SPRING CORE FOR A MATTRESS
A spring core is provided that includes a head portion, a foot portion, and a middle portion positioned between the head portion and the foot portion. The head portion and the foot portion each include a plurality of coil springs arranged in a matrix with each coil spring of the head portion and foot portion having a first height and a second height, respectively. The middle portion also includes a plurality of coil springs arranged in a matrix, but with each coil spring of the middle portion having a third height and with the middle portion providing greater support, less motion transfer, or both greater support and less motion transfer than the head portion and the foot portion.
The present invention relates to spring cores. In particular, the present invention includes spring cores that have multiple zones, which each provide different levels of support, motion transfer, or both support and motion transfer.
BACKGROUNDSpring cores are typically made of either a plurality of coil springs interconnected into a single unit or pocketed coil springs, which are also known as wrapped coils, encased coils, encased springs, or Marshall coils. Pocketed coil springs are generally recognized as providing a unique feel to a mattress when used in the spring core because each discrete coil is capable of moving independently to support the body of a user, or a portion thereof, resting on the mattress. In particular, in pocket coil spring assemblies, each coil is wrapped in a fabric pocket and move s substantially independently of the other coils in the pocket coil spring assembly to thereby provide individualized comfort and contouring to the body of a user. Moreover, as a result of moving substantially independently from one another, the pocket coils also do not directly transfer motion from one pocket coil to another, such that the movement of one user resting on a mattress assembly using pocket coils will not disturb another user resting on the mattress assembly. In this regard, mattress assemblies constructed with pocketed coil springs are generally recognized as providing a soft and luxurious feel, and are often more desirable than a traditional interconnected coil spring mattress. Accordingly, a spring core that includes pocketed coil spring assemblies and further improves upon the support and feel provided by traditional pocketed coil spring assemblies would be both highly desirable and beneficial.
SUMMARYThe present invention includes spring cores. In particular, the present invention includes spring cores that have multiple zones, which each provide different levels of support, motion transfer, or both support and motion transfer.
In one exemplary embodiment of the present invention, a spring core is provided that includes a head portion, a foot portion, and a middle portion positioned between the head portion and the foot portion. The head portion includes a plurality of coil springs arranged in a matrix. The foot portion also includes a plurality of coil springs arranged in a matrix. Similar to the head portion and the foot portion, the middle portion additionally includes a plurality of coil springs arranged in a matrix, but unlike the plurality of coil springs of the head portion and the foot portion, each of the coil springs of the middle portion is surrounded by a flexible enclosure.
With respect to the coil springs of the exemplary spring core, the plurality of coil springs of the head portion have a first height, the plurality of coil springs of the foot portion have a second height that is substantially the same as the first height of the coil springs of the head portion, and the plurality of coil springs of the middle portion have a third height that is substantially the same as the first height of the coil springs of the head portion as well as the second height of the coil springs of the foot portion.
With respect to the flexible enclosure surrounding each of the plurality of coil springs of the middle portion, the flexible enclosure is generally a cylindrical (or tubular) fabric pocket that completely encloses the respective coil spring. In this regard, the flexible enclosure is preferably made of an inelastic fabric which can be joined or welded together by heat and pressure (e.g., via ultrasonic welding or by a similar thermal welding procedure) to form such a cylindrical structure. For example, suitable fabrics that can be used for the flexible enclosure can include one of various thermoplastic fibers known in the art, such as non-woven polymer-based fabric, non-woven polypropylene material, or non-woven polyester material. Furthermore, the flexible enclosure surrounding each of the plurality of coil springs of the middle portion is connected to the flexible enclosure of an adjacent one of the plurality of coil springs of the middle portion. The connection between the flexible enclosures allows each of the plurality of coil springs of the middle portion to partially compress independently of an adjacent one of the plurality of coil springs of the middle portion. As such, the middle portion exhibits a small amount of motion transfer across the middle portion as compared to the head portion and the foot portion of the spring core resulting in a softer feel that conforms more to the portion of a user's body positioned on the middle portion of the spring core.
