US 5,040,255 AGranted

Cushion or mattress structure

AssigneeBarber Manufacturing Company, Inc.

InventorJohn W. Barber, Jr.

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Abstract

An improved cushion or mattress assembly is disclosed including side boxing sections which are glued to top and bottom sections thereby defining a cavity. Prior to glueing the top cover to the assembly, an insulation layer is inserted into the cavity defined therein and glue is applied to the top side of the insulation piece. A string of encased springs is then placed on top of the insulation piece. A second insulation piece with glue applied to the underside is placed on top of the encased spring array in the cavity. The top cover then is glued on the cushion assembly. The entire cushion assembly may be fiber or down covered and encased in a fabric, plastic, leather, or vinyl outer covering. The springs contained within the spring encasement assembly include an hourglass or dual radius contour and are heat treated or mormalized to provide improved stiffness and prolonged life. In addition, the ends of the springs are turned inward and toward the opposite end of the spring to minimize snagging of the spring ends on materials likely to contact the spring within the cushion.

Claims8

Dependent claims

A cushion or mattress construction comprising:

a boxing structure having a bottom wall, top wall, and side walls defining a completely enclosed cavity wherein said walls are formed of foam material, said walls being permanently joined by an adhesive;
a plurality of coil springs wherein each spring has a profile with top and bottom coils of the spring being larger in diameter than the remaining coils of said spring, said springs having ends pointed inwardly of the spring;
a pliable casing material having said springs encased therein, said casing material having a plurality of pockets each of which has one of said springs therein to form an encased spring assembly, each of said springs being compressed to a predetermined height by said casing material said casing including pairs of vertical, thermally welded seams defining a cutting strip between adjacent pockets;
and
said encased spring assembly being arranged in serpentine fashion within said cavity and joined by an adhesive to an upper and lower surface of said cavity thereby filling said cavity with an array of springs defined by the serpentine positioning of the casing containing said springs.

2 more elements

Dependencies are inferred from the claim text.