Coil spring containing mattress and method

A mattress comprising:

• a coil spring comprising first and second major opposed surfaces;
• at least one compressible first foam support surrounding the sides of the coil spring and comprising open-celled foam material capable of compression in response to the application of pressure and expansion upon the relief of pressure;
• at least one compressible second foam support comprising a plurality of cross portions extending transversely relative to the longitudinal axis of the coil spring and positioned at least partially between coils of the coil spring, the second support being spaced from the respective ends of the coil spring;
• at least one first foam pad overlying the first major surface of the coil spring, the first foam pad comprising open-celled foam material capable of compression in response to the application of pressure and expansion upon the relief of pressure;
• a casing comprised of a polymer material which contains and seals the coil spring, the first and second foam supports, and the first foam pad within the casing;
• and
• a valve coupled to the casing and selectively operable to permit the ingress and egress of air into and out of the casing when the valve is in the open position and to block the ingress and egress of air into and out of the container when the valve is in a closed position.

A method of shipping mattresses comprising:

• removing air from the interior of a first mattress containing open celled foam and a coil spring in a sealed air impermeable mattress cover to compress the mattress;
• blocking the re-entry of air into the mattress to maintain the mattress in a compressed state;
• repeating the above steps for a plurality of mattresses;
• and
• stacking a plurality of mattresses in the compressed state for shipment.

A method of making a mattress comprising:

• preparing a sandwich comprised of a coil spring having first and second opposed major surfaces, at least one first foam pad at least partially overlying the first major surface, at least one second foam pad at least partially overlying the second major surface, a first sheet comprised of a polymer material overlying the first foam pad, a second sheet comprised of a polymer material overlying the second foam pads, and the first and second sheets having peripheral edges;
• heat sealing the first and second sheets to encase the first and second foam pads and coil spring within a sealed casing;
• and
• mounting a valve to the casing, the valve being operable for shifting between an open position and a closed position, whereby when in the open position the valve provides communication through the valve to the interior of the sealed casing.

A method of making a mattress comprising:

• preparing a sandwich comprised of a coil spring having first and second opposed major surfaces, first and second opposed ends, and first and second opposed sides, at least one first foam pad at least partially overlying the first major surface, at least one first foam support surrounding the sides and ends of the coil spring, a first sheet comprised of a polymer material overlying the first pad, a second sheet comprised of a polymer material overlying the second major surface of the coil spring, and the first and second sheets having peripheral edges;
• heat sealing the peripheral edges of the first and second sheets to encase the first pad, the first foam support and the coil spring within a sealed casing;
• and
• mounting a valve in the casing, the valve being operable for shifting between a first open position and a first closed position, whereby when in the open position the valve provides communication through the valve to the interior of the sealed casing.

A mattress comprising:

• a coil spring comprising first and second major opposed surfaces;
• at least one first pad at least partially overlaying the first major surface, the first pad comprising open celled foam material capable of compression in response to pressure and expansion upon the relief of pressure;
• a container comprised of polymer material which contains and seals the coil spring and first pad within the container;
• a valve coupled to the container and selectively operable to permit the ingress and egress of air into and out of the container when the valve is in an open position and to block the ingress and egress of air into and out of the container when the valve is in a closed position;
• whereby with the valve in the open position, the first pad and coil spring may be compressed to a compressed state with the valve then being closed to assist in maintaining the coil spring and first pad in the compressed state until the valve is returned to the open position;
• the first pad having a cross-sectional area which is greater than the cross-sectional area of the first major surface, the first pad ranging in thickness from three-fourth inch to one and one-fourth inch, wherein the first pad is comprised of a material which compresses to twenty-five percent of its uncompressed thickness when subjected to a force in the range of from thirty-three to forty-three pounds per square inch;
• and
• the mattress further comprising at least one first intermediate layer disposed at least partially between the first foam pad and the first major surface and at least one second intermediate layer disposed at least partially overlying second major surface.

A mattress comprising:

• a coil spring;
• first and second foam support means and at least one foam pad means for supporting and cushioning a user of the mattress;
• means surrounding and sealing the coil spring, the first and second foam support means, and at the least one foam pad means;
• and
• valve means positioned and operable to selectively permit the ingress and egress of air into and out of the means surrounding and sealing the coil spring.

A mattress comprising:

• a coil spring having first and second opposed major surfaces, opposed sides and opposed ends;
• a first compressible support at least partially surrounding the sides and ends of the coil spring;
• a compressible pad overlaying the first major surface of the coil spring;
• a sealed casing containing the coil spring, first compressible support and compressible pad;
• and
• a valve operable to selectively allow air to flow into and out of the casing.