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 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.   
     
     
         2 . The fabric of  claim 1  wherein the ultrasonically weldable synthetic fibers comprise at least thirty percent of the fibers. 
     
     
         3 . 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 piece of single layer 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 piece of single layer ultrasonically weldable fabric comprises non-woven fabric made with at least some fibers made from at least partially recycled material.   
     
     
         4 . The string of springs of  claim 3  wherein the non-woven fabric is made entirely of fibers made from at least partially with recycled material. 
     
     
         5 . The string of springs of  claim 3  wherein the recycled material is polyethylene terephthalate. 
     
     
         6 . 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 pieces of ultrasonically weldable non-woven fabric, the ultrasonically weldable top and bottom pieces 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.   
     
     
         7 . The comfort layer of  claim 6  wherein at least one of the top and bottom pieces comprises non-woven fabric. 
     
     
         8 . The comfort layer of  claim 7  wherein the non-woven fabric is made entirely of fibers made at least partially with recycled material. 
     
     
         9 . The comfort layer of  claim 6  wherein the seams of the pockets are circular. 
     
     
         10 . The comfort layer of  claim 6  wherein the seams of the pockets are straight. 
     
     
         11 . The comfort layer of  claim 6  wherein the recycled material is a polymer. 
     
     
         12 . The comfort layer of  claim 6  wherein the recycled material is polyethylene terephthalate.