BR112019023872B1 - COMFORT LAYERS AND METHODS FOR MANUFACTURING THEM - Google Patents

Abstract

A comfort layer for a bed or seat product has slow-action pockets, characterized by the comfort layer's individual springs being pocketed with either semi-waterproof or waterproof fabric. Each seam joining opposing layers of fabric around each comfort layer coil spring can be segmented, allowing air to flow between the segments, thereby increasing the luxurious "feel" of the comfort layer. The comfort layer manufacturing method includes compressing the springs and creating pockets with a welder and an anvil.

Description

DESCRIPTIVE REPORT Cross Reference to Related Requests

[0001] This Application is a continuation in part of US Patent Application 15/062,318, filed on March 7, 2016, a continuation in part of US Patent Application 14/879,672, filed on October 9, 2015, which claims the benefit of US Provisional Patent Application 62/115,785, filed February 13, 2015, each application of which is fully incorporated by reference herein.

Technical Field of Invention

[0002] This invention relates to a comfort layer for bed and seat products. More particularly, this invention relates to a pocket spring comfort layer for use in seating or bed products and the method of manufacturing such a comfort layer.

Background of the Invention

[0003] Comfort layers are commonly used in seat or bed products above/below a core, which may or may not include a spring assembly. Such comfort layers may include foam, fiber, or gel products. US Patent 8,087,114 discloses a comfort layer made of pocket springs. Such spring assemblies may be made from chains of individually pocketed helical springs joined together or multiple helical springs joined together by helical loop wires.

[0004] The spring cores may generally be covered at the top and often at the bottom by resilient foam pads such as, for example, a urethane pad or latex/urethane blend of foamed material. Within the last several years, more expensive pillows or mattresses have had the spring cores covered by a visco-elastic foam cushion, which is a slow-acting foam, or latex, which is faster-acting than visco-elastic foam. . That is, the visco-elastic foam pillow is slow to compress under load and slow to recover to its original height when the load is removed from the visco-elastic foam pillow. These visco-elastic pillows, as well as latex pillows, convey a supposed feeling of luxury to the mattress or pillow. These pillows, because of their closed cellular structure, also retain heat and are slow to dissipate body heat when a person sits or lies on such a pillow or mattress containing foam padding.

[0005] Individually pocketed spring cores have been made with fabric material semi-impermeable to air flow through the fabric material, as more fully explained below. US Patent 7,636,972 discloses such a pocket spring core.

[0006] European Patent EP 1707081 discloses a pocket spring mattress, in which each pocket has a ventilation hole in order to improve airflow in and out of the pocket. However, a disadvantage of such a product, depending on the fabric used in the product, is that the pocket fabric can create “noise”, as the sound is called in the industry. Such noise can be created by the fabric expanding with the removal of the load due to the upward directed force of the coil spring on the fabric.

[0007] It is, therefore, an object of this invention to provide a comfort layer for a seating or bedding product, which has the same luxurious feel as a comfort layer containing visco-elastic or latex cushion, but without the characteristics of heat retention of such a comfort layer.

[0008] Yet another object of this invention is to provide one or more layers of comfort to a seating or bedding product, having the same feeling of luxury or a slow-to-compress and slow-to-recover to its height feeling of luxury. similar to memory foam.

[0009] Another object of this invention is to provide a comfort layer for a seating or bedding product made, at least partially, with fabric that is impervious to air flow through the fabric, but which allows air to enter and exit the pockets in different flow rates, in reaction to different loads being applied to one or more pockets.

[0010] Another object of this invention is to provide a comfort layer for a seating or bedding product made at least partially with fabric that is impervious to air flow through the fabric, but which allows air to enter and exit the pockets through through openings in the seams of at least some of the pockets.

Summary of the Invention

[0011] The invention, which realizes these objectives, comprises a comfort layer for a seat or bed product. The comfort layer comprises an assembly or array of individually pocketed springs, each spring being contained within a fabric pocket. The fabric pocketing material within which the springs are contained may be semi-impermeable to airflow through the fabric material. As used herein, the term “semi-impermeable” means that the fabric material, while allowing some air flow through the material, does so at a rate that slows or slows the rate at which a spring held in a pocket of the fabric it can compress under load or return to its original height when a load is removed from the pocket spring. In other words, air can pass through such a semi-impermeable material, but at a reduced rate compared to the rate at which air normally flows through non-woven polypropylene material commonly used in the bedding industry.

[0012] Alternatively, the fabric material within which the springs are contained may be non-permeable or impervious to air flow through the fabric material. In other words, air may not flow through the fabric material.

[0013] When a load is applied to a comfort layer made with semi-impermeable fabric, the rate of deflection of the comfort layer is slowed by the rate at which air escapes through the semi-impermeable fabric within which the pocket springs are located. contained and by the rate at which air travels between segments of weld seams separating individual pockets.

[0014] When a load is applied to the comfort layer made with waterproof fabric, the rate of deflection of the comfort layer is slowed only by the rate at which air escapes or travels between segments of weld seams separating individual pockets. Regardless of the type of fabric used to make the comfort layer, the stitching segments can be any desired shape, including curved or straight, and any desired length to control airflow within the comfort layer. The length, size and/or shape of the seam segments can be manufactured to achieve a desired airflow between the interior of the pocket and the space outside the pocket.

[0015] Any of the comfort layer embodiments shown or described herein can be incorporated into a bedding product, such as a mattress, bed foundation or pillow. Furthermore, any of the comfort layer embodiments shown or described herein may be incorporated into a seating product, such as a vehicle and/or office seat or home furniture, such as a recliner.

[0016] Alternatively, any of the comfort layer embodiments shown or described herein may be sold independently as a retail or wholesale item. In such an application, the comfort layer may be added to and/or removed from a bed or seating product by a consumer.

[0017] The comfort layer of the present invention, whether incorporated within a bed or seating product, or manufactured and sold as a separate product, provides an additional cooling effect to the product due to airflow through the comfort layer. comfort, including between adjacent pockets. The amount of airflow between the pockets can be changed by changing the size of the teeth or slots on a welding tool, including an ultrasonic welding tool. This is an easy way to adjust airflow within a comfort layer and outside the comfort layer without changing the fabric material of the comfort layer.

[0018] Another advantage of this invention is that the comfort layer allows air to flow between pockets within a pocket spring comfort layer and either exit or enter the comfort layer along the periphery or edge of the comfort layer. , such airflow contributing to the luxurious “feel” of any bed or seating product incorporating the comfort layer. The comfort layer of the present invention has the slow-acting compression and height recovery characteristics of hitherto expensive visco-elastic foam comfort layers, but without the undesirable heat retention characteristics of such foam comfort layers.

[0019] According to another aspect of the present invention, a method of manufacturing a comfort layer for a bed or seat product is provided. The comfort layer is characterized by slow, gentle compression when a load is applied to the product. The method comprises forming a continuous blanket of individually pocketed springs, each spring being contained within a pocket of fabric formed by joining multiple layers of fabric with welded seams.

[0020] The continuous blanket of individually pocketed springs is cut to a desired size after passing through a machine. The machine inserts multiple springs between the two layers of fabric and joins the fabric layers together along weld seams around the perimeter of each of the springs.

