Spring Mattress and Method for Assembling a Spring Mattress

Abstract

A bedding mattress comprising a spring suspension (1) defining a sleeping plane and a ticking (109, 111) on each side and on the edges. The mattress further comprises a fabric (120, 121, 122, 123) closed around the suspension and maintaining the suspension in compression parallel to the sleeping plane, the ticking (109, 111) being placed outside the fabric (120, 121, 122, 123). The invention further relates to the manufacturing method.

Description

The invention belongs to the field of spring suspension mattresses—as opposed to foam core mattresses—typically the family of mattresses resting on a frame.

The invention is suitable for all mattress dimensions, including large or very large dimensions—in terms of thickness, length and/or width—hence including high-end and luxury positioning mattresses.

The invention is also suitable for mattresses used with a relaxation bed base, i.e. mattresses with raisable head and feet. The frame may be a bed base, a slatted frame, a bed frame, or a boxspring bed base. The mattress may be reversible, i.e. have upper and lower faces that can both be used for sleeping, and that it is advisable to use e.g. one for the summer and the other for the winter. It may also be non-reversible, with two different faces, only one being recommended for sleeping.

The suspension springs may be composed of pocket springs assembled in a sheet, or of single springs forming a spring frame. The suspension may also consist of a superposition of spring assemblies of the same type or of different types, including a superposition of a stack of pocket springs and of a non-pocket sprung carcass.

Mattresses with such a spring suspension are known, in a ticking which is a thick fabric, arranged in the form of a rectangle on each of the faces and sewn on the four sides of each face, by means of a braid, with ticking flanks arranged on the four edges of the mattress. The interior of the ticking often encloses sheets of non-woven fabric, blocks of fairing foam, points or lines of glue, sometimes staples and sometimes a metal frame.

Within the framework of a sustainable approach, one seeks to eliminate from the composition of the mattresses, the foam, glue, metal frame, staples and the sheets of non-woven fabric.

Moreover, such an approach is likely to reduce supply and production costs.

It is thereby possible to propose an ecological mattress made almost exclusively of natural materials, apart from the springs, or coming from recovery or recycling sectors, which also reduces the carbon footprint.

One of the manufacturing and assembly constraints is to ensure the sizing, stability and the perfect geometry of the mattress. In terms of sizing measurement and control, the standards only tolerate a margin of error of 1 cm with regard to the length and the width of the mattress.

According to the known manufacturing and assembly methods, it is not easy to ensure such dimensioning, stability and geometry by assembling only the spring layer or carcass and the ticking, i.e. the thick fabric covering, whether by pocketing the layer in the ticking or by padding the layer and ticking assembly, once assembled.

The necessary flexibility and elasticity of the spring layer, more particularly the pocket springs, is substantial, in particular along the lengthwise direction of the mattress when the spring strips are assembled lengthwise. The layer is at risk of retracting or stretching with variable force, depending on the size and the number of assembled springs, when pressing from the edge or when pressing on the layer from above.

According to the most widespread solutions, the sizing, stability and the geometry are ensured by the installation of a steel frame attached to each of the faces of the layer or carcass, or by fairing with foam blocks, bordering the edges of the layer or of the carcass, and glued to a sheet of non-woven fabric on each side of the suspension.

For mattresses composed of sheets of large pocket springs, the framing alone may not suffice. The pressure exerted by the springs with variable force, depending on the height of the springs, twists the lateral band of the framing positioned lengthwise either outwards (extension) or inwards (retraction). In such case, it is necessary to compensate with the addition of a slight foam fairing to stabilize the layer once same is assembled. The invention proposes solutions to such difficulties.

The invention consists of a bedding mattress comprising a suspension with springs defining a sleeping plane and a ticking on each face and on the edges.

The mattress is remarkable because same further comprises a fabric closed around the suspension and maintaining said suspension in compression parallel to said sleeping plane, the ticking being placed outside the fabric. The fabric is defined by the resistant character thereof: the fabric stretches little, whether plastically or elastically, and keeps such a property over time despite regular and significant stresses.

Thereby, due to the use of the fabric, the suspension is maintained in compression to undergo the stresses imposed on a daily basis by the bodies of people sleeping on the mattress, and the dimension of the latter is constant over time. Thereby, the size of the fabric when it is closed guarantees the size of the mattress.

