Pocket-spring core and method for producing the pocket-spring core

A method for producing a pocket spring core having at least one first zone and at least one second zone,

• wherein the at least one first zone includes at least two rows of a first spring strand section including a first plurality of helically wound compression springs arranged in a single layer, each of the first plurality of helically wound compression springs having a first spring constant,
• wherein at least one of the at least one second zone includes at least one row of a second spring strand section and at least one row of a third spring strand section, wherein the at least one row of a second spring strand section includes a second plurality of helically wound compression springs arranged in a first layer, and a third plurality of helically wound compression springs arranged in a second layer located vertically over the first layer, each of the second plurality of helically wound compression springs having a second spring constant and each of the third plurality of helically wound compression springs having a third spring constant, wherein the third spring constant is different from the second spring constant, and wherein ones of the second plurality of helically wound compression springs and corresponding ones of the third plurality of helically wound compression springs are operable in combination, the combination having a progressive spring rate,
• wherein the at least one row of a third spring strand section includes a fourth plurality of helically wound compression springs, each of the fourth plurality of helically wound compression springs having a fourth spring constant, wherein the at least one row of a third spring strand section includes a fourth plurality of helically wound compression springs arranged in a first layer, each of the fourth plurality of helically wound compression springs having a fourth spring constant, a fifth plurality of springs arranged in a second layer located vertically over the first layer, and a sixth plurality of springs arranged in a third layer located vertically over the second layer, wherein a height of the at least one row of a third spring strand section is less than a height of the at least two rows of a first spring strand section and less than a height of the at least one row of a second spring strand section, and wherein the at least one row of a third spring strand section cooperates with at least one of the at least two rows of a first spring strand section and the at least one of a second spring strand section to define at least one channel-like depression, the method comprising the steps of:
• a) providing wire, a textile material, a machine for automated manufacturing of endless spring strands from pocketed springs, a machine for the severing of the spring strands and the alignment, layering, and adhesive bonding of spring strand sections, and adhesive;
• b) producing a first spring strand of pocketed compression springs;
• c) producing a second spring strand of pocketed compression springs arranged vertically one over another;
• d) producing a third spring strand of pocketed compression springs arranged vertically one over another;
• e) severing the respective spring strand of pocketed compression springs into the respective spring strand sections and aligning, juxtaposing to form a defined pattern, and adhesively bonding the spring strand sections to form a pocket spring core so that the zoned pocket spring core is formed having at least one first zone and one second zone, wherein at least one of the first zone(s) of the at least two zones has channel-like depressions.