[0021] The comfort layer is characterized, when a load is applied to the comfort layer, by the rate of deflection of the comfort layer being slowed by the rate at which air passes through the weld seam openings, the openings widening or changing size or shape or both when subjected to a load, allowing air to exit the comfort layer pockets at a desired rate.

[0022] The comfort layer is further characterized by the rate of recovery of the comfort layer to its original height, after removal of a load from the comfort layer, being slowed by the rate at which air returns between segments of the weld seams. into the pockets. The openings decrease in width as load is removed, allowing air to enter the comfort layer pockets at a desired rate. The rate at which air travels between individual pockets is determined by the size of the openings between segments of weld seams separating adjacent pockets. Around the perimeter of the comfort layer, air enters and leaves the interior of the comfort layer through the openings between segments of the comfort layer perimeter weld seams. By constructing a comfort layer with openings of a predetermined size, airflow into and out of the comfort layer can be controlled. Airflow into and out of the comfort layer may be further dependent on the type of fabric used to construct the comfort layer.

[0023] The method of manufacturing a comfort layer for a bed or seat product may comprise the following steps. The first step involves forming a continuous blanket of individually pocketed springs, each of the springs being surrounded by a segmented weld seam, which allows airflow through the weld seam. The continuous blanket of individually pocketed springs can later be cut to a desired size. Each spring is contained within a pocket having a weld seam comprising multiple segments. The fabric is impervious to airflow through the fabric. However, air can flow through the pockets due to openings between the weld seam segments, forming the pockets. The comfort layer is characterized by slow, gentle compression when a load is applied to the comfort layer. When a load is placed on the comfort layer and then removed, the rate of return of the comfort layer to its original height is slowed by the rate at which air returns through the semi-impermeable pockets within which the springs are contained. At least some of the openings of the weld seams surrounding a pocket increase in width, i.e., size or shape, when a load is applied to the pocket, allowing air to exit the affected comfort pockets at a controlled rate. For example, when a heavy person sits on a product having such a comfort layer, the sudden increase in load quickly opens the weld seam openings and allows air to escape quickly and efficiently from the affected pockets of the comfort layer. This prevents any damage to the comfort layer and provides a luxurious feeling to the user regardless of the load applied.

[0024] The comfort layer is further characterized, when a load is removed from the comfort layer, by the openings decreasing in width, to control the flow of air in the affected pockets of the comfort layer.

[0025] The fabric from which the pockets are made may be wholly or partially made of fabric, non-permeable or impervious to air flow. In such a situation, air entering and leaving the pockets is limited by air flowing through the openings between the segments of weld seams surrounding the springs.

[0026] The fabric from which the pockets are made may be wholly or partially made of fabric that is semi-impermeable to airflow. In such a situation, air entering and leaving the pockets is limited by not only air flowing through openings between segments of weldment surrounding the springs, but also by air flowing through the fabric. Regardless of which fabric is used to make the layers, by controlling the flow of air in and out of individual pockets, the rate of recovery of the comfort layer when a load is removed can be different than the rate of entry. of air in the pockets when a load is applied.

[0027] By restricting airflow through the weld seams of a pocket spring comfort layer, a comfort layer manufacturer can create a comfort layer with a luxurious feel, without using any foam, in a cost-effective manner. .

[0028] These and other objects and advantages of this invention will be readily apparent from the following drawings, in which:

Brief Description of the Drawings

[0029] FIG. 1 is a partially broken perspective view of a bedding product incorporating one of the comfort layers of this invention;

[0030] FIG. 2 is a perspective view of the comfort layer of Fig. 1 being manufactured;

[0031] FIG. 2A is a perspective view of a part of the machine of Fig. 2, the coil springs being inserted in predetermined positions.

[0032] FIG. 3A is a cross-sectional view of an early part of the manufacturing process using the machine of Figs. 2 and 2A;

[0033] FIG. 3B is a cross-sectional view of the springs being compressed in the manufacturing process using the machine of Figs. 2 and 2A;

[0034] FIG. 3C is a cross-sectional view of the springs being moved laterally in the manufacturing process using the machine of Figs. 2 and 2A;

[0035] FIG. 3D is a cross-sectional view of the top layer of fabric being moved in the manufacturing process using the machine of Figs. 2 and 2A;

[0036] FIG. 3E is a cross-sectional view of one of the springs being sealed in the manufacturing process using the machine of Figs. 2 and 2A;

[0037] FIG. 4 is an enlarged perspective view of a portion of the comfort layer of Fig. 1 partially disassembled and showing a portion of a soldering tool;

[0038] FIG. 4A is an enlarged perspective view of a portion of the comfort layer of Fig. 1 partially disassembled and showing a portion of another soldering tool;

[0039] FIG. 5 is a top plan view of a portion of the comfort layer of Fig. 1, the arrows showing the flow of air within the comfort layer;

[0040] FIG. 5A is a cross-sectional view taken along line 5A-5A of Fig. 5;

[0041] FIG. 5B is an enlarged cross-sectional view of an alternative embodiment having a different fabric;

[0042] FIG. 6 is a top plan view of a portion of another comfort layer, the arrows showing airflow within the comfort layer;

[0043] FIG. 6A is a cross-sectional view taken along line 6A-6A of Fig. 6;

[0044] FIG. 7 is a partially broken perspective view of a bedding product incorporating another embodiment of the comfort layer in accordance with the present invention;

[0045] FIG. 8 is a perspective view of the comfort layer of Fig. 7 being manufactured;

[0046] FIG. 9 is an enlarged perspective view of a portion of the comfort layer of Fig. 7, partially disassembled and showing a portion of a soldering tool;

[0047] FIG. 9A is an enlarged perspective view of a portion of the comfort layer of Fig. 7, partially disassembled and showing a portion of another soldering tool;

[0048] FIG. 10 is a top plan view of a portion of the comfort layer of Fig. 7, the arrows showing an air flow within the comfort layer;

[0049] FIG. 10A is a cross-sectional view taken along line 10A-10A of Fig. 10;

[0050] FIG. 10B is an enlarged cross-sectional view of an alternative embodiment having a different fabric;

[0051] FIG. 11 is a top plan view of a corner portion of the comfort layer of Fig. 1, the arrows showing airflow into and out of the comfort layer;

[0052] FIG. 11A is a top plan view of a corner portion of the comfort layer of Fig. 7, the arrows showing airflow into and out of the comfort layer;

[0053] FIG. 12 is a top plan view of a corner portion of another embodiment of the comfort layer;

[0054] FIG. 12A is a top plan view of a corner portion of another embodiment of the comfort layer;

[0055] FIG. 13A is a perspective view of a posturized comfort layer;

[0056] Fig. 13B is a perspective view of another posturized comfort layer;

[0057] FIG. 14 is a top view of a part of another embodiment of the comfort layer;

[0058] FIG. 14A is a cross-sectional view taken along line 14A-14A of Fig. 14;

[0059] FIG. 14B is an enlarged cross-sectional view of an alternative embodiment having a different fabric;

[0060] FIG. 15 is a top view of a part of another embodiment of the comfort layer;

[0061] FIG. 15A is a detailed cross-sectional view taken along a portion of line 15A-15A of Fig. 15;

[0062] FIG. 15B is a detailed cross-sectional view of the pocket spring of Fig. 15A under a load; It is

[0063] FIG. 15C is a detailed cross-sectional view of the pocket spring of Fig. 15B under additional load.

