Pocket Coil Spring Assemblies Having Separated Seams and Support Cushions Including the Same

Abstract

A pocketed coil spring assembly is provided that comprises a plurality of pocketed coil springs arranged in a row. Each of the pocketed coil springs includes a coil spring surrounded by a flexible enclosure. A seam is positioned between each one of the plurality of pocketed coil springs and an adjacent one of the plurality of pocketed coil springs. Each seam is configured to allow one or more ends of each of the pocketed coil springs to move independently of the corresponding end of an adjacent one of the pocketed coil springs. Support cushions, such as mattresses, that include a plurality of such pocketed coil spring assemblies arranged in a matrix are further provided.

What is claimed is: 
     
         1 . A pocketed coil spring assembly, comprising:
 a plurality of pocketed coil springs arranged in a row, each one of the plurality of pocketed coil springs including a coil spring surrounded by a flexible enclosure, and each one of the plurality of pocketed coil springs including a lower end and an upper end; and   a seam positioned between each one of the plurality of pocketed coil springs and an adjacent one of the plurality of pocketed coil springs in the row, each seam having a top portion and a bottom portion, and each seam defining a separation at the top portion, the bottom portion, or both the top portion and the bottom portion of the respective seam to allow the upper end, the lower end, or both the upper end and the lower end of each one of the plurality of pocketed coil springs to move independently of the upper end, the lower end, or both the upper end and the lower end of the adjacent one of the plurality of pocketed coil springs. The pocketed coil spring assembly of  claim 1 , wherein the separation is at the top portion of the seam or the bottom portion of the seam. The pocketed coil spring assembly of claim  2 , wherein the separation is at the top portion of the seam.   
     
     
         4 . The pocketed coil spring assembly of  claim 3 , wherein each seam comprises:
 a first weld extending from adjacent the lower end of each one of the plurality of pocketed coil springs to a node;   a second weld extending from the node to adjacent the upper end of one of the plurality of pocketed coil springs; and   a third weld extending from the node to adjacent the upper end of the adjacent one of the plurality of pocketed coil springs.   
     
     
         5 . The pocketed coil spring assembly of  claim 4 , wherein the separation is defined by the second weld and the third weld such that the seam has a Y-shaped configuration. 
     
     
         6 . The pocketed coil spring assembly of  claim 1 , wherein each seam comprises:
 a first weld extending from adjacent the lower end to adjacent the upper end of each one of the plurality of pocketed coil springs; and   a second weld extending from adjacent the lower end to adjacent the upper end of the adjacent one of the plurality of pocketed coil springs; and   wherein the separation is defined by each seam between the first weld and the second weld.   
     
     
         7 . The pocketed coil spring assembly of  claim 1 , wherein each seam comprises
 a first weld extending from adjacent the lower end to adjacent the upper end of each one of the plurality of pocketed coil springs,   a second weld extending from adjacent the lower end to adjacent the upper end of the adjacent one of the plurality of pocketed coil springs, and   a third weld positioned between the first weld and the second weld, the third weld extending to a height less than that of the first weld and the second weld; and   wherein the separation is defined by the seam between the first weld and the second weld and above the third weld.   
     
     
         8 . The pocketed coil spring assembly of  claim 1 , wherein each coil spring includes an upper section comprised of one or more upper helical convolutions and a lower section comprised of one or more lower helical convolutions; and
 wherein the one or more lower helical convolutions has a first spring constant and the one or more upper helical convolutions has a second spring constant different than the first spring constant.   
     
     
         9 . The pocketed coil spring assembly of  claim 8 , wherein the second spring constant is less than the first spring constant. 
     
     
         10 . The pocketed coil spring assembly of  claim 8 , wherein the one or more lower helical convolutions define a first pitch between each of the one or more lower helical convolutions, and
 wherein the one or more upper helical convolutions define a second pitch between each of the one or more upper helical convolutions, the second pitch being less than the first pitch.   
     
     
         11 . The pocketed coil spring assembly of  claim 8 , wherein the separation is positioned adjacent to the upper section of each coil spring. 
     
     
         12 . The pocketed coil spring assembly of  claim 1 , wherein the flexible enclosure is comprised of a non-woven fabric. 
     
     
         3 . The pocketed coil spring assembly of  claim 1 , wherein the seam includes one or more ultrasonic welds. 
     
     
         14 . A support cushion, comprising:
 a plurality of rows of pocketed coil springs arranged to form a matrix of pocketed coil springs, each of the pocketed coil springs including a coil spring surrounded by a flexible enclosure, and each of the pocketed coil springs including a lower end and an upper end; and   a seam positioned between each of the pocketed coil springs and an adjacent one of the pocketed coil springs in the respective row, each seam having a top portion and a bottom portion, and each seam defining a separation at the top portion, the bottom portion, or both the top portion and the bottom portion of the respective seam to allow the upper end, the lower end, or both the upper end and the lower end of each one of the pocketed coil springs to move independently of the respective upper end, the lower end, or both the upper end and the lower end of the adjacent one of the pocketed coil springs.   
     
     
         15 . The support cushion of  claim 14 , further comprising an adhesive positioned between each of the rows of pocketed coils springs, the adhesive connecting the flexible enclosure of the pocketed coil springs in one of the plurality of rows of pocketed coil springs to the flexible enclosure of an adjacent one of the plurality rows of pocketed coil springs. 
     
     
         16 . The support cushion of  claim 15 , wherein each coil spring includes an upper section including one or more upper helical convolutions and a lower section including one or more lower helical convolutions; and
 wherein the adhesive is positioned adjacent to the lower section of each coil spring.   
     
     
         17 . A mattress assembly, comprising:
 a spring core including
 a plurality of rows of pocketed coil springs arranged to form a matrix of pocketed coil springs, each of the pocketed coil springs including a coil spring surrounded by a flexible enclosure, and each of the pocketed coil springs including a lower end and an upper end; and 
 a seam positioned between each of the pocketed coil springs and an adjacent one of the pocketed coil springs in the respective row, each seam having a top portion and a bottom portion, and each seam defining a separation at the top portion, the bottom portion, or both the top portion and the bottom portion of the respective seam to allow the upper end, the lower end, or both the upper end and the lower end of each one of the pocketed coil springs to move independently of the respective upper end, the lower end, or both the upper end and the lower end of the adjacent one of the pocketed coil springs; 
   an upper body supporting layer positioned atop the spring core; and   a lower foundation layer positioned below the spring core.   
     
     
         18 . The mattress assembly of  claim 17 , wherein each seam comprises
 a first weld extending from adjacent the lower end of each one of the pocketed coil springs to a node,   a second weld extending from the node to adjacent the upper end of one of the pocketed coil springs, and   and a third weld extending from the node to adjacent the upper end of the adjacent one of the pocketed coil springs.   
     
     
         19 . The mattress assembly of  claim 1 . 7 , wherein each coil spring includes an upper section including one or more upper helical convolutions and a lower section including one or more lower helical convolutions; and
 wherein the one or more lower helical convolutions has a first spring constant and the one or more upper helical convolutions has a second spring constant different than the first spring constant.   
     
     
         20 . The mattress assembly of  claim 17 , further comprising a cover for surrounding the spring core, the upper body supporting layer, and the lower foundation layer.