Pocketed foam systems and methods

Abstract

A padding system includes a first pocket assembly and a second pocket assembly. The first pocket assembly includes a first pocket, where the first pocket has a top and a bottom and defines a first cavity, and a first padding component, the first padding component being positioned in the first cavity. The second pocket assembly includes a second pocket, where the second pocket has a top and a bottom and defines a second cavity, and a second padding component, the second padding component being positioned in the first cavity. The padding system also includes a first transition portion attaching the first pocket assembly to the second pocket assembly, where the first pocket assembly and the second pocket assembly form a string array, and a second transition portion configured to attach the string array to a bedding substrate.

What is claimed is: 
     
         1 . A padding system comprising:
 (a) a first pocket assembly, the first pocket assembly including;
 (i) a first pocket, wherein the first pocket has a top and a bottom and defines a first cavity; and 
 (ii) a first padding component, the first padding component being positioned in the first cavity; 
   (b) a second pocket assembly, the second pocket assembly including;
 (i) a second pocket, wherein the second pocket has a top and a bottom and defines a second cavity; and 
 (ii) a second padding component, the second padding component being positioned in the first cavity; 
   (c) a first transition portion attaching the first pocket assembly to the second pocket assembly, wherein the first pocket assembly and the second pocket assembly form a string array; and   (d) a second transition portion configured to attach the string array to a bedding substrate.   
     
     
         2 . The padding system of  claim 1 , wherein the first padding component and the second padding component are constructed from different materials. 
     
     
         3 . The padding system of  claim 1 , wherein the first padding component has a first section with a first set of properties and a second section with a second set of properties, wherein the first set of properties are different from the second set of properties. 
     
     
         4 . The padding system of  claim 3 , wherein the first section is a first material and the second section is a second material, wherein the first material is different from the second material. 
     
     
         5 . The padding system of  claim 3 , wherein the first section has a first density and the second section has a second density, wherein the first density is different from the second density. 
     
     
         6 . The padding system of  claim 3 , wherein the first section and the second section are constructed from the same type of material. 
     
     
         7 . The padding system of  claim 1 , further comprising the bedding substrate, wherein the first transition portion defines a plurality of apertures, the plurality of apertures being attachment points between the first pocket assembly and the bedding substrate. 
     
     
         8 . The padding system of  claim 1 , wherein the first transition portion is a weld. 
     
     
         9 . The padding system of  claim 1 , wherein the first pocket and the second pocket are constructed from a single piece of material such that the single piece of material is folded and fused at spaced apart welds to form the first pocket and the second pocket. 
     
     
         10 . The padding system of  claim 1 , wherein the first pocket and the second pocket are constructed from a first ply and a second ply of material, where the first ply and the second ply are fused at spaced apart welds to form the first pocket and the second pocket. 
     
     
         11 . The padding system of  claim 10 , wherein the spaced apart welds are formed with a pocket coil system. 
     
     
         12 . The padding system of  claim 1 , wherein the first pocket and the second pocket each comprise a porous material. 
     
     
         13 . The padding system of  claim 1 , wherein the first pocket and the second pocket each comprise a material selected from the group consisting of polypropylene, cotton, nylon, lycra, UBL, and polyester. 
     
     
         14 . The padding system of  claim 1 , wherein the first pocket has a height dimension and a width dimension, and a ratio of the height dimension to the width dimension is 2:1. 
     
     
         15 . The padding system of  claim 1 , wherein at least one of the first padding component or the second padding component has a shape of a cylinder, an hour glass, a barrel, a cuboid, a sphere, a cone, a hexagonal prism, or a pyramid. 
     
     
         16 . The padding system of  claim 1 , wherein the first padding component is selected from the group consisting of polyurethane foam, polyethylene foam, polyether foam, viscoelastic memory foam, gel foam, latex foam, and combinations thereof. 
     
     
         17 . The padding system of  claim 1 , wherein the first padding component has a density of between about 0.01 pounds per cubic foot to about 15 pounds per cubic foot. 
     
     
         18 . The padding system of  claim 1 , wherein the padding system comprises a plurality of string arrays forming a substantially rectangular sheet. 
     
     
         19 . The padding system of  claim 19 , wherein the plurality of string arrays comprises a plurality of pockets, and the plurality of pockets is adhered to a layer of material. 
     
     
         20 . A padding system comprising:
 (a) a first pocket assembly, the first pocket assembly including;
 (i) a first pocket, wherein the first pocket has a top and a bottom and defines a first cavity; and 
   (ii) a first padding component, the first padding component being positioned in the first cavity;   (b) a second pocket assembly, the second pocket assembly including;
 (i) a second pocket, wherein the second pocket has a top and a bottom and defines a second cavity; and 
 (ii) a second padding component, the second padding component being positioned in the first cavity; 
   (c) a transition portion configured to attach the first pocket assembly and the second pocket assembly to a bedding substrate.