In a second exemplary embodiment of the present invention, a spring core is provided that also includes a head portion, a foot portion, and a middle portion positioned between the head portion and the foot portion. The head portion includes a plurality of coil springs arranged in a matrix as well as a flexible enclosure that surrounds each of the plurality of coil springs of the head portion. The middle portion similarly includes a plurality of coil springs arranged in a matrix as well as a flexible enclosure that surrounds each of the plurality of coil springs of the middle portion, and the foot portion also includes a plurality of coil springs arranged in a matrix as well as a flexible enclosure that surrounds each of the plurality of coil springs of the foot portion. Moreover, with respect to the coil springs of the second exemplary spring core, the plurality of coil springs of the head portion all have a first height, the plurality of coil springs of the foot portion have a second height that is substantially the same as the first height of the coil springs of the head portion, and the plurality of coil springs of the middle portion have a third height that is greater than the first height of the coil springs of the head portion as well as the second height of the coil springs of the foot portion. In this regard, due to the greater height of the coil springs of the middle portion, the middle portion of the spring core provides a greater level of support as compared to the head portion and the foot portion. Furthermore, because springs are typically more durable than foam and do not lose height as quickly or as severely over time, the greater initial height of the coil springs of the middle portion results in the spring core preventing the formation of a permanent indentation in the center of a mattress as is typically seen in foam mattresses.
In a third exemplary embodiment of the present invention, a spring core is provided that also includes a head portion, a foot portion, and a middle portion positioned between the head portion and the foot portion. The head portion includes a plurality of coil springs arranged in a matrix as well as a flexible enclosure that surrounds each of the plurality of coil springs of the head portion. The middle portion similarly includes a plurality of coil springs arranged in a matrix as well as a flexible enclosure that surrounds each of the plurality of coil springs of the middle portion. The foot portion also includes a plurality of coil springs arranged in a matrix as well as a flexible enclosure that surrounds each of the plurality of coil springs of the foot portion. In this third exemplary spring core, the matrix of the middle portion defines one or more spaces and the middle portion of the spring core further includes one or more interstitial springs positioned within a respective one of the spaces.
With further respect to the coil springs of the third exemplary spring core, the plurality of coil springs of the head portion all have a first height, the plurality of coil springs of the foot portion have a second height that is substantially the same as the first height of the coil springs of the head portion, and the plurality of coil springs of the middle portion have a third height that is substantially the same as the first height of the coil springs of the head portion and the second height of the coil springs of the foot portion. The interstitial springs positioned within the spaces of the middle portion then each have a height that is greater than the third height of the coil springs of the middle portion or, in certain embodiments, the height of the interstitial spring is substantially the same as the height of the coil springs of the middle portion. Regardless of the particular configuration and height of the interstitial springs, however, the inclusion of the interstitial springs in the middle portion increases the spring density within the middle portion such that the middle portion of the spring core provides a greater level of support as compared to the head portion and the foot portion.
Further features and advantages of the present invention will become evident to those of ordinary skill in the art after a study of the description, figures, and non-limiting examples in this document.
The present invention includes spring cores. In particular, the present invention includes spring cores that have multiple zones, which each provide different levels of support, motion transfer, or both support and motion transfer.