Detailed Description of the Drawings

[0064] Fig. 1 illustrates a single-sided mattress 10 incorporating an embodiment of the comfort layer in accordance with this invention. This mattress 10 comprises a spring core 12 on top of which there is a conventional cushioning pad 14, which may be partially or entirely made of foam or fiber or gel, etc. The cushioning pad 14 may be covered by a comfort layer 16 constructed in accordance with the present invention. A second conventional cushioning pad 14 may be located above the comfort layer 16. In some applications, one or more of the cushioning pads 14 may be omitted. This complete assembly can be mounted on a base 18 and is completely enclosed within a cover 20, such as an upholstered cover, for example.

[0065] As shown in Fig. 1, the mattress 10 has a longitudinal dimension or length L, a transverse dimension or width W, and a height H. Although the length L is shown to be greater than the width W, they can be identical. The length, width and height may be any desired distance and are not intended to be limited by the drawings.

[0066] While various comfort layer embodiments are illustrated and described as being realized in a single-sided mattress, any of the comfort layers shown or described herein can be used in a single-sided mattress, double-sided mattress or pillow seat. If any such comfort layer is used in connection with a two-sided product, then the underside of the core of the product may have a comfort layer applied over the underside of the core and any of the comfort layers may be covered. by one or more cushioning pads made of any conventional material. In accordance with the practice of this invention, however, both the cushioning pad and the pads on the top and/or bottom of the core may be omitted. The innovative features of the present invention reside in the comfort layer and/or bagged core of the product.

[0067] Although the spring core 12 is illustrated as being made of unbagged coil springs held together with helical loop wires, the core of any of the products, such as mattresses shown or described herein, may be made entirely or partially of coil springs. bagged screws (see Figs. 7 and 14), one or more pieces of foam (not shown) or any combination thereof. Any of the comfort layers described or shown herein may be used in any single-sided or double-sided bed or seat product having any conventional core. The core may be any conventional core, including but not limited to conventional or pocket spring cores.

[0068] Fig. 4 illustrates the components of an embodiment of comfort layer 16 incorporated into the mattress 10 shown in Fig. 1. The comfort layer 16 comprises a first layer or top layer of fabric 22 and a second layer or bottom layer of fabric 24, with a plurality of mini helical springs 28 therebetween. The fabric layers 22, 24 are joined with circular retainers or weld seams 30, each weld seam 30 involving a mini helical spring 28. Each circular weld seam 30 comprises multiple arcuate or curved segments 26, with openings 31 therebetween. The first and second layers of fabric 22, 24 are joined along each arcuate or curved segment 26 of each circular weld seam 30. The first and second layers of fabric 22, 24 are not joined along each opening 31, between adjacent segments 26 of each circular weld seam 30. The curved segments 26 are strategically located around a mini-helical spring 28 and create the circular weld seam 30. The two fabric layers 22, 24, in combination with one of the circular weld seams 30. circular welds 30, define a cylindrical shaped pocket 44, within which is at least one resilient member, such as a mini helical spring 28. See Figs. 5 and 5A.

[0069] During the welding process, the mini helical springs 28 may be at least partially compressed before the pocket 44 is closed and thereafter. If desired, resilient members other than mini helical springs, such as foam or plastic or gel, or a combination thereof, may be used. Each of the resilient members can return to its original configuration after a load is removed from the pockets in which the resilient members are located.

[0070] The size of the curved segments 26 of the weld seams 30 is not intended to be limited by the illustrations; they can be any desired size depending on the desired airflow within the comfort layer. Similarly, the size, i.e., diameter of the illustrated weld seams 30 is also not intended to be limiting. For example, the weld seams 30 may be arranged in aligned rows and columns, as shown in Figs. 5 and 5A or arranged with adjacent columns being offset from each other, as illustrated in Figs. 6 and 6A. Any desired arrangement of weld seams may be incorporated into any embodiment shown or described herein.

[0071] The weld segments may assume shapes other than the illustrated curved weld segments. For example, the weld seams may be circular around the mini helical springs, but the weld segments may take other shapes, such as triangles or circles or ovals of the desired size and pattern, to obtain the desired airflow between adjacent pockets. within the comfort layer and to and from the perimeter of the comfort layer.

[0072] In any of the embodiments shown or described in this document, the mini helical springs 28 can be of any desired size. A mini coil spring, in a relaxed condition, may be approximately two inches tall, have a diameter of approximately three inches, and be made of seventeen and a half gauge wire. While compressed within one of the pockets 44, each of the mini helical springs 28 may be approximately one and a half inches tall. However, the mini helical springs 28, in a relaxed condition, may be any desired height, have any desired shape, such as an hourglass or barrel shape, have any desired diameter, and/or be made of any desired thickness or gauge of wire.

[0073] Referring to Fig. 4, a portion of a mobile ultrasonic welder 32 and anvil 42 is illustrated. The mobile ultrasonic welder 32 has a plurality of cutouts or slots 34 along its lower edge 36. The remaining parts 38 of the bottom of the ultrasonic welder 36 between the slots 34 are the parts that weld the two pieces of fabric 22, 24 together and create the curved weld segments 26. Along the bottom edge of the ultrasonic welder 36, the ultrasonic welder 32 can be milled to make the slits of a desired length, to allow a desired airflow between the curved weld segments 26, as illustrated by arrows 40 of Fig. 5. The airflows affect the feel/compression of the individually bagged mini helical springs 28, when a user lies on the mattress 10.

[0074] As shown in Fig. 4, under the second layer 24 is an anvil 42, compressing a 3/8 inch thick steel plate. However, the anvil can be of any desired thickness. During the manufacturing process, the ultrasonic welder 32 comes into contact with the anvil 42, the two layers of fabric 22, 24 therebetween, to create the circular weld seams 30 and, consequently, the cylindrical shaped pockets 44, at least least one spring being in each pocket 44.

[0075] These curved weld segments 26 are created by the welder 32 of a machine (not shown), having multiple spaced protrusions 38 on the ultrasonic welder 32. As a result of these circular weld seams 30 joining layers 22, 24, layers 22 , 24 define a plurality of pockets containing springs 44 of the comfort layer 16. One or more mini helical springs 28 may be contained within an individual pocket 44.

[0076] Fig. 4A illustrates another apparatus for forming circular weld seams 30, comprising multiple curved segments 26 having openings 31 therebetween for air flow. In this apparatus, the ultrasonic welder 32a does not have protrusions on its lower surface 39. Instead, the lower surface 39 of the ultrasonic welder 32a is smooth. As shown in Fig. 4A, the anvil 42a has a plurality of curved projections 41, which together form a projection circle 43. A plurality of projection circles 43 extend upwardly from the generally flat upper surface 45 of the anvil 42a . When the ultrasonic welder 32a moves downward and presses the layers 22, 24 of fabric between one of the projection circles 43, and the smooth bottom surface 39 of the ultrasonic welder 32a, a circular weld seam 30 is created, as described above. Thus, a plurality of pockets 44 are created by the circular weld seams 30, each pocket 44 containing at least one mini helical spring 28.

