Mattress assembly including coil innerspring units, coil innerspring units, and processes for making the same
AssigneeDreamwell, Ltd.
InventorsStephen M. Groppel, Ben Storch, Jeffrey Mastropaolo, Dishant Purani
Life of this patent
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Abstract
Mattress assemblies including coil innerspring units, coil innerspring units by themselves, and processes for making the coil innerspring units, wherein the coils within the coil innerspring unit are manufactured with the same geometry, same composition, and from the same gauge wire using different heat treatments to provide the coil innerspring unit with different spring rates.
Claims22
A process for producing a coil innerspring unit, the process comprising:
- forming a plurality of first coils from a wire, wherein a selected one of the plurality of first coils or the wire are exposed to a first heat treatment process to provide the plurality of coils with a first spring rate;
- forming a plurality of second coils from the wire free of a heat treatment process or to a second heat treatment process to provide a second spring rate;
- and
- arranging the plurality of the first and second coils in a side-by-side relationship to form the coil innerspring unit, wherein the first spring rate is different from the second spring rate, and wherein the first coils and the second coils have an identical geometry and composition.
A process for producing a coil innerspring unit, the process comprising:
- heat treating a wire prior to or subsequent to forming heat-treated coil springs from the wire and forming the heat-treated coil springs if the wire is heat treated prior to forming the coil springs;
- arranging the heat-treated coil springs in at least one zone within the coil innerspring unit, wherein the heat-treated coil springs have an identical geometry to each other;
- and
- arranging additional coil springs having a second spring rate in at least one additional zone, wherein the first spring rate is different from the second spring rate, and wherein the additional coil springs have the identical geometry to the heated treated springs and are formed from a wire having an identical gauge and composition.
A coil innerspring unit for a cushioning article having at least two sets of coils, the coil innerspring unit comprising:
- a first set of coils springs, wherein each of the coil springs has a first spring rate;
- and
- a second set of coil springs wherein each of the coil springs has a second spring rate,
- wherein the first and second sets of the coil springs comprise an identical geometry, gauge wire, and composition.
A mattress assembly comprising:
- a coil innerspring unit comprising a first set of coils springs, wherein each of the coil springs has a first spring rate;
- and a second set of coil springs, wherein each of the coil springs has a second spring rate, wherein the coil springs in the first and second sets comprise an identical geometry, gauge wire, and composition.
Dependencies are inferred from the claim text.