Depending on Optional and Advantageous Features:

• • the fabric can be a woven material. The binder of the non-woven materials is avoided, and good strength is obtained along the direction of the weft yarns and warp yarns.
  • the fabric can be made of cotton and is e.g. a cretonne. Alternatively, a hemp or flax cretonne is conceivable.
  • the fabric may have a weight of 120 to 160 g/m2, but more particularly 140 g/m2.
  • the fabric can be held assembled around the suspension by stapling or a seam, or both. The seam is advantageous.
  • the fabric can be quilted from side to side on the periphery of the suspension.
  • the ticking may include a padding.
  • the ticking can be quilted on the suspension and can comprises a side strip or side strips sewn with pads for both sides.
  • the fabric can be closed around the suspension with interposition along the edges of the suspension blocks of foam or layers of cotton wool and cretonne.
  • the fabric can be closed around the suspension with comfort coating plates interposed on the faces of the suspension.
  • the fabric is closed around the suspension along the lengthwise direction and along the widthwise direction of the mattress.

The invention further consists of a method for manufacturing or assembling a bedding mattress comprising the installation of a suspension with springs defining a sleeping plane and the installation of a ticking on each face of the suspension and on the edges of the suspension.

The method is remarkable because same further comprises the compression of said suspension parallel to said lying plane and the closing of a fabric mounted tightly around the suspension under compression.

Thereby, the fabric keeps the suspension springs in compression, and ensures the longevity of the mattress.

According to advantageous and optional features of the method,

• • the fabric can be a woven material.
  • the fabric can be made of cotton and is e.g. a cretonne. Alternatively, a hemp or flax cretonne is conceivable.
  • the fabric may have a weight of 120 to 160 g/m2, but more particularly 140 g/m2.
  • the fabric can be held assembled around the suspension by stapling or a seam, or both. The seam is advantageous.
  • the fabric can be quilted from side to side on the periphery of the suspension.
  • the ticking may include a padding.
  • the ticking can be quilted on the suspension and can comprises a side strip or side strips sewn with pads for both sides.
  • the fabric can be closed around the suspension with interposition along the edges of the suspension blocks of foam or layers of cotton wool and cretonne.
  • the fabric can be closed around the suspension with comfort coating plates interposed on the faces of the suspension.
  • the fabric is closed around the suspension along the lengthwise direction and along the widthwise direction of the mattress.
  • the fabric is closed around the suspension with interposition along the edges of the suspension blocks of foam or of agglomerated fibers or layers of cotton wool and cretonne, and the fabric is held assembled around the suspension by stapling or a seam, or both.

The invention will be better understood, and other goals, features, details and advantages thereof will become clearer from the following explanatory description with reference to the encloses drawings given only as an example illustrating a plurality of embodiments of the invention and wherein:

FIG. 1 is a sectional view of a mattress of known construction.

FIG. 2 is a three-quarter exploded view of the mattress shown in FIG. 1.

FIG. 3 is a schematic view of a mattress according to one embodiment of the invention, during preparation.

FIG. 4A is a three-quarter view of the mattress shown in FIG. 3.

FIG. 4B is a view of the mattress shown in FIGS. 3 and 4A, finished.

FIG. 5 is a sectional view of a mattress according to a second embodiment of the invention, at the same stage as the representation shown in FIG. 3.

FIG. 6 shows a detail of the making of the mattress shown in FIG. 5.

FIG. 7 shows a step of manufacturing a mattress according to the invention.

FIG. 1 For high-end mattresses, a known composition for a summer-winter double-sided mattress is the composition shown in FIG. 1. The method used for sizing and stability is the method of the foam fairing. The composition with framing is not suitable for mattresses used with an articulated relaxation frame wherein the frame would fold irremediably when the articulation system starts to work.

FIG. 1 shows the composition of the mattress: the pocket springs 1 form a layer on each of the faces of which sheet of non-woven fabric 2 was placed, with a weight of 50 g/m2, glued at the periphery over foam blocks 3 forming the fairing, and folded over the flank thereof. The adhesive 4 is present on the face, at the periphery and extends on the flank.

On each of the faces, on the non-woven face, a thick sheet of foam is present forming a coating 5. However, the coating 5 is not mandatory. The function thereof is to give more comfort quality to the mattress. The coating is preferably made of foam but may be composed of any useful synthetic or natural material. It is glued on the periphery to the non-woven sheet. The adhesive 6 is present on the face at the periphery.