[0077] In embodiments in which the fabric material of the layers 22, 24 defining the pockets 44 and enclosing the mini helical springs 28 therein is non-permeable or impervious to air flow, when subjected to a load, a pocket 44 containing fur At least one mini-helical spring 28 is compressed, compressing the mini-helical spring(s) 28 and air contained within the pocket 44. Air exits the pocket 44 through openings 31 between the curved segments 26 of the seams. circular welds 30. Similarly, when a load is removed from the pocket 44, the mini helical spring 28 separates the fabric layers 22, 24, and air re-enters the pocket 44, through the openings 31, between the curved segments 26 of the circular weld seams 30. As shown in Fig. 5, the size of the openings 31 between the segments 26 of the circular seams 30 of the peripheral pockets 44 defines how quickly air can enter or leave the comfort layer 16.

[0078] In embodiments where the fabric material is semi-impermeable to airflow, the rate at which the mini helical springs 28 compress when a load is applied to a comfort layer of the pocket spring core 16 is slowed or delayed by air trapped within the individual pockets as the pocket spring comfort layer 16 is compressed. Similarly, the rate of return of the compressed pocket spring comfort layer to its original height after compression is slowed or slowed by the rate at which air can pass through the semi-impermeable fabric material into the interior. of the individual pockets 44 of the pocket spring comfort layer 16. In these embodiments, air passes through the openings 31 between the curved segments 26 of the circular weld seams 30, as described above in relation to embodiments having non-permeable fabric. However, furthermore, some air passes through the fabric, both when the pocket 44 is compressed, and when the pocket 44 is unloaded and enlarging or expanding due to the inherent characteristics of the minisprings 28.

[0079] As best illustrated in Fig. 5, the individual pockets 44 of the comfort layer 16 may be arranged in longitudinally extending columns 46, extending from the head to the foot of the bedding product, and transversely extending rows 48, extending from side to side of the bedding product. As shown in Figs. 5 and 5A, individual pockets 44 of one column 46 are aligned with pockets 44 of adjacent columns 46.

[0080] Fig. 5B illustrates a part of an alternative embodiment of comfort layer 16b. In this embodiment, the fabric material of each of the first and second layers 23, 25 may be a three-layer fabric impervious to air flow. Each fabric layer 23, 25 comprises three layers, including, starting from the inside, moving outward: 1) a protective fabric layer 27; 2) an airtight layer 29; and 3) a sound attenuating or silencing layer 33. More specifically, the protective fabric layer 27 may be a polypropylene non-woven fabric having a density of one ounce per square yard. The airtight layer 29 may be a layer of thermoplastic polyurethane film having a thickness of approximately 1.0 mil (0.001 inches). The sound attenuating layer 33 may be a lofted polyester fiber batt, having a density of 0.5 ounces per square foot. These materials and material specifications, such as the densities provided for the outer layers, have proven to be effective, but are not intended to be limiting. For example, the thickness of the waterproof intermediate layer of thermoplastic polyurethane film can be any desired thickness, depending on the desired characteristics of the multi-layer fabric and the composition of the multi-layer fabric. A middle layer, impervious to airflow, that has proven to work satisfactorily is 2.0 millimeters thick. The fiber blanket layer does not need to be made of polyester; it can be made from other materials. Similarly, the fiber blanket layer does not need to be lofted.

[0081] In any of the embodiments shown or described herein, the fabric material of at least one of the layers may be impervious to air flow through the fabric. Each layer may comprise three layers, including from the inside, moving outward: 1) a layer of 27 polypropylene nonwoven fabric, having a density of approximately one ounce per square yard, commercially available from Atex, Incorporated of Gainesville, Georgia; 2) a layer of polyether 29 thermoplastic polyurethane film, having a thickness of approximately 1.0 mil (0.001 inches), commercially available from American Polyfilm, Incorporated of Branford, Connecticut; and 3) a layer of 33 lofted needle punched polyester fiber batt, having a density of 0.5 ounces per square foot, commercially available from Milliken & Company, of Spartanburg, South Carolina. The intermediate thermoplastic polyurethane film layer 29 is impervious to air flow and can be of any desired thickness. A thickness that has proven to work satisfactorily is 2.0 millimeters. The lofted needle punched polyester fiber blanket layer 33 acts as a sound dampening layer, which silences and muffles the film layer 29, as the springs are released from a load (pressure in the pocket goes from positive to negative) or loaded (pressure in the pocket goes from neutral to positive). The polypropylene non-woven fabric layer 27 keeps the segmented air passages open so that the pocket 44 can “breathe”. Without the polypropylene non-woven fabric layer 27 closest to the springs, the intermediate thermoplastic polyurethane film 29 would seize up on itself and not allow sufficient air to pass through the segmented air passages. The polypropylene non-woven fabric layer 27 closest to the springs would also make the product more durable by protecting the intermediate thermoplastic polyurethane film layer 29 from coming into contact with the spring 28 and from deteriorating through abrasion against the spring 28.

[0082] Heat-activated glue can be placed between the airtight layer 29 and the sound attenuating layer 33. The airtight layer 29 and the sound attenuating layer 33 can then be laminated together by passing them through the activated laminator by heat (not shown). The protective layer 27 may or may not be glue laminated to the other two layers. After passing through the heat-activated laminator, at least two of the three layers can be combined.

[0083] An alternative method for laminating all three layers, without the use of glue, may be to utilize an ultrasonic lamination procedure. This process creates ultrasonic welds in an established pattern across the fabric, thus making the fabric a unitary three-layer piece of material.

[0084] Figs. 6 and 6A illustrate another comfort layer 50 having the same pockets 44 and the same springs 28 as the comfort layer 16 of Figs. 1-5A. As best illustrated in Fig. 6, the individual pockets 44 of comfort layer 50 are arranged in longitudinally extending columns, extending from the head to the foot of the bedding product, and transversely extending rows 54, extending from side to side of the bed. bedding product. As shown in Figs. 6 and 6A, individual pockets 44 of one column 52 are offset from pockets 44 of adjacent columns 52 rather than aligned.

[0085] Fig. 7 illustrates an alternative embodiment of the comfort layer 56 incorporated into a one-sided mattress 60. The one-sided mattress 60 comprises a pocket spring core 62, a cushioning pad 14 on top of the pocket spring 62, a base 18, another cushioning pad 14 above the comfort layer 56, and a cover 20, such as an upholstered cover. The pocket spring core 62 may be incorporated into any bed or seat product, including a two-sided mattress, and is not intended to be limited to single-sided mattresses. As described above, the comfort layer 56 can be used in any bed or seat product, including a spring core made with non-pocket springs, such as coil springs.

[0086] As shown in Fig. 7, the mattress 60 has a longitudinal dimension or length L, a transverse dimension or width W, and a height H. Although the length L is shown to be greater than the width W, they can be identical. The length, width and height may be any desired distance and are not intended to be limited by the drawings.