Referring first to
With respect to the coil springs of the exemplary spring core 10 shown in
With respect to the helical wires 26 in the head portion 20 of the spring core 10, and as shown in
With respect to the flexible enclosure 34 surrounding each of the plurality of coil springs 32 of the middle portion 30, in the exemplary spring core 10 shown in
With further respect to the flexible enclosures 34, by surrounding each of the coil springs 32 of the middle portion 30 with a flexible enclosure 34, it is possible to impart a desired level of pre-compression to the coil springs 32. As previously mentioned, the first height of each of the plurality of coil springs 22 of the head portion 20, the second height of each of the plurality of coil springs 42 of the foot portion 40, and the third height of each of the plurality of coil springs 32 of the middle portion 30 are substantially the same. However, it should be understood that in the exemplary embodiment shown in
Referring now to
With respect to the coil springs of the exemplary spring core 110 shown in
With respect to the flexible enclosures 124, 134, 144 surrounding each of the plurality of coil springs 122, 132, 142 of the head portion 120, the middle portion 130, and the foot portion 140 in the exemplary spring core 110 shown in
Referring now to
With respect to the coil springs of the exemplary spring core 210 shown in
With respect to the flexible enclosures 224, 234, 244 surrounding each of the plurality of coil springs 222, 232, 242 of the head portion 220, the middle portion 230, and the foot portion 240 in the exemplary spring core 210 shown in
With further respect to the flexible enclosures 234 of the middle portion 230 of the spring core 210, and as mentioned above, a plurality of spaces 236 are defined in the middle portion 230. In particular, four adjacent flexible enclosures 234 that form a square define one of the spaces 236 between the four flexible enclosures 234. Of course, it should be understood that in other embodiments of the present invention the plurality of coil springs can be alternatively arranged, in which case the spaces would be defined by a different number of flexible enclosures. For example, in a triangular matrix where each row of coil springs is offset from the immediately adjacent row, the spaces would be defined by three adjacent flexible enclosures. In any event, and as shown in the partial sectional view of
Referring now more specifically to
As also shown in
In each of the exemplary spring cores 10, 110, 210 described above, the middle portion 30, 130, 230 differs from a head portion 20, 120, 220 and a foot portion 40, 140, 240 that are substantially identical. It is contemplated, however, that different arrangements are also possible without departing from the spirit and scope of the present invention. For example, in contrast to the spring core 10 described above with reference to
Similarly, in other embodiments the spring core can be characterized as including a first side portion (e.g., a left side) and a second side portion (e.g., a right side) opposite the first side portion, and the configuration of the first side portion can be different than the configuration of the second side portion much in the same way that the middle portion differed from the head and foot portions of the above described spring cores. In this way, it is the left or right side of the spring core that provides greater support, less motion transfer, or both greater support and less motion transfer as compared to the other side of the spring core. For example, in contrast to the spring core 10 described above with reference to
One of ordinary skill in the art will recognize that additional embodiments are also possible without departing from the teachings of the present invention or the scope of the claims which follow. This detailed description, and particularly the specific details of the exemplary embodiments disclosed herein, is given primarily for clarity of understanding, and no unnecessary limitations are to be understood therefrom, for modifications will become apparent to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the claimed invention.
Claims
1. A spring core comprising:
- a head portion including a plurality of coil springs arranged in a matrix with each coil spring of the head portion having a first height;
- a foot portion including a plurality of coil springs arranged in a matrix with each coil spring of the foot portion having a second height; and
- a middle portion positioned between the head portion and the foot portion, the middle portion including a plurality of coil springs arranged in a matrix with each coil spring of the middle portion having a third height, the middle portion providing greater support, less motion transfer, or both greater support and less motion transfer than the head portion and the foot portion.
2. The spring core of claim 1, further comprising a flexible enclosure surrounding each of the plurality of coil springs of the middle portion.
3. The spring core of claim 2, wherein the first height, the second height, and the third height are substantially the same.
4. The spring core of claim 1, wherein each of the plurality of coil springs of the middle portion is configured to partially compress independently of an adjacent one of the plurality of coil springs of the middle portion.
5. The spring core of claim 3, wherein the head portion further comprises one or more helical wires connecting each of the plurality of coil springs of the head portion to an adjacent one of the plurality of coil springs of the head portion; and
- wherein the foot portion further comprises one or more helical wires connecting each of the plurality of coil springs of the foot portion to an adjacent one of the plurality of coil springs of the foot portion.
