# US 11,026,517 B2 · Mattress assembly with a mattress topper that includes pocketed coil springs and methods of producing the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,026,517 B2 - Document ID: US11026517B2 - Status: Granted - Kind: B2 - Application number: 16/474,318 - Filed: 2016-12-29 - Published: 2019-11-14 - Granted: 2021-06-08 - Earliest claimed: 2016-12-29 - Assignees: Sealy Technology, LLC - Applicants: Sealy Technology, LLC - Inventors: Larry K. DeMoss; Brian M. Manuszak; Darin T. Thomas; Kevin Tar - Web page: https://patentgrep.com/patent/US11026517B2 ## CPC - A47C 27/053: {with only one layer of foamed material} - A47C 27/056: {with different layers of foamed material} - A47C 27/064: {Pocketed springs} - A47C 27/14: with foamed material inlays - A47C 27/22: with both fibrous and foamed material inlays - B68G 7/10: Finishing of edges - B68G 9/00: Placing upholstery springs in pockets; Fitting springs in upholstery - A47C: CHAIRS; SOFAS; BEDS - B68G: METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR ## Abstract A mattress assembly is provided that includes a mattress core having a bottom surface and a top surface opposite the bottom surface, and a mattress topper positioned adjacent to the top surface of the mattress core. The mattress topper includes a plurality of coil springs, an upper fabric layer extending above the plurality of coil springs, and a lower fabric layer extending below the plurality of coil springs. The lower fabric layer is connected to the upper fabric layer around each coil spring such that the upper fabric layer and the lower fabric layer collectively form a fabric pocket encasing each coil spring. The mattress topper further includes a padded layer positioned atop the upper fabric layer, with the padded layer connected to the upper fabric layer by ultrasonic welds and/or tufts. Methods of producing a mattress topper for connection to a mattress core are further provided. ## Claims ### Claim 1 A mattress assembly, comprising: a mattress core having a bottom surface and a top surface opposite the bottom surface; and a mattress topper positioned adjacent and connected to the top surface of the mattress core, the mattress topper including: a plurality of coil springs, an upper fabric layer extending above the plurality of coil springs, a lower fabric layer extending below the plurality of coil springs and connected to the upper fabric layer around each coil spring by a plurality of overlapping welds such that the upper fabric layer and the lower fabric layer collectively form a fabric pocket encasing each coil spring, a padded layer positioned atop and connected to the upper fabric layer, wherein the padded layer is comprised of a visco-elastic foam, a fibrous material, or both a visco-elastic foam and a fibrous material, a textile layer on a top surface of said padded layer, a backing layer disposed along a bottom surface of said lower fabric layer, wherein said upper fabric layer is connected to the lower fabric layer by said plurality of overlapping welds, said backing layer is connected to said lower fabric layer by said plurality of overlapping welds, said padded layer is connected to said upper fabric layer by the plurality of overlapping welds, and the textile layer is connected to the padded layer by said plurality of overlapping welds. ### Claim 2 (depends on 1) The mattress assembly of claim 1, wherein the padded layer is comprised of a visco-elastic foam. ### Claim 3 (depends on 1) The mattress assembly of claim 1, wherein the padded layer is comprised of a plurality of layers. ### Claim 4 (depends on 1) The mattress assembly of claim 1, wherein the upper fabric layer, the lower fabric layer, or both are comprised of a non-woven textile. ### Claim 5 (depends on 1) The mattress assembly of claim 1, wherein the lower fabric layer is connected to the upper fabric layer by an ultrasonic weld. ### Claim 6 (depends on 1) The mattress assembly of claim 1, wherein the padded layer is connected to the upper fabric layer by an ultrasonic weld. ### Claim 7 (depends on 1) The mattress assembly of claim 1, wherein the padded layer is connected to the upper fabric layer by an adhesive. ### Claim 8 (depends on 1) The mattress assembly of claim 1, wherein the padded layer is connected to the upper fabric layer by a plurality of tufts that extend through the lower fabric layer, the upper fabric layer, and the padded layer. ### Claim 9 (depends on 1) The mattress assembly of claim 1, wherein the mattress topper further includes a textile layer positioned atop the padded layer. ### Claim 10 (depends on 1) The mattress assembly of claim 1, wherein the backing layer is comprised of a non-woven textile. ### Claim 11 A method of producing a mattress topper for connection to a mattress core, comprising the steps of: providing an array of coil springs; positioning the array of coil springs between an upper fabric layer and a lower fabric layer; connecting the lower fabric layer to the upper fabric layer between each coil spring with a plurality of overlapping welds; connecting a backing layer to said lower fabric layer by said plurality of overlapping welds; connecting a padded layer to said upper fabric layer by the plurality of overlapping welds; connecting the textile layer to the padded layer by said plurality of overlapping welds. ### Claim 12 (depends on 11) The method of claim 11, wherein the step of connecting the lower fabric layer to the upper fabric layer comprises ultrasonically welding the lower fabric layer to the upper fabric layer. ### Claim 13 (depends on 12) The method of claim 12, wherein the step of ultrasonically welding the lower fabric layer to the upper fabric layer is performing by positioning a circular iron around each said coil spring of the array of coil springs such that the iron simultaneously forms an ultrasonic weld completely surrounding each said coil spring. ### Claim 14 (depends on 11) The method of claim 11, further comprising a step of connecting a padded layer to the upper fabric layer. ### Claim 15 (depends on 14) The method of claim 14, wherein the step of connecting the padded layer to the upper fabric layer comprises roll coating the upper fabric layer with an adhesive and positioning the padded layer atop the upper fabric layer. ### Claim 16 (depends on 14) The method of claim 14, wherein the step of connecting the padded layer to the upper fabric layer comprises: positioning the padded layer atop the upper fabric layer; compressing the lower fabric layer, the upper fabric layer, and the padded layer around each coil spring; and ultrasonically welding together the lower fabric layer, the upper fabric layer, and the padded layer around each coil spring. ### Claim 17 (depends on 14) The method of claim 14, wherein the step of connecting the padded layer to the upper fabric layer comprises forming a plurality of tufts extending through the lower fabric layer, the upper fabric layer, and the padded layer. ### Claim 18 A mattress topper, comprising: a plurality of coil springs, an upper fabric layer extending above the plurality of coil springs, and a lower fabric layer extending below the plurality of coil springs and connected to the upper fabric layer by an overlapping weld around each coil spring of said plurality of coil springs such that the upper fabric layer and the lower fabric layer collectively form a fabric pocket encasing each of said coil spring; a padded layer positioned atop the upper fabric layer, said padded layer comprising a visco-elastic foam, or a fibrous material, or both a visco-elastic foam and a fibrous material; a textile layer positioned atop the padded layer; and a backing layer positioned below the lower fabric layer, wherein said upper fabric layer is connected to the lower fabric layer by said overlapping welds, said backing layer is connected to said lower fabric layer by said overlapping welds, said padded layer is connected to said upper fabric layer by the overlapping welds, and the textile layer is connected to the padded layer by said overlapping welds. ### Claim 19 (depends on 18) The mattress topper of claim 18, further comprising a plurality of tufts that extend through the lower fabric layer, the upper fabric layer, and the padded layer. ### Claim 20 (depends on 19) The mattress topper of claim 19, wherein the plurality of tufts also extend through the backing layer, the textile layer, or both the backing layer and the textile layer.