On each of the faces, on the outer face of the coating 5, there is a sheet of non-woven fabric 7 of 15 g/m2. Same is glued at the periphery to the coating 5. The adhesive 8 is present on the face at the periphery.

The padding materials, fabrics, textiles or other, are inserted into two trays 9, which are closed by sewing and pressed against the suspension by cushions 10 (each consisting of a thread passing through the assembly from side to side and a button placed on the surface that holds the pad tightly against the suspension). The cushions are placed e.g. over the entire surface, in rows and columns, according to a rectangular two-dimensional array. A button on one surface can be connected by a common thread to a button on the opposite surface, arranged in the same place on the second side. The threads pass between two springs or through a spring.

FIG. 2 is a sectional view of the same mattress, certain parts being artificially removed to allow the parts same would have hidden, to be seen. In addition, the lateral strip 11 protecting the side of the mattress can be seen, attached by a braid 12 to the edges of the pads 9.

the Order of Assembly is the Following:

• • Step 1. The blocks (or strips) of foam 3 for the length and width fairing are laid in a compression table. In French, the table is also called a “cadreuse” (literately, a frame making machine)
  • Step 2. The layer formed by the springs 1 already rigidly attached to one another is laid manually. The layer is brought slightly into compression by an appropriate adjustment of the “cadreuse”. There is no standard adjustment—the layer has to be completely flattened by pressure without there being too much resistance nor space between the layer and the foam blocks 3 forming the fairing.
  • Step 3. A sheet of non-woven fabric 2 of 50 g/m2 is glued to the summer face, from above, over the sheet of springs, using glue 4.
  • Step 4. The coating 5, namely the comfort material, is placed and glued using the adhesive 6.
  • Step 5. The veil, which is a sheet of non-woven fabric 7 of 15 g/m2, is glued using adhesive 8.
  • Step 6. The assembly is turned over.
  • Steps 7 to 9. Steps 3 to 5 are repeated on the winter side.
  • Step 10. The pads 9 are placed—the low pad already being assembled with the strip 11 forming the edge of the mattress, made of ticking, by sewing.
  • Step 11. The quilting is carried out (the laying of the quilting points 10) and the closure is carried out by sewing the strip 11 of ticking forming the edge of the mattress on the upper face.

FIG. 3 Shown in FIG. 3, the new embodiment is a significant development. An envelope or cover for the layer of pocket spring is created. Same does not use non-woven fabric.

The composition of the envelope or cover and of the layer or carcass of springs is shown in FIG. 3, which is a sectional view.

The new spring suspension mattress 101 is based on the creation of a cretonne cover, or another preferably natural material, with low elasticity and sufficient resistance to absorb without deformation over time, the movements of the spring layer, without being stretched. Cretonne is a fairly strong fabric, consisting of hemp, linen or cotton threads on a weave (the weave being the mode of interlacing of the threads) such as a fabric and the contexture (interlacing) of which is square. For example, a cretonne with a grammage of 140 g/m2 or a fabric with a grammage of between 120 and 160 g/m2 is chosen. A cotton cretonne is preferred, or even 100% cotton.

An assembly is used in a compression table, without framing, and without fairing, or else with a lightweight fairing. The assembly is carried out without gluing, with the exception of gluing the pocket springs together (in the case where the mattress suspension consists of a layer of pocket springs).

The order of assembly is the following.

Step 1. Parts of the cretonne fabric cover are sewn, by sewing the bottom part, which is a rectangular face 120 with the dimensions of the suspension face, to the lateral part, the strip forming the flank, and choosing adjusted dimensions to prepare a tight threading of the suspension into the cover. The strip is assembled continuously with a coverage of about 10 cm. Two of the four sides, 121 and 122, are visible in the figure whereas two other sides at 90° are not visible in the figure. The sides are of the same material as the face and have the dimension of the flanks of the suspension. The seam is referenced by 119. The seam is carried out over the entire rectangular perimeter of the rectangular face 120.

Step 2. The blank of the cretonne cover is placed in the compression table.

Step 3. A coating 105 formed for one of the faces, e.g. the summer face, is placed in the blank of the cover in the table, preferably without gluing.

Step 4. Blocks 103 of foam, or of fiber agglomerate, or assembly of cotton wool and cretonne are placed so as to form the sides of the suspension, preferably without gluing, in the blank of the cover, in the table. The dimensions of the cover were chosen knowing that the flanks will be present. The flanks form a perimeter belt, which in the case of foam is a fairing.