[0087] Fig. 9 illustrates the components of the comfort layer 56 incorporated into the mattress 60 shown in Fig. 7. The comfort layer 56 comprises a first fabric layer 64 and a second fabric layer 66 joined with linear weld seams or straight 70, each weld seam 70 comprising multiple linear weld segments 68. These weld seams 70 are strategically placed around a mini helical spring 28 and create a rectangular containment or pocket 84 made from the intersecting weld seams 70 During the welding process, the mini helical springs 28 may be compressed. The length and/or width of the linear weld segments 68 of the weld seams 70 are not intended to be limited to those illustrated; the weld segments can be any desired size depending on the desired airflow through the comfort layer.

[0088] Similarly, the shape, as well as the size, of the weld seams of any of the weld seams shown or described in this document are not intended to be limiting. Weld segments of shapes other than linear 68 may be used to create weld seams 70, as well as any weld seams shown or described herein. For purposes of this document, “weld segment” is not intended to be limited to linear segments. A “weld segment” of a weld seam is intended to include such shapes as triangles or circles or ovals of any desired size or pattern, to obtain the desired air flow between adjacent pockets and into or out of the perimeter of the weld. comfort layer.

[0089] With reference to Fig. 9, a part of an ultrasonic welder 72 and anvil 74 is illustrated. The mobile or mobile ultrasonic welder 72 has a plurality of spaced cutouts or slots 76 between the projections 80. The projections 80 of the ultrasonic welder 72 are the parts that weld the two pieces of fabric 64, 66 together and create the linear weld segments 68 along the weld seams 70. Along the bottom of the ultrasonic welder 78, the ultrasonic welder 72 may be milled, to allow a desired airflow between the linear weld segments 68, as illustrated by arrows 82 of Fig. 7. The airflows affect the sensation/compression of the individually pocketed mini helical springs 28, when a user lies on the mattress 60.

[0090] As shown in Fig. 9, beneath the second layer 66 is an anvil 74, comprising a 3/8 inch thick steel plate. However, the anvil can be of any desired thickness. During the manufacturing process, the ultrasonic welder 72 comes into contact with the anvil 74, the two fabric layers 64, 66 being therebetween, to create the intersecting linear weld seams 70 and, consequently, pockets 84, at least a spring 28 being in each pocket 84. See Figs. 10 and 10A.

[0091] These linear weld segments 68 can be created by the welder 72 of a machine (shown in Fig. 8 and described below) having multiple spaced protrusions 80 on the ultrasonic welder 72. As a result of these linear or straight intersecting weld seams 70 defining the spring-containing pockets 84 of the comfort layer 56, each mini helical spring 28 is contained within its own individual pocket 84. Air exits the pocket 84 through the openings 77 between the weld segments 68 of the intersecting weld seams 70 Similarly, when a load is removed from the pocket 84, the mini helical spring 28 separates the fabric layers 64, 66 and air re-enters the pocket 84 through the openings 77 between the weld segments 68 of the intersecting weld seams 70 As shown in Fig. 10, the size of the openings 77 between the segments 68 of intersecting weld seams 70 of the pockets 84 defines how quickly air can enter or leave the pockets 84 of the comfort layer 56.

[0092] Fig. 9A illustrates another apparatus for forming linear weld seams 70, each weld seam 70 comprising multiple linear weld segments 68 having openings 77 therebetween for airflow. In this apparatus, the ultrasonic welder 72a does not have protrusions on its lower surface 79. Instead, the lower surface 79 of the ultrasonic welder 72a is smooth. The anvil 74a has a plurality of linear projections 71, which together form a projection pattern 73, shown in Fig. 9A. A plurality of closely spaced projections 71 in pattern 73 extend upwardly from the generally flat upper surface 75 of the anvil 74a. When the ultrasonic welder 72a moves downward and presses the layers 64, 66 of fabric between the projections 71 and the smooth bottom surface 79 of the ultrasonic welder 72a, intersecting weld seams 70 are created. Thus, a plurality of pockets 84 are created by the intersecting weld seams 70, each pocket 84 containing at least one mini helical spring 28.

[0093] In some embodiments, the fabric material defining the pockets 84 and enclosing the mini helical springs 28 therein is non-permeable to air flow. When subjected to a load, these pockets 84 (with mini helical springs 28 therein) are compressed, causing the air contained within the pockets 84 to move between the pockets 84, as shown by arrows 82 of Figs. 10 and 11A, until air exits the peripheral pockets 84 into the atmosphere, as shown in Fig. 11A. Due to such fabric material being impervious to air, the rate at which the mini springs 28 compress when a load is applied to the pocket spring core comfort layer 56 containing the mini helical springs 28 is slowed or slowed by the size of the openings. 77 between the linear weld segments 68 of intersecting weld seams 70. Upon removal of the load, the rate of return of the spring comfort layer 56 to its original height depends on the mini helical springs 28 in the pockets 84 returning to its original height , causing separation of the fabric layers, drawing air into the pockets 84 through the openings 77 between the linear weld segments 68 of intersecting weld seams 70.

[0094] In other embodiments, the fabric material is semi-impermeable to airflow, and some air passes through the fabric. The rate at which the mini-springs 28 compress when a load is applied to a pocket spring core comfort layer 56 is slowed or slowed by the air trapped within the individual pockets 84, since the pocket spring comfort layer 56 is compressed and, similarly, the rate of return of the compressed coil spring comfort layer 56 to its original height after compression is slowed or slowed by the rate at which air can pass through the semi-impermeable fabric material to within the interior of the individual pockets 84 of the pocket spring comfort layer 56. In these embodiments, air passes through the openings 77 between the weld segments 68 of the weld seams 70, as described above with respect to embodiments having non-permeable fabric. However, in addition, some air passes through the fabric, both when pocket 84 is compressed and when pocket 84 is expanded due to the spring(s) therein.

[0095] In accordance with the practice of this invention, an airflow semi-impermeable fabric material, which can be used in either of the two layers of the pocket spring comfort layers disclosed or shown herein, can be a material of multiple layers, including a fabric layer, such as a material available from Hanes Industries of Conover, North Carolina, under the product name Eclipse 540. In testing, using a loaded 13.5-inch disk plate with a weight of 25 pounds, six locations on a queen size mattress were tested, to determine the time required for the mini pocket coil springs to form a comfort layer having welded seams in the rectangular shape, made with the multi-layer fabric material described above, compress to half the distance of their initial height. Once the weight of the sheet was removed, the time for the comfort layer's mini pocket helical springs to return to their initial height was measured. Using this test method, the average compression rate was 0.569 inches per second, and the average recovery rate was 0.706 inches per second. These averages are not intended to be limiting. These averages may be dependent on the type(s) of layer material(s) and/or the size and shape of the weld segments comprising the weld seams which, in turn, may vary the compression rate and recovery rate due to the air flow. Such variables can be adjusted/changed to achieve variations in the feel and comfort of the final product.

[0096] In an air permeability test known in the industry as ASTM Standard D737, 2004 (2012), “Standard Test Method for Air Permeability of Textile Fabrics”, ASTM International, West Conshohocken, PA 2010, the air flow through of the multi-layer semi-impermeable material available from Hanes Industries, of Conover, North Carolina, described above was measured. Results varied between 0.029-0.144 cubic feet per minute.