6. The spring core of claim 2, wherein the flexible enclosure surrounding each of the plurality of coil springs of the middle portion is connected to the flexible enclosure of an adjacent one of the plurality of coil springs of the middle portion.
7. The spring core of claim 2, wherein the third height is greater than the first height and the second height.
8. The spring core of claim 7, wherein the first height and the second height are substantially the same.
9. The spring core of claim 7, further comprising a flexible enclosure surrounding each of the plurality of coil springs of the head portion and a flexible enclosure surrounding each of the plurality of coil springs of the foot portion.
10. The spring core of claim 9, wherein the flexible enclosure surrounding each of the plurality of coil springs of the head portion is connected to the flexible enclosure of an adjacent one of the plurality of coil springs of the head portion, and
- wherein the flexible enclosure surrounding each of the plurality of coil springs of the foot portion is connected to the flexible enclosure of an adjacent one of the plurality of coil springs of the foot portion.
11. The spring core of claim 2, wherein the matrix of the middle portion defines one or more spaces between the plurality of coil springs of the middle portion, and
- wherein the middle portion further includes one or more interstitial springs, each of the one or more interstitial springs positioned within a respective one of the one or more spaces.
12. The spring core of claim 11, wherein each of the one or more interstitial springs has a height greater than the third height of the plurality of coil springs of the middle portion.
13. The spring core of claim 11, wherein each of the plurality of coil springs of the middle portion has a diameter, and
- wherein each of the one or more interstitial springs has a diameter smaller than the diameter of each of the plurality of coil springs of the middle portion.
14. The spring core of claim 11, further comprising a flexible enclosure surrounding each of the plurality of coil springs of the head portion and a flexible enclosure surrounding each of the plurality of coil springs of the foot portion.
15. A spring core for a mattress, the spring core comprising:
- a first section including a plurality of coil springs arranged in a matrix; and
- a second section including a plurality of coil springs arranged in a matrix with each of the plurality of coil springs of the second section surrounded by a flexible enclosure, the second section providing greater support, less motion transfer, or both greater support and less motion transfer than the first section.
16. The spring core of claim 15, wherein the flexible enclosure of each of the plurality of coil springs of the second section is connected to the flexible enclosure of an adjacent one of the plurality of coil springs of the second section.
17. The spring core of claim 15, wherein the spring core can be characterized as including a head portion, a foot portion, and a middle portion positioned between the head portion and the foot portion,
- wherein the first section comprises the head portion, the foot portion, or both the head portion and the foot portion, and
- wherein the second section comprises the middle portion.
18. The spring core of claim 15, wherein the spring core can be characterized as including a first side portion and a second side portion opposite the first side portion, and
- wherein the first section comprises the first side portion and the second section comprises the second side portion.
19. A spring core for a mattress, the spring core comprising:
- a plurality of coil springs arranged in a matrix, the matrix defining one or more spaces between the plurality of coil springs, and each of the plurality of coil springs surrounded by a flexible enclosure; and
- one or more interstitial springs, each of the one or more interstitial springs positioned within a respective one of the one or more spaces.
20. The spring core of claim 19, wherein each of the plurality of coil springs and each of the one or more interstitial springs has a height, and wherein the height of each of the one or more interstitial springs is greater than the height of each of the plurality of coil springs.
21. The spring core of claim 19, wherein each of the plurality of coil springs and each of the one or more interstitial springs has a diameter, and wherein the diameter of each of the one or more interstitial springs is less than the diameter of each of the plurality of coil springs.
Type: Application
Filed: Aug 24, 2016
Publication Date: Mar 1, 2018
Inventors: Larry K. DeMoss (Greensboro, NC), Brian M. Manuszak (Thomasville, NC), David J. Pleiman (Peyton, CO), Randy Sizemore (Rensselaer, IN), Darin Taze Thomas (Salisbury, NC), Mark J. Reisz (Demotte, IN)
Application Number: 15/246,106