Step 5. The layer or carcass of springs 101 is laid. The layer has to be completely flattened by pressure without there being too much resistance nor space between the layer and the foam blocks 103 forming the flanks. The compression table, or “cadreuse”, compresses the suspension: the springs are compressed perpendicular to the axis thereof, and are thus ready to accommodate the weight of a person sleeping on the mattress.

Step 6. A coating 105 formed for the winter face without gluing is preferably placed over the layer or the carcass of springs and on the blocks 103.

Step 7. The upper part of the cretonne 123, which is a rectangular face cut to the right size, is placed on the winter face.

Step 8. The envelope (or cover) is closed by stapling on the periphery of the upper part. The staples are referenced by 118. The stapling is carried out over the entire rectangular perimeter of the rectangular face of cretonne 123, with the four sides of which only two are visible in the figure-same are referenced by 121 and 122.

The closing is carried out tightly, and the suspension is thus kept compressed parallel to the plane of the sleeping surface, because the thickness of the mattress is less than the length and width thereof. The suspension can be taken out of the “cadreuse” (or compression table). Since the cover is closed along the lengthwise direction and along the widthwise direction of the mattress, the compression parallel to the plane of the sleeping surface is maintained in both dimensions.

If appropriate, a row of quilting points 130 is fitted along the edges, in line with the blocks 103. The quilting point each consist of a thread passing through the assembly from side to side and a button placed on the surface which keeps the face of the cretonne 123 tight against the blocks 103). A button on one surface can be connected by a common thread to a button on the opposite surface, placed in the same place on the second side. The thread runs through the foam. In order to reinforce stability, in the absence of gluing, it is preferable to carry out the quilting of the assembly of the cover and the layer springs, on the periphery, at the blocks 103.

FIG. 4A shows the suspension in the cover thereof, in a three-quarter view, certain parts being artificially removed to allow the parts same would have hidden, to be seen.

The coating 105 is not mandatory. Same improves the stability of the assembly and has a comfort function.

Stapling on one of the faces of the cretonne envelope (herein the upper face, i.e. the winter face) is envisaged to ensure the stability of the assembly when sitting on the mattress, whether on the winter face or on the summer face. On the other hand, the mattress remains perfectly stable, the cretonne sewn on one of the faces (herein the lower face or the summer face) thereof. But it is also possible that there is no stapling.

The dimensions of the envelope determine with reliability and reproducibility the size of the mattress, according to the length of the cretonne fabric and the height of the peripheral cretonne strip. The size of the seams and of the stapling of the top and bottom perimeter of the cretonne cover ensures the sizing and the geometry of assembly of the cover and of the layer (or spring frame).

It is specified that the blocks 103 internal to the envelope can be made without foam.

The blocks of material placed around the circumference of the layer or the carcass of springs can then be composed of three layers, parallel to the flank of the suspension (and hence of the mattress): a layer of cretonne or cotton, a layer of cotton wool and a new layer of cretonne, in this order, and the three layers are pre-assembled by sewing. The strip of the assembly is in four parts-two lengths and two widths, with the four parts joining each other in the corners.

The effect of the strip is to eliminate an undesirable effect on the edges of the mattress, called a rollover effect, which occurs if the sheet of springs comes directly into contact with the bell-shaped cover. To reinforce the corners, in the absence of fairing foam, it is also proposed to insert connections in the corners to smooth the geometric appearance of the spring strips and fill the void related to the circular character of the corner spring. But it is also possible to put a set of three layers, cretonne, cotton wool, cretonne on the entire flank.

The method then continues.

FIG. 4B Once the layer or carcass of springs is inserted and the envelope is closed, the padded pads and the lateral ticking strip are arranged around the envelope (or cover) to complete the assembly of the product by quilting and sewing. The envelope or cover has thereby been preassembled, tightened, with the layer or the carcass of springs enclosed and compressed before being then assembled with the pads and the strip for the quilting and the closing of the assembly equipped with the ticking thereof by sewing.

FIG. 4B thereby shows the fitting of the suspension, the dimension of which is guaranteed by the cover, in the padding.

Step 9. A padded pad 109 is placed for the lower part with the strip 111 for the flank of the mattress already assembled by sewing on the sides of the padded pad 109. The pad and the strip also form, in addition to a padding for comfort, a ticking for the appearance and the touch. The ticking is placed on the outside of the fabric.