[0097] Alternatively, the fabric material of the first and second layers of any of the embodiments shown or disclosed herein may be material disclosed in US Patents 7,636,972; 8,136,187; 8,474,078; 8,484,487 and 8,464,381, each of which is fully incorporated herein. In accordance with the practice of this invention, this material may have one or more coatings of acrylic or other suitable material sprayed onto or roller-coated onto one side of the fabric, to render the fabric semi-impermeable to air flow, as described above.

[0098] Fig. 10B illustrates a part of an alternative embodiment of the comfort layer 56b. In this embodiment, the fabric material of each of the first and second layers 65, 67 may be the same as the airflow impermeable three-layer fabric shown in Fig. 5B and described above. This airflow impervious three-layer fabric may be used in any embodiment shown or described herein, including for any pocket spring core. Each fabric layer 65, 67 comprises three layers, including, from the inside moving outward: 1) a protective fabric layer 27; 2) an airtight layer 29; and 3) a sound attenuating or silencing layer 33. If desired, the protective fabric layer 27 can be omitted. More specifically, the protective fabric layer 27 may be a polypropylene non-woven fabric having a density of one ounce per square yard. The airtight layer 29 may be a layer of thermoplastic polyurethane film having a thickness of approximately 1.0 mil (0.001 inch). The sound attenuating layer 33 may be a lofted polyester fiber batt having a density of 0.5 ounces per square foot. These materials and material specifications, such as the densities provided for the outer layers, have proven to be effective, but are not intended to be limiting. For example, the thickness of the airflow-impermeable intermediate layer 29 may vary depending on the desired characteristics of the multilayer fabric. The fiber blanket does not have to be made of polyester; it can be made from other materials. Similarly, the fiber blanket layer does not need to be lofted.

[0099] In any of the embodiments shown or described herein, the fabric material of at least one of the layers may be impervious to air flow through the fabric. Each layer may comprise three layers, including, from the inside moving outward: 1) a layer of 27 polypropylene nonwoven fabric, having a density of approximately one ounce per square yard, commercially available from Atex, Incorporated, of Gainesville, Georgia ; 2) a layer of thermoplastic polyether 29 polyurethane film, having a thickness of approximately 1.0 mil (0.001 inch), commercially available from American Polyfilm, Incorporated, of Branford, Connecticut; and 3) a layer of 33 lofted needle punched polyester fiber batt, having a density of 0.5 ounces per square foot, commercially available from Milliken & Company, of Spartanburg, South Carolina. The intermediate thermoplastic polyurethane film layer 29 is impervious to air flow. The lofted needle punched polyester fiber blanket layer 33 acts as a sound dampening layer, which silences and muffles the film layer 29, once the springs are released from a load (pressure in the pocket goes from positive to negative) or loaded (pressure in the pocket goes from neutral to positive). The polypropylene non-woven fabric layer 27 keeps the segmented air passage open such that the pocket 84 can “breathe”. Without the layer of polypropylene non-woven fabric 27 closest to the springs 28, the intermediate thermoplastic polyurethane film 29 would seize up on itself and not allow sufficient air to pass through the segmented air passages. The polypropylene non-woven fabric layer 27 closest to the springs 28 also makes the product more durable by protecting the intermediate thermoplastic polyurethane film layer 29 from coming into contact with the spring 28 and from deteriorating through abrasion against the spring 28 .

[00100] Heat-activated glue may be placed between the hermetic layer 29 and the sound-attenuating layer 33. In some applications, additional heat-activated glue may be placed between the hermetic layer 29 and the protective layer 27. At least two layers can then be laminated together by passing them through a heat-activated laminator (not shown). The protective layer 27 may remain independent of the other two layers after passing through the laminator. However, in some processes, after passing through the heat-activated laminator, all three layers can be combined and form one of the fabric layers. An alternative method to laminate all three layers may be to utilize an ultrasonic lamination procedure. This process creates ultrasonic welds in an established pattern across the fabric, thus making it a piece or layer of material.

[00101] As best illustrated in Fig. 10, the individual pockets 84 of the comfort layer 56 may be arranged in longitudinally extending columns 86, extending from the head to the foot of the bedding product, and transversely extending rows 88, extending from side to side of the bedding product. As shown in Figs. 10 and 10A, individual pockets 84 of one column 86 are aligned with pockets 84 of adjacent columns 86. Air can flow between the pockets 84 and into and out of the comfort layer 56 between the linear segments 68 of the seams. of welding 70.

[00102] Fig. 11 illustrates a corner of the comfort layer 16 of the mattress 10, showing airflow between the curved weld segments 26 of the peripheral pockets 44, as illustrated by arrows 40. Although Fig. 11 illustrates arrows 40 only in a corner pocket 44, each of the pockets 44 around the periphery of the comfort layer 16 allows airflow through the openings 31 between the weld segments 26 of the circular seams 30. This airflow controls the amount of air entering the comfort layer 16 when a user changes position, or leaves the bed or seat product, thereby allowing the springs 28 in the pockets 44 to expand and air to flow into the comfort layer 16. Similarly, when a user climbs onto a bed or seat product, the springs 28 compress and cause air to exit the pockets 44 around the periphery of the comfort layer 16 and exit the comfort layer. The amount of air leaving the comfort layer 16 affects the feel/compression of the individually pocketed mini coil springs 28 when a user lies on the mattress 10.

[00103] Fig. 11A illustrates a corner of the comfort layer 56 of the mattress 60 of Fig. 7, showing air flow between the weld segments 68 of the peripheral pockets 84, as illustrated by arrows 82. Although Fig. 11A illustrate the arrows 82 only in a corner pocket 84, each of the pockets 84 around the periphery of the comfort layer 56 allows air flow through the openings 77 between the weld segments 68 of intersecting weld seams 70. This flow control the amount of air entering the comfort layer 56 when a user changes position or leaves the bed or seat product, thereby allowing the springs 28 in the pockets 84 to expand and air to flow into the comfort layer 84. comfort 56. Similarly, when a user changes position or enters a bed or seat product, springs 28 compress and cause air to exit pockets 84 around the periphery of comfort layer 16 and exit the comfort layer . The amount of air exiting the comfort layer 56 affects the feel/compression of the individually pocketed mini coil springs 28 when a load is applied to the mattress 10.

[00104] Fig. 12 illustrates a corner of an alternative embodiment of the comfort layer 16a, which can be used in any bed or seat product. The comfort layer 16a comprises aligned rows 48 and columns 46 of pockets 44a, each pocket 44a comprising a circular seam 30a joining the upper and lower layers of fabric as described above. However, each of the circular seams 30a is a continuous seam, as opposed to a seam having curved weld segments, with openings therebetween, to allow airflow through the circular seam. These circular seams 30a of the pockets 44a allow no air flow through the seams 30a. Therefore, the fabric material of the first and second layers of pockets 44a of the comfort layer 16a must be made of semi-impermeable material, to manage or control the flow of air into and out of the pockets 44a of the comfort layer 16a. The type of material used for the comfort layer 16a only controls the amount of air entering the comfort layer 16a when a user leaves the bed or seat product, thereby allowing the springs 28 in the pockets 44a to expand and the air flows into the comfort layer 16a. Similarly, when a user climbs onto a bed or seat product, the springs 28 compress and cause air to exit the pockets 44a of the comfort layer 16a and exit the comfort layer. The amount of air exiting the comfort layer 16a affects the sensation/compression of the individually pocketed mini helical springs 28 when a user lies on the product incorporating the comfort layer 16a.

