Pocketed Spring Assembly

Abstract

A pocketed spring assembly comprises a plurality of parallel strings of individually pocketed springs. Each string is joined to at least one adjacent string. Each string comprises one piece of fabric joined to itself to create first and second opposed plies on opposite side of coil springs. The plies are joined by transverse seams to form a plurality of pockets along a length of the string. At least one spring is positioned in each of the pockets. The piece of fabric is a non-woven ultrasonically weldable fabric made with fiber made with at least some used or recycled material or content.

What is claimed is: 
     
         1 . A bedding or seating product comprising:
 a pocketed spring assembly comprising a plurality of parallel strings of springs joined together, each of the strings of springs comprising a plurality of individually pocketed springs, each of the strings of springs comprising an ultrasonically weldable fabric, the ultrasonically weldable fabric being ultrasonically welded to itself along a longitudinal seam, having first and second opposed sides covering opposite surfaces of the springs, a plurality of pockets being formed along a length of the string of springs by transverse seams joining the first and second sides, at least one spring being positioned in each said pocket, wherein the ultrasonically weldable fabric is made at least partially with fibers made with at least some recycled material;   cushioning materials; and   a covering encasing the pocketed spring assembly and cushioning materials.   
     
     
         2 . A pocketed spring assembly for use in a bedding or seating product, the pocketed spring assembly comprising:
 a pocketed spring assembly comprising a plurality of parallel strings of springs joined together, each of the strings of springs comprising a plurality of individually pocketed springs, each of the strings of springs comprising an ultrasonically weldable fabric, the ultrasonically weldable fabric being ultrasonically welded to itself along a longitudinal seam, having first and second opposed sides covering opposite surfaces of the springs, a plurality of pockets being formed along a length of the string of springs by transverse seams joining the first and second sides, at least one spring being positioned in each said pocket, wherein the ultrasonically weldable fabric is made at least partially with fibers made with at least some recycled material.   
     
     
         3 . The pocketed spring assembly of  claim 2  wherein the ultrasonically weldable fabric is stitchbond fabric. 
     
     
         4 . The pocketed spring assembly of  claim 2  wherein the ultrasonically weldable fabric is spunlaced fabric. 
     
     
         5 . The pocketed spring assembly of  claim 2  wherein the ultrasonically weldable fabric is needle-punched fabric. 
     
     
         6 . The pocketed spring assembly of  claim 2  wherein the recycled material is polyethylene terephthalate. 
     
     
         7 . The pocketed spring assembly of  claim 2  wherein the ultrasonically weldable fabric has a weight of 0.75 to 4.0 ounces per square yard. 
     
     
         8 . The pocketed spring assembly of  claim 2  wherein the ultrasonically weldable fabric is made of one hundred percent fibers made with at least some recycled material. 
     
     
         9 . The pocketed spring assembly of  claim 2  wherein the ultrasonically weldable fabric is made of at least fifty percent fibers made with at least some recycled material. 
     
     
         10 . The pocketed spring assembly of  claim 2  wherein at least some of the fibers are polymer fibers. 
     
     
         11 . The pocketed spring assembly of  claim 2  wherein the parallel strings of springs are joined together with adhesive having at least some bio-based material. 
     
     
         12 . The pocketed spring assembly of  claim 2  wherein the parallel strings of springs are joined together with adhesive having at least some recycled material. 
     
     
         13 . A pocketed spring assembly for use in a bedding or seating product, the pocketed spring assembly comprising:
 a plurality of parallel strings of springs joined together, each of said strings comprising a plurality of individually pocketed springs, each of the strings being formed from a piece of ultrasonically weldable fabric, said ultrasonically weldable of fabric being joined to itself along a longitudinal seam, a plurality of pockets being formed along a length of the string by transverse seams joining the first and second sides of the fabric, at least one spring being positioned in each of the pockets, wherein the longitudinal seam and each of the transverse seams joins the piece of ultrasonically weldable fabric to itself, wherein the parallel strings of springs are joined together with adhesive having at least some bio-based material.   
     
     
         14 . The pocketed spring assembly of  claim 13  wherein the ultrasonically weldable fabric has at least some fibers made at least partially with recycled material. 
     
     
         15 . The pocketed spring assembly of  claim 14  wherein the fibers are made at least partially of polyethylene terephthalate. 
     
     
         16 . A pocketed spring assembly for use in a bedding or seating product, the pocketed spring assembly comprising:
 a plurality of parallel strings of springs joined together, each of said strings comprising a plurality of individually pocketed springs, each of the strings being formed from a piece of ultrasonically weldable fabric, said ultrasonically weldable of fabric being joined to itself along a longitudinal seam, a plurality of pockets being formed along a length of the string by transverse seams joining the first and second sides of the fabric, at least one spring being positioned in each of the pockets, wherein the longitudinal seam and each of the transverse seams joins the piece of ultrasonically weldable fabric to itself, wherein the parallel strings of springs are joined together with adhesive having at least some recycled material.   
     
     
         17 . The pocketed spring assembly of  claim 13  wherein the ultrasonically weldable fabric has at least some fibers made at least partially with recycled material. 
     
     
         18 . A fabric for use in a bedding or seating product, said fabric comprising:
 at least one layer of non-woven ultrasonically weldable fabric made at least partially from fibers containing at least some recycled material.   
     
     
         19 . The fabric of  claim 18  wherein the recycled material is polyethylene terephthalate. 
     
     
         20 . The fabric of  claim 18  wherein the recycled material is a polymer. 
     
     
         21 . A fabric for use in a bedding or seating product, said fabric comprising:
 at least one layer made of a mixture of non-woven ultrasonically weldable synthetic fibers and non-ultrasonically weldable fibers, at least some of the fibers containing at least some recycled material.   
     
     
         22 . The fabric of  claim 21  wherein the ultrasonically weldable synthetic fibers comprise at least thirty percent of the fibers. 
     
     
         23 . A string of springs for use in a pocketed spring assembly, the string of springs comprising:
 a plurality of individually pocketed springs, said string of springs comprising a ultrasonically weldable fabric joined to itself along a longitudinal seam, first and second opposed plies of the ultrasonically weldable fabric being on opposite sides of the springs, a plurality of pockets being formed along a length of the string by transverse seams joining the first and second plies of the ultrasonically weldable fabric, at least one spring being positioned in each of the pockets, wherein the ultrasonically weldable fabric comprises non-woven fabric made with at least some fibers made from at least partially recycled material.   
     
     
         24 . The string of springs of  claim 23  wherein the non-woven fabric is made entirely of fibers made from at least partially with recycled material. 
     
     
         25 . The string of springs of  claim 23  wherein the recycled material is polyethylene terephthalate. 
     
     
         26 . A comfort layer for a bedding or seating cushion product, said comfort layer comprising:
 a matrix of interconnected pocketed springs, each spring of which is contained within a pocket between top and bottom plies of ultrasonically weldable non-woven fabric, the ultrasonically weldable top and bottom plies being joined by a seam around the pocket, wherein the ultrasonically weldable fabric has at least some fibers made at least partially with recycled material.   
     
     
         27 . The comfort layer of  claim 26  wherein at least one of the plies comprises non-woven fabric. 
     
     
         28 . The comfort layer of  claim 26  wherein the seams of the pockets are circular. 
     
     
         29 . The comfort layer of  claim 26  wherein the seams of the pockets are straight. 
     
     
         30 . The comfort layer of  claim 26  wherein the recycled material is a polymer.