Pocketed coil spring units

A spring unit comprising:

• a plurality of spring sets in which each spring set includes a first coil spring and a second coil spring joined together by a connecting wire which joins together corresponding end turns of the first and second coil springs, each spring set being formed of a different and integral piece of wire;
• wherein the connecting wire of a first spring set is proximate a top of the spring unit and the connecting wire of a second spring set adjacent to the first spring set is proximate a bottom of the spring unit;
• and
• a plurality of connected fabric pockets, each of the spring sets being encased in a grouping of adjacent fabric pockets such that the first coil spring is encased in a first fabric pocket and the second coil spring is encased in a second fabric pocket with a third fabric pocket between the first and second fabric pockets such that the first, second and third fabric pockets are integrally and serially connected together with the connecting wire spanning the third fabric pocket which does not have a coil spring therein.

A method of making a spring unit comprising:

• forming a plurality of spring sets each with a first coil spring having spaced end turns joined by a connecting wire to a second coil spring having spaced end turns such that the connecting wire joins opposite end turns of the first and second coil springs;
• manipulating the first coil spring relative to the second coil spring of each spring set so that the connecting wire joins corresponding end turns of the first and second coil springs;
• forming a plurality of fabric pockets;
• inserting the first and second coil springs of each spring set into selected fabric pockets;
• and
• arranging the pocketed spring sets into a spring unit.

A method of making a spring unit comprising:

• forming a plurality of spring sets each with a first coil spring having a first longitudinal axis and spaced end turns, the first coil spring being joined by a connecting wire to a second coil spring having a second longitudinal axis and spaced end turns such that the connecting wire joins opposite end turns of the first and second coil springs, wherein each of the spring sets are formed with the first and second longitudinal axes being spaced from one another:
• manipulating the first coil spring relative to the second coil spring of each spring set so that the connecting wire joins corresponding end turns of the first and second coil springs and the first and second longitudinal axes remain spaced from one another;
• wherein the manipulating further comprises pivoting one of the first and second coil springs approximately 180° relative to the other coil spring;
• forming a plurality of fabric pockets;
• inserting the first and second coil springs of each spring set into selected fabric pockets;
• and
• arranging the pocketed spring sets into a spring unit.

A method of making a spring unit comprising:

• forming a plurality of spring sets each with a first coil spring having spaced end turns joined by a connecting wire to a second coil spring having spaced end turns such that the connecting wire joins opposite end turns of the first and second coil springs;
• manipulating the first coil spring relative to the second coil spring of each spring set so that the connecting wire joins corresponding end turns of the first and second coil springs;
• forming a grouping of first, second and third adjacent and serially connected fabric pockets with the third fabric pocket being between the first and second fabric pockets;
• inserting the first coil spring of one spring set into the first fabric pocket;
• inserting the second coil spring of the one spring set into the second fabric pocket so that the connecting wire of the one spring set spans the third fabric pocket;
• arranging the pocketed spring sets into a spring unit.

A method of making a spring unit comprising:

• forming a plurality of spring sets each with a first coil spring joined by a connecting wire to a second coil spring;
• forming a plurality of fabric pockets including a grouping of first, second and third adjacent and serially connected fabric pockets with the third fabric pocket being between the first and second fabric pockets;
• inserting the first coil spring of one spring set into the first fabric pocket;
• inserting the second coil spring of the one spring set into the second fabric pocket so that the connecting wire of the one spring set spans the third fabric pocket;
• and
• arranging the pocketed spring sets into a spring unit.

A method of making a spring unit comprising:

• forming a plurality of spring sets each with a first coil spring having spaced end turns joined by a connecting wire to a second coil spring having spaced end turns such that the connecting wire joins opposite end turns of the first and second coil springs;
• manipulating the first coil spring relative to the second coil spring of each spring set so that the connecting wire joins corresponding end turns of the first and second coil springs;
• forming a plurality of fabric pockets;
• inserting the first and second coil springs of each spring set into individual respective first and second fabric pockets;
• and
• arranging the pocketed spring sets into a spring unit.