Pocketed spring comfort layer having at least one foam layer and method of making same
AssigneeL&P Property Management Company
InventorsKyle S. Lisenbee, Darrell A. Richmond
Life of this patent
Estimating the term…
Abstract
A pocketed spring comfort layer for a bedding or seating product has pockets characterized by the individual mini coil springs of the comfort layer being pocketed with between at least one cushion assembly and a sheet of polypropylene fabric. Each cushion assembly includes at least one foam layer. A segmented seam joins the cushion assembly and the sheet of polypropylene fabric around each of the mini coil springs of the pocketed spring comfort layer. The method of making the pocketed spring comfort layer includes compressing the mini coil springs and creating pockets with a welding horn and an anvil.
Claims31
A method of manufacturing a pocketed spring comfort layer configured to overlay a spring core of a bedding or seating product, said method comprising:
- forming a continuous blanket of individually pocketed springs, each spring being contained within a pocket formed by joining first and second cushion assemblies together with weld seams, each of the cushion assemblies including at least one layer of foam sandwiched between inner and outer protective layers of fabric;
- and
- cutting said continuous blanket of individual pocketed springs to a desired size to create a comfort layer.
A pocketed spring comfort layer configured to overlay a spring core of a bedding or seating product, said pocketed spring comfort layer comprising:
- a matrix of interconnected pocketed mini springs, each mini spring of which is contained within a pocket between cushion assemblies on opposite sides of the pocket, each pocket having a weld seam around the pocket joining the cushion assemblies, wherein each of the cushion assemblies includes a layer of foam sandwiched between inner and outer protective layers of non-woven fabric.
A pocketed spring comfort layer for a bedding or seating product, said pocketed spring comfort layer comprising:
- a matrix of interconnected pocketed mini springs, each mini spring of which is contained within a pocket between an upper cushion assembly and a lower cushion assembly on opposite sides of the pocket, each cushion assembly comprising an inner protective layer, an outer protective layer and a middle foam layer, each pocket having a weld seam around the pocket joining the cushion assemblies of the pocket.
A pocketed spring comfort layer for a bedding or seating product, said pocketed spring comfort layer comprising:
- a matrix of interconnected pocketed mini springs, each mini spring of which is contained within a pocket between multi-layered cushion assemblies, each pocket having a segmented weld seam around the pocket joining the multi-layered cushion assemblies of the pocket, each weld seam comprising multiple weld segments and each multi-layered cushion assembly having a layer of foam between inner and outer protective layers of fabric.
A bedding or seating product, comprising:
- a core;
- and
- a pocketed spring comfort layer overlaying the core, the pocketed spring comfort layer comprising a matrix of interconnected pocketed mini springs, each mini spring of which is contained within a pocket between multi-layered cushion assemblies on opposite sides of the pocket, each of the multi-layered cushion assemblies comprising an inner protective layer, an outer protective layer and a foam layer between the inner and outer protective layers, each pocket having a segmented weld seam around the pocket joining the multi-layered cushion assemblies, each weld seam comprising multiple weld segments.
A bedding or seating product, comprising:
- a core;
- and
- a pocketed spring comfort layer overlaying the core, the pocketed spring comfort layer comprising a matrix of interconnected mini pocketed springs, each mini spring of which is contained within a pocket between multi-layered cushion assemblies, each pocket having a segmented weld seam around the pocket joining the multi-layered cushion assemblies of the pocket, each weld seam comprising multiple weld segments and each multi-layered cushion assembly having a layer of foam sandwiched between layers of non-woven fabric.
Dependencies are inferred from the claim text.