[00105] Fig. 12A illustrates a corner of an alternative embodiment of comfort layer 56a, which can be used in any bed or seat product. The comfort layer 56a comprises aligned rows 88 and columns 86 of pockets 84a, each pocket 84a comprising intersecting weld seams 70a joining the upper and lower layers of fabric as described above. However, each of the intersecting weld strings 70a is a continuous seam, as opposed to a seam having weld segments with openings therebetween to allow airflow through the seam. These intersecting weld seams 70a of the pockets 84a allow no airflow through the weld seams 70a. Therefore, the fabric material of the first and second layers of pockets 84a of the comfort layer 56a must be made of semi-impermeable material, to allow some airflow into and out of the pockets 84a of the comfort layer 56a. The type of material used for the comfort layer 56a only controls the amount of air entering the comfort layer 56a when a user leaves the bed or seat product, thereby allowing the springs 28 in the pockets 84a to expand and the air flows into the comfort layer 56a. Similarly, when a user climbs onto the bed or seat product, the springs 28 compress and cause air to exit the pockets 84a of the comfort layer 56a and exit the comfort layer. The amount of air exiting the comfort layer 56a affects the feel/compression of the individually pocketed mini helical springs 28 when a user lies on the product incorporating the comfort layer 56a.

[00106] Fig. 2 illustrates a machine 90 used to make several of the comfort layers shown and disclosed in this document, including the comfort layer 16 shown in Fig. 1. Some parts of the machine 90 can be changed to make other layers of comfort shown or described herein, such as the comfort layer 56 shown in Fig. 7. The machine 90 comprises a pair of ultrasonic welders 32, and at least one stationary anvil 42, as shown in Fig. 4. Alternatively, the welders ultrasonic sensors 32a and anvil 42a in Fig. 4A can be used in the machine.

[00107] The machine 90 reveals a conveyor 92, onto which the multiple mini helical springs 28 are loaded. The conveyor 92 moves the mini helical springs 28 in the direction of the arrow 94 (to the right, as shown in Fig. 2), until the mini helical springs 28 are located in predetermined locations, at which time the conveyor 92 stops moving. Machine 90 further discloses a plurality of drives 96, which move a pusher assembly 97, including a pusher plate 98, in the direction of arrow 100. Although two drives 96 are illustrated in Figs. 2 and 2A, any number of actuators 96, of any desired configuration, may be used to move the pusher assembly 97. The pusher plate 98 has a plurality of closely spaced spring pushers 102, attached to the pusher plate 98, beneath the pusher plate. 98. Spring pushers 102 push mini helical springs 28 between stationary guides 104, from a first position shown in Fig. 2 to a second position shown in Fig. 4, wherein mini helical springs 28 are located above stationary anvil 42 (or above the alternative anvil 42a shown in Fig. 4A). Fig. 2A illustrates mini helical springs 28 being transported from the first position to the second position, each mini helical spring 28 being transported between adjacent stationary guides 104. The stationary guides 104 are secured to a stationary mounting plate 106.

[00108] The machine 90 further comprises a compression plate 108, which is movable between raised and lowered positions by elevators 110. Although two elevators 110 are illustrated in Figs. 2 and 2A, any number of elevators 110 of any desired configuration may be used to move the compression plate 108.

[00109] As best shown in Fig. 2, the machine 90 further comprises three presses 112 movable between the raised and lowered positions, by means of the actuators 116. Figs. 3B and 3C show one of the presses 112 in an elevated position, while Figs. 3A, 3D and 3E show the press in a lowered position. Each press has a blade 114 at the bottom thereof, for joining layers 22, 24 of fabric, when the press is lowered, as shown in Figs. 3A, 3D and 3E.

[00110] As best shown in Fig. 3A, the machine 90 further comprises rollers 120, 122, around which layers 22, 24, respectively, pass before coming together. After the circular seams 30 are created by the ultrasonic welder 32 and anvil 42, thereby creating the pockets 44, a main roller 116 and secondary roller 118 pull the continuous spring blanket 124 downward. Once a desired amount of continuous spring blanket 124 is made, a blade 126 cuts the continuous spring blanket 120 to create the comfort layer 16 of the desired size. Of course, the machine 90 can be programmed to create the desired length and width of the comfort layer. This machine 90 is adapted to make any of the comfort layers shown or disclosed herein having circular weld seams.

[00111] Fig. 3A illustrates the ultrasonic welder 32 in a lowered position bringing the stationary anvil 42 into contact with at least one of the presses 112 in a lowered position, pressing the upper layer 22 into contact with the lower layer 24. A new row of mini helical springs 28 has been moved to a loading position with the compression plate 108 in its raised position.

[00112] Fig. 3B illustrates the ultrasonic welder 32 in an elevated position, spaced from the anvil 42 with at least one of the presses 112 in an elevated position. The compression plate 108 is moved to its lowest position by the elevators 110, thereby compressing the row of mini helical springs 28 located on the conveyor 92.

[00113] Fig. 3C illustrates the row of compressed mini helical springs 28 located on the conveyor 92 being pushed downstream towards the ultrasonic welder 32 and stationary anvil 42 by the pusher assembly 97. More particularly, the pushers 102 attached to the pusher plate 98 contact the compressed mini helical springs 28 and move them downstream between the stationary guides 104 and beyond the elevated presses 112.

[00114] Fig. 3D illustrates the pusher assembly 97 being moved away in the direction of arrow 128. Additionally, the presses 112 are moved to a lowered position, pressing the upper layer 22 into contact with the lower layer 24. Additionally, the plate compression 108 is moved to its elevated position by elevators 110.

[00115] Fig. 3E illustrates the ultrasonic welder 32 in a lowered position, placing the stationary anvil 42 in contact with at least one of the presses 112 in a lowered position, pressing the upper layer 22 into contact with the lower layer 24. A The new row of mini helical springs 28 has been moved by the conveyor 92 to a position where they can be compressed with the compression plate 108 during the next cycle.

[00116] Fig. 8 illustrates a machine 130, like the machine 90 shown in Figs. 2 and 2A. However, instead of having two ultrasonic welders 32, the machine 130 has four ultrasonic welders 72 together with the anvil 74. Alternatively, the ultrasonic welders 72a and anvil 74a of Fig. 9A can be used in the machine 130. This machine 124 is adapted to make any of the comfort layers shown or disclosed herein having intersecting linear weld seams, as opposed to circular weld seams.

