Mattress having a foam panel which interlocks a spring assembly and a quilted assembly

Abstract

A mattress including a housing having a panel forming a base and a border connected to the panel, wherein the panel and border define a receptacle having a first end and a second end. The mattress further includes a spring assembly positioned on the panel and within the receptacle, wherein the spring assembly comprises a plurality of first and second coils arranged in rows extending continuously from the first end to the second end of the receptacle, wherein the first coils are different in size from the second coils; wherein groups of one or more of the first coils and groups of one or more of the second coils define at least three zones of firmness between the first end and the second end of the receptacle, wherein each of the first and second coils includes a first end and a second end; and wherein the first ends of the first and second coils are disposed adjacent the housing panel and lie in a first plane parallel to the housing panel. The mattress further includes a quilted assembly; and a foam panel disposed between the quilted assembly and the second ends of the first and second coils.

1 . A mattress, comprising:
 a housing, wherein the housing comprises:
 a panel forming a base; and 
 a border connected to the panel, wherein the panel and border collectively define a receptacle having a first end and a second end; 
   a spring assembly positioned on the panel and within the receptacle, wherein the spring assembly extends continuously from the first end of the receptacle to the second end of the receptacle, the spring assembly comprising a plurality of first coils and a plurality of second coils, wherein:
 each of the first and second coils is disposed adjacent the panel and has a first end which lies in a first plane parallel to the panel; 
 the first coils are less resistant to compression than are the second coils; and 
 the spring assembly defines at least three zones of firmness between the first end of the receptacle and the second end of the receptacle; 
   a quilted assembly; and   at least one foam panel disposed between the quilted assembly and the spring assembly.   
     
     
         2 . The mattress of  claim 1 , wherein the border comprises a foam material. 
     
     
         3 . The mattress of  claim 1 , wherein the border is substantially uniform in cross-section. 
     
     
         4 . The mattress of  claim 1 , wherein:
 the first coils are arranged in rows; and   the second coils are arranged in rows.   
     
     
         5 . The mattress of  claim 4 , wherein:
 a first row of the first coils is positioned within the receptacle and between the first and second ends of the receptacle;   a first row of the second coils is positioned within the receptacle and between the first row of the first coils and the second end of the receptacle; and   a second row of the first coils is positioned within the receptacle and between the first row of the second coils and the second end of the receptacle.   
     
     
         6 . The mattress of  claim 5 , wherein a second row of the second coils is positioned between the second row of the first coils and the second end of the receptacle. 
     
     
         7 . The mattress of  claim 1 , wherein a wire gauge of the first coils is different than a wire gauge of the second coils. 
     
     
         8 . The mattress of  claim 1 , wherein a height of the first coils is greater than a height of the second coils. 
     
     
         9 . The mattress of  claim 1 , wherein a material which comprises the first coils is different from a material which comprises the second coils. 
     
     
         10 . The mattress of  claim 1 , wherein a shape of the first coils is different from a shape of the second coils. 
     
     
         11 . The mattress of  claim 1 , wherein:
 each of the first coils has a second end which lies in a second plane parallel to the housing panel; and   each of the second coils has a second end which lies in a third plane parallel to the housing panel, wherein the second plane is parallel to and spaced from the third plane.   
     
     
         12 . The mattress of  claim 1 , wherein at least some of the second coils define at least one of the at least three zones of firmness. 
     
     
         13 . The mattress of  claim 1 , wherein the at least three zones of firmness comprise:
 a head firmness zone;   a leg firmness zone; and   a torso firmness zone between the head and leg firmness zones.   
     
     
         14 . The mattress of  claim 1 , wherein the at least one foam panel comprises a first foam panel having:
 a first surface adjacent a second end of the second coils; and   a substantially planar second surface which lies in a second plane parallel to the housing panel.   
     
     
         15 . The mattress of  claim 14 , wherein the first foam panel is substantially uniform in cross-section. 
     
     
         16 . The mattress of  claim 14 , wherein the at least one foam panel further comprises a second foam panel disposed between the first foam panel and the quilted assembly. 
     
     
         17 . The mattress of  claim 16 , wherein the second foam panel is substantially uniform in cross-section: 
     
     
         18 . The mattress of  claim 1 , wherein the at least one foam panel has:
 a first surface adjacent a second end of the second coils;   a second surface adjacent a second end of the first coils; and   a substantially planar third surface which lies in a second plane parallel to the housing panel.   
     
     
         19 . The mattress of  claim 1 , further comprising:
 a first fabric pocket which surrounds one of the first coils; and   a second fabric pocket which surrounds one of the second coils.