Pocketed Spring Comfort Layer and Method of Making Same
AssigneeL&P Property Management Company
InventorAustin G. Long
Life of this patent
Estimating the term…
Abstract
A comfort layer for a bedding or seating product has slow-acting pockets characterized by the individual springs of the comfort layer being pocketed with either semi-impermeable or impermeable fabric. Each seam joining opposed plies of fabric around each of the coil springs of the comfort layer may be segmented, allowing air to flow between the segments, thereby increasing the luxury “feel” of the comfort layer. The method of making the comfort layer includes compressing the springs and creating pockets with a welding horn and an anvil.
Claims24
A method of manufacturing a comfort layer for a bedding or seating product, which comfort layer is characterized by slow and gentle compression when a load is applied to the product, the method comprising:
- forming a continuous blanket of individually pocketed springs, each spring being contained within a pocket of fabric formed by joining multiple plies of fabric with weld seams, the fabric being impermeable to airflow through the fabric, the opposed plies of fabric being joined along segments with gaps between adjacent segments;
- and
- cutting the continuous blanket of individual pocketed springs to a desired size to create a comfort layer,
- the comfort layer being characterized, when a load is placed upon the comfort layer, by the rate of deflection of the comfort layer being retarded by the rate at which air passes through the gaps of the weld seams, the gaps widening upon being subjected to the load, allowing air to exit the pockets of the comfort layer at a desired rate.
A method of manufacturing a comfort layer for a bedding or seating product, the method comprising:
- forming a blanket of individually pocketed springs, each spring of which is contained within a pocket of fabric, the fabric being impermeable to airflow through the fabric, each of the pockets being surrounded by weld seams, each of the weld seams comprising spaced segments joining opposed plies of the pocket, wherein air flows into and out of each pocket through gaps between the spaced segments, the comfort layer being characterized by slow and gentle compression when a load is applied to the comfort layer, the gaps increasing in width and allowing air to exit affected pockets of the comfort layer through the gaps at a controlled rate.
A comfort layer for a bedding or seating cushion product, the comfort layer comprising:
- a matrix of interconnected pocketed springs, each spring of which is contained within a pocket of fabric, the fabric being impermeable to airflow through the fabric, the pockets being created by joining opposed plies of the fabric with weld seams;
- the comfort layer being characterized, when a load is placed upon the comfort layer, by the rate of deflection of the comfort layer being at least partially retarded by the rate at which air escapes pockets affected by the load through gaps between the segments of the weld seams surrounding the pockets affected by the load, the gaps increasing in width and allowing air to exit the pockets of the comfort layer affected by the load at a desired rate.
A comfort layer for a bedding or seating product, the comfort layer comprising:
- a matrix of interconnected pocketed springs, each spring of which is contained within a pocket of fabric, the fabric being impermeable to air flow, each pocket of fabric comprising an upper ply and a lower ply joined by weld seams, each of the weld seams allowing air to flow through gaps between segments in the weld seam;
- the comfort layer being characterized, when a load is placed upon the comfort layer and then removed, by the rate of return of the comfort layer to its original height being retarded by the rate at which air flows between pockets through the gaps of the weld seams.
A comfort layer for a bedding or seating product, the comfort layer comprising:
- a matrix of interconnected pocketed springs, each spring of which is contained within a pocket of fabric, each pocket of fabric allowing air to flow between segments in weld seams joining multiple plies of the pocket;
- the comfort layer being characterized, when a load is placed upon the comfort layer, by the rate of compression of the comfort layer from its original height being retarded by the rate at which air escapes the pockets through gaps between the segments of the weld seams, the gaps changing in size depending on the load.
Dependencies are inferred from the claim text.