[00117] Fig. 13A illustrates a posturized comfort layer 132, having three different areas or regions of firmness, depending on the air flow within each of the areas or regions. The comfort layer 132 has a head section 134, a foot section 136, and a lumbar or intermediate section 138 therebetween. The size and number of segments in the seams, along with the type of material used to construct the posturized comfort layer 132, may be selected so that at least two of the sections may have a different firmness due to different airflows within the seams. different sections. Although three sections are illustrated in Fig. 13A, any number of sections can be incorporated into a posturized comfort layer. Although each of the sections is illustrated as being a certain size, they can be other sizes. The drawings are not intended to be limiting. Although Fig. 13A shows each of the segmented weld seams of the comfort layer 132 being circular, a posturized comfort layer, such as that shown in Fig. 13A, may have intersecting linear weld seams.

[00118] Fig. 13B illustrates a posturized comfort layer 140 having two different areas or regions of firmness, depending on the airflow within each of the areas or regions. The comfort layer 140 has a first section 142 and a second section 144. The size and number of segments in the seams, along with the type of material used to construct the posturized comfort layer 140, can be selected so that at least two sections may have different firmness due to different airflows within the different sections. Although two sections are illustrated in Fig. 13B, any number of sections can be incorporated into a posturized comfort layer. Although each of the sections is illustrated as being a certain size, they can be other sizes. The drawings are not intended to be limiting. Although Fig. 13B shows each of the segmented seams of the comfort layer 140 being circular, a posturized comfort layer, such as that shown in Fig. 13B, may have intersecting linear weld seams.

[00119] Fig. 14 illustrates a part of an alternative embodiment of the comfort layer 56c. In this embodiment, the fabric of each of the first and second layers 65, 67 may have the same airflow-impermeable three-layer fabric shown in Figs. 5B and 10B and described above. However, any of the fabrics described in this document can be used in this embodiment.

[00120] As best illustrated in Fig. 14, the individual pockets 84c of the comfort layer 56c may be arranged in longitudinally extending columns 86, extending from the head to the foot of the bedding product, and transversely extending rows 88, extending from side to side of the bedding product. As shown in Figs. 14 and 14A, individual pockets 84c of one column 86 are aligned with pockets 84c of adjacent columns 86.

[00121] Air flows between the pockets 84c and into and out of the comfort layer 56c through the openings 83 between the linear segments 81 of the weld seams 70c. Segments 81 of weld seams 70c are longer than other segments of other weld seams shown herein. One purpose of the longer segments 81 of the weld seams 70c is for air to flow between the pockets 84c at the corners of the pockets 84c, as represented by arrows 85. The segments 81 of the weld seams 70c join the first and second layers 65, 67 of the fabric, so that air does not flow between them. Thus, air flows between pockets 84c only at the corners of pockets 84c, as represented by arrows 85. The desired amount of air flow between pockets 84c can be achieved by projecting openings 83 between segments 81 of 70c weld seams to a desired size.

[00122] Figs. 15, 15A, 15B and 15C illustrate another aspect of the present invention, which is present along each of the weld seams shown or described herein, regardless of the size and shape of the weld seam and regardless of the size and shape of the weld segments. welding seam.

[00123] This aspect of the invention is illustrated with respect to a comfort layer 56d, a portion of which is shown in Fig. 15. In this embodiment, the fabric of each of the first and second layers 89, 91 may be the same airflow-impermeable three-layer fabric shown in Figs. 5B and 10B and described above. However, any of the fabrics described in this document can be used in this embodiment.

[00124] As best illustrated in Fig. 15, the individual pockets 84d of the comfort layer 56d may be arranged in longitudinally extending columns 86, extending from the head to the foot of the bedding product, and transversely extending rows 88, extending from side to side of the bedding product. As shown in Fig. 15, individual pockets 84d of a column 86 are aligned with pockets 84d of adjacent columns 86. Likewise, individual pockets 84d of a row 88 are aligned with pockets 84d of adjacent rows 88.

[00125] As shown in Figs. 15A, 15B and 15C, comfort layer 56d comprises two fabric layers 89, 91 joined along linear segments 68 of intersecting linear weld seams 70, thereby creating pockets 84d, at least one spring 28 being in each pocket 84d. Air flows through pockets 84d through openings 77, between linear weld segments 68, as illustrated by arrows 87 of Fig. 15. Airflows affect the feel/compression of the individually pocketed mini helical springs 28, when a user lies on a mattress or seating product having at least a 56d comfort layer as described above.

[00126] In this embodiment, the fabric of each of the first and second layers 89, 91 may be the same airflow impermeable three-layer fabric shown in Figs. 5B and 10B and described above. However, any of the fabrics described in this document can be used in this embodiment.

[00127] For the purposes of this document, the openings 77 of the weld seams 70 of the comfort layer 56d can be considered valves that change size depending on the load placed on the pockets 84d of the comfort layer 56d or removed from the pockets 84d of the 56d comfort layer to control airflow as described below. The openings 77 of the weld seams 70 function as valves in controlling the flow of air into and out of the pockets 84d of the comfort layer 56d, without any material or apparatus other than the multi-layer fabric of the layers 89, 91 of the 56d comfort layer. The construction of the comfort layer 56d has valves inherent there, between the seam segments, the valves controlling the flow of air into and out of the pockets 84d of the comfort layer 56d depending on the size of the openings and seam segments, a( s) load(s) placed on the comfort layer 56d and the material composition of the fabric of layers 89, 91 of the comfort layer 56d, among other factors.

[00128] Fig. 15A shows a pocket 84d of the comfort layer 56d, without any load placed on the pocket 84d. Pocket 84d is in a relaxed condition. Air is not flowing through the openings 77 of the weld seams 70 of the pocket 84d. The air pressure within the pockets 84d is at atmospheric pressure, at room temperature, so that the valves 77 are in a relatively restricted, that is, relatively flat, state. The opposing layers 89, 91 of fabric of the openings 77 of the weld seams 70 may be in contact with each other or very close to each other. See Fig. 15A.

[00129] Fig. 15B shows pocket 84d with a light load placed over pocket 84d, as indicated by arrows 146. Once a light load is placed over pocket 84d, at least some of the seam valves or openings 77 weld seams 70 surrounding the pocket 84d open slightly so that air flows through at least some of the openings 77 of the weld seams 70 of the pocket 84d.

[00130] Fig. 15C shows pocket 84d with a heavier load placed over pocket 84d, as indicated by the four arrows 148. Since a wider or larger load is placed over pocket 84d, at least some of the valves or openings 77 of the weld seams 70 open further so that more air flows through at least some of the openings 77 of the weld seams 70 of the pocket 84d. For the purposes of this document, the term “open” means to increase in width. Therefore, when a valve or opening 77 opens, it increases in width.

[00131] If a load is applied to the pocket 84d that is significantly greater than the load required to open the valves 77 of the weld seams 70, the fabric material of the pocket 84d will elastically stretch and open further to allow more air passes through valves or openings in the weld seams. Thus, the valves react to the specific load applied. Such a reaction contributes to the unique luxurious feeling of a comfort layer made in accordance with the present invention.

[00132] In the event that the layers are made of the multi-layer fabric disclosed herein, the ability of the valves to stretch and react to air pressure is largely due to the intermediate thermoplastic polyurethane film layer. The middle thermoplastic polyurethane film layer is a relatively elastic material, which returns to its original shape after a load is removed. When a load is released, the valves return to their original condition, which is a relatively restricted state in which the air pressure inside the pockets is atmