Variable coil density anisotropic innersprings

Abstract

Variable coil density anisotropic innersprings in which the placement and density of the coils or spring units varies between one or more regions or areas of the innerspring to provide innersprings with different average spring rates in different zones or regions of the innerspring. Various anisotropic arrangements of coils in innersprings are disclosed.

1 . An anisotropic variable coil density innerspring comprising a plurality of coils interconnected in an anisotropic array wherein relative spacing between axes of the coils arranged in rows and columns in the array is not constant throughout the innerspring, and lacing wires which extend between the coils to interconnect the coils in the anisotropic array and maintain the relative spacing between the axes of the coils. 
     
     
         2 . The innerspring of  claim 1  wherein the coils in at least two columns of coils of the array located at longitudinal perimeters of the innerspring are more closely spaced than other coils in the array. 
     
     
         3 . The innerspring of  claim 1  wherein the spacing of coils in each row of the coils of the innerspring is not constant and the spacing of coils in each column of coils of the innerspring is constant. 
     
     
         4 . The innerspring of  claim 1  wherein a density of coils in the longitudinal perimeter regions of the innerspring is greater than a density of coils in other regions of the innerspring. 
     
     
         5 . The innerspring of  claim 1  wherein an average spring rate of the longitudinal perimeter regions is greater than an average spring rate of other regions of the innerspring. 
     
     
         6 . An innerspring comprising:
 an anisotropic array of interconnected coils arranged in columns in rows with a common number of coils in each column and row;   at least two columns of coils spaced apart at a first distance, and at least two other column of coils spaced at a second distance which is greater than the first distance;   the coils being interconnected by lacing wires located between each row of coils and oriented transverse to the columns of coils.   
     
     
         7 . The innerspring of  claim 6  wherein perimeter longitudinal regions of the innerspring each comprise at least two columns of coils spaced apart at the first distance. 
     
     
         8 . The innerspring of  claim 6  wherein a central longitudinal region is comprised of at least two columns of coils spaced at the first distance, and columns of coils lateral to the central longitudinal region are spaced from the central longitudinal region at the second distance. 
     
     
         9 . The innerspring of  claim 6  wherein the lacing wires extend between columns of coils spaced at the first distance and columns of coils spaced at the second distance. 
     
     
         10 . An anisotropic innerspring with different numbers of coils in different regions of the innerspring, the innerspring comprising;
 a plurality of interconnected coils arranged with axes of the coils parallel and ends of the coils located in common respective planes, the innerspring having multiple regions defined by groups of coils with axes of the coils spaced apart at a common distance, including a first region with coil axes spaced at a first distance and a second region with coil axes spaced at a second distance which is greater than the first distance;   the coils of the multiple regions of the innerspring being interconnected by lacing wires which extend between the coils and from one region of the innerspring to another region of the innerspring.   
     
     
         11 . The anisotropic innerspring of  claim 10  wherein the plurality of interconnected coils are arranged in columns and rows. 
     
     
         12 . The anisotropic innerspring of  claim 11  wherein the first region includes at least a portion of a perimeter of the innerspring. 
     
     
         13 . The anisotropic innerspring of  claim 10  wherein the first region includes at least two adjacent rows or columns of coils. 
     
     
         14 . The anisotropic innerspring of  claim 10  wherein the second region includes at least two adjacent rows or columns of coils. 
     
     
         15 . The anisotropic innerspring of  claim 10  wherein the first region extends along a length of the innerspring. 
     
     
         16 . The anisotropic innerspring of  claim 10  wherein rows of coils of the innerspring are spaced apart at a constant distance in all regions of the innerspring. 
     
     
         17 . The anisotropic innerspring of  claim 10  wherein the lacing wires extend transversely between columns of coils and from one region of the innerspring to another region of the innerspring. 
     
     
         18 . The anisotopic innerspring of  claim 10  wherein columns of coils of the innerspring are spaced apart at a constant distance in all regions of the innerspring. 
     
     
         19 . The anisotropic innerspring of  claim 10  wherein a coil density in one region of the innerspring is at least 25% greater than a coil density in another region of the innerspring. 
     
     
         20 . The anisotropic innerspring of  claim 10  wherein a region of the innerspring with a relatively greater density of coils than another region includes at least a portion of a perimeter of the innerspring. 
     
     
         21 . The anisotropic innerspring of  claim 10  wherein a region of the innerspring with a relatively greater density of coils than another region is at least partially located in a central region of the innerspring. 
     
     
         22 . An innerspring comprising:
 a plurality of interconnected coils arranged with axes of the coils parallel and respective ends of the coils in common planes which define opposed support planes of the innerspring;   a first group of coils arranged with axes of the coils of the first group spaced apart at a common first distance, the first group of coils defining a first region of the innerspring;   a second group of coils arranged with axes of the coils of the second group spaced apart at a common second distance which is greater than the common first distance, the second group of coils defining a second region of the innerspring,   whereby a density of coils in the first region is greater than a density of coils in the second region, and a coil density of the first region is greater than a coil density of the second region.   
     
     
         23 . The innerspring of  claim 22  wherein the first region of the innerspring has a higher spring rate than the second region of the innerspring. 
     
     
         24 . The innerspring of  claim 22  wherein all of the coils of the innerspring are located in parallel rows which extend through the first region and through the second region. 
     
     
         25 . The innerspring of  claim 22  wherein all of the coils of the innerspring are located in parallel columns which extend through the first region and through the second region. 
     
     
         26 . The innerspring of  claim 22  wherein the coils are arranged in columns and rows and wherein the coils are spaced at a common distance in each row of coils of the innerspring. 
     
     
         27 . The innerspring of  claim 22  wherein the coils are arranged in columns and rows and wherein the coils are spaced at a common distance in each column of coils of the innerspring. 
     
     
         28 . The innerspring of  claim 22  wherein the coils are interconnected by lacing wires which extend between each row of coils and which extend from the first region to the second region of the innerspring. 
     
     
         29 . The innerspring of  claim 22  further comprising a third group of coils defining a third region of the innerspring wherein axes of the coils in the third group are spaced at a common third distance which is different from the spacing of coils in the first region and different from the spacing of coils in the second region. 
     
     
         30 . The innerspring of  claim 22  in a one-sided mattress.