheet 352 extending across a lower portion 324 of each of the plurality of coil springs 320. The upper continuous sheet 350 is connected to the lower continuous sheet 253 around and between each of the plurality of coil springs 320, and the upper continuous sheet 350 and the lower continuous sheet 352 together form a fabric pocket encasing each of the coil springs 320. In particular, a portion of the upper continuous sheet 350 forms, at least in part, an upper region 332 of the fabric pocket that covers the upper portion 322 of each of the coil springs 320 of the plurality of pocket coil spring assemblies 310. Similarly, a portion of the lower continuous sheet 352 forms, at least in part, a bottom region 334 of the fabric pocket that covers the lower portion 324 of each of the coil springs 320 of the plurality of pocket coil spring assemblies 310.

[0024] 3, the flexible foam 340 is disposed in the area between the pocket coil spring assemblies 310 instead of on top of the pocket coil spring assemblies as shown in FIGS. 1 and 2. In particular, the coil spring assemblies 310 are disposed as a matrix extending from the lower base 360 ​​of the mattress assembly 300 to the body support layer 370 of the mattress assembly. The flexible foam 340 of the mattress assembly 300 is disposed in the area between the coil spring assemblies 310 such that the upper surface 342 of each flexible foam 340 is approximately flush with the upper portion 322 of each of the coil spring assemblies 310. For example, in the illustrated embodiment of FIG. 3, the upper surface of each of the flexible foam 340 is flush with the top convolution of each of the coil springs 320, and the first support surface of the mattress assembly 300 is formed by both the upper surface 342 of the flexible foam 340 and the first convolution of the upper portion 322 of the coil spring 320.

[0025] 4, as another embodiment, an exemplary mattress assembly 400 is formed substantially similar to the mattress assembly 300 described above with reference to FIG. 3, except that the flexible foam 340 is disposed as a continuous quantity in the areas between the pocket coil spring assemblies 410 instead of on top of the pocket coil spring assemblies 410. In particular, whereas the flexible foam 340 shown in FIG. 3 is a discrete quantity disposed between the rows of coil springs 310, the flexible foam 440 shown in FIG. 4 extends as a continuous quantity along the rows of coil springs 410. As with the mattress assembly 300 of FIG. 3, each flexible foam 440 is disposed between the coil spring assemblies 410, with the top surface 442 of each flexible foam 440 being flush with the respective upper portion 422 of the coil spring assemblies 410. In this manner, the upper support surface of the mattress assembly 400 is formed from both the top surface 442 of the flexible foam 440 and the first convolutions of the top portions 422 of the coil springs 420.

[0026] One of ordinary skill in the art will recognize that additional embodiments are also possible without departing from the teachings of the present invention or the scope of the claims which follow. This detailed description, and particularly the specific details of the exemplary embodiments described herein, are provided primarily for clarity of understanding and should not be understood as unnecessary limitations therefrom, as variations will be apparent to those of ordinary skill in the art upon reading this disclosure and can be made without departing from the spirit or scope of the invention as claimed.

Claims

1. a coil spring (20) having an upper portion (22) and a lower portion, the upper portion and the lower portion together defining a height of the coil spring; a generally cylindrical fabric pocket (30) encasing the coil spring and including an upper region (32) covering an upper portion of the coil spring and a bottom region (34) covering a lower portion of the coil spring; a flexible foam (40) dispensed as a liquid directly onto the upper region of the fabric pocket, the flexible foam (40) being disposed directly onto the fabric pocket encasing the coil spring; The liquid dispensed onto the upper region of the fabric pocket reacts with and bonds to the fabric pocket itself (30), forming a hemispherical flexible foam having a convex shaped top surface and a flat bottom surface, forming a pocket coil spring assembly (10).

2. 10. The pocket coil spring assembly of claim 1, wherein the fabric pocket is formed from a woven fabric.

3. 2. The pocket coil spring assembly of claim 1, wherein the flexible foam is formed from a viscoelastic foam.

4. 2. The pocket coil spring assembly of claim 1, wherein the liquid dispensed onto the upper region of the fabric pocket reacts with and bonds to the fabric pocket itself, thereby adhering the flexible foam to the fabric pocket.

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