Coil springs, pocketed coil springs assemblies, and mattresses including the same

A method of manufacturing a mattress assembly, comprising:

• providing a plurality of coil springs, each coil spring including
• a continuous wire forming a lowermost convolution, an uppermost convolution opposite the lowermost convolution, and a plurality of helical intermediate convolutions between the lowermost convolution and the uppermost convolution, the continuous wire defining a pitch between the lowermost convolution and the helical convolution adjacent to the lowermost convolution, a pitch between each one of the plurality of intermediate convolutions, and a pitch between the uppermost convolution and the intermediate convolution adjacent to the uppermost convolution, and the continuous wire divided into
• a lower portion including the lowermost convolution and one or more of the intermediate convolutions, each of the one or more intermediate convolutions of the lower portion having a diameter greater than or equal to a lower minimum diameter, the pitch between each of the convolutions of the lower portion greater than or equal to a lower minimum pitch, and
• an upper portion including the uppermost convolution and one or more of the intermediate convolutions, each of the one or more intermediate convolutions of the upper portion having a diameter greater than or equal to an upper minimum diameter, the pitch between each of the convolutions of the upper portion less than or equal to an upper maximum pitch;
• forming a pocket around each coil spring with a flexible enclosure such that each pocketed coil spring is in a strand of pocketed coil springs;
• and
• positioning a plurality of the strands of pocketed coil springs in parallel,
• wherein the upper maximum pitch is less than the lower minimum pitch,
• wherein, prior to forming the pocket around each coil spring, the coil spring is positioned in either a first orientation or a second orientation rotated 180° about a longitudinal axis of the coil spring relative to the first orientation, and
• wherein the upper minimum diameter is less than or equal to the lower minimum diameter.

A coil spring, comprising:

• a continuous wire forming a lowermost convolution, an uppermost convolution opposite the lowermost convolution, and a plurality of helical intermediate convolutions between the lowermost convolution and the uppermost convolution, the continuous wire defining a pitch between the lowermost convolution and the helical convolution adjacent to the lowermost convolution, a pitch between each one of the plurality of intermediate convolutions, and a pitch between the uppermost convolution and the intermediate convolution adjacent to the uppermost convolution, and the continuous wire divided into
• a lower portion including the lowermost convolution and one or more of the intermediate convolutions, each of the one or more intermediate convolutions of the lower portion having a diameter greater than or equal to a lower minimum diameter, and the pitch between each of the convolutions of the lower portion greater than or equal to a lower minimum pitch, and
• an upper portion including the uppermost convolution and one or more of the intermediate convolutions, each of the one or more intermediate convolutions of the upper portion having a diameter greater than or equal to an upper minimum diameter, the pitch between each of the convolutions of the upper portion less than or equal to an upper maximum pitch,
• wherein one of the helical intermediate convolutions of the lower portion forms a central convolution having a diameter equal to the lower minimum diameter,
• wherein the diameter of each of the other intermediate convolutions of the lower portion is the same and the diameter of each of the other intermediate convolutions of the lower portion is greater than the lower minimum diameter such that the lower portion has an hourglass shape,
• wherein the upper minimum diameter is less than or equal to the lower minimum diameter, and
• wherein the upper maximum pitch is less than the lower minimum pitch.