Step 10. An external quilting is carried out by the padded pads. As herein above, the quilting points 140 each consist of a thread passing through the assembly from side to side and a button placed on the surface which retains the pad tight against the suspension. The cushions are placed e.g. over the entire surface, in rows and columns, according to a rectangular two-dimensional array. A button on one surface can be connected by a common thread to a button on the opposite surface, arranged in the same place on the second side. The threads pass between two springs or through a spring.

Step 11. The strip 111 for the flank and the padded pad for the upper part, are closed by sewing. A braid is also placed on the sewn edges (four braids visible in FIG. 4B).

There is no turning over during the process. There is limited stapling, partial stapling, or no stapling at all throughout the product.

FIG. 5 The foam fairing is advantageous for large height mattresses with superposed layers or carcasses of springs 201, as shown in FIG. 5. The fairing then consists of two strips of foam 203 and 204 or of fiber agglomerate, glued together with a central groove or hollows to allow the glue to spread.

FIG. 5 is thereby a sectional plane of the cover for a mattress of large size obtained herein by superimposing two spring carcasses. There is a fabric in four pieces: 220, 221, 222 and 223, sewn (the seam is referenced by 219) or stapled, with coating plates 205, and a quilt point 230.

FIG. 6 is a sectional view of the foam fairing shown in FIG. 5. The hollows 250 are arranged along the heightwise direction to prevent a clumping of glue during the operation of gluing the top and bottom parts 203 and 204 of the strip of foam or of another material. Another solution, if appropriate implemented jointly on the same product, rather than using hollows, is to form a groove 251 around the entire periphery, at the junction of the top and bottom parts of the strip.

Such method is suitable for any type and size of spring suspension mattresses, whether or not the springs are pocketed.

FIG. 7 is a view of the envelope, the faces 120 and 121 of which can be seen, and of the padded pad 109 and of the ticking strip 111 at the stage of final assembly. It should be noted that in present example the different materials compose the top/winter face. The assembly is attached permanently during the final assembly of the top face pad 109 and of the lateral strip 111 by sewing.

Claims

1. A bedding mattress comprising a spring suspension defining a sleeping plane and a ticking on each face and on the edges, characterized in that the mattress further comprises a fabric closed around the suspension and maintaining said suspension in compression parallel to said sleeping plane, the ticking being placed outside the fabric.

2. The bedding mattress according to claim 1, characterized in that the fabric is a woven material.

3. The bedding mattress according to claim 1, characterized in that the fabric is made of cotton, and is e.g. a cretonne.

4. The bedding mattress according to claim 1, characterized in that the fabric has a weight of 120 to 160 g/m2.

5. The bedding mattress according to claim 1, characterized in that the fabric is held together around the suspension by stapling or sewing or both.

6. The bedding mattress according to claim 1, characterized in that the fabric is quilted throughout the periphery of the suspension.

7. The bedding mattress according to claim 1, characterized in that the ticking comprises a padding.

8. The bedding mattress according to claim 1, characterized in that the ticking is quilted to the suspension and comprises a lateral strip sewn with pads for both sides.

9. The bed mattress according to claim 1, characterized in that the fabric is closed around the suspension with foam blocks or layers of cotton wool and cretonne interposed along the edges of the suspension.

10. The bedding mattress according to claim 1, characterized in that the fabric is closed around the suspension with comfort-coating plates interposed on the faces of the suspension.

11. The bedding mattress according to claim 1, characterized in that the fabric is closed around the suspension along the lengthwise direction and along the widthwise direction of the mattress.

12. A method of manufacturing a bedding mattress comprising providing the fitting a spring suspension defining a sleeping plane and the fitting of a ticking on each side of the suspension and on the edges of the suspension, characterized in that the manufacturing method further comprises the compression of said suspension parallel to said sleeping plane and the closing of a fabric mounted tightly around the suspension under compression.

13. The method according to claim 12, characterized in that the fabric is closed around the suspension with interposition along the edges of the suspension of blocks of foam or of agglomerated fibers or layers of cotton wool and cretonne, the fabric being held assembled around the suspension by stapling or a seam, or both.

14. The method according to claim 12, characterized in that the fabric is a woven material.

15. The method according to claim 12, characterized in that the fabric is made of cotton, and is e.g. a cretonne.

16. The method according to claim 1, characterized in that the fabric has a weight of 120 to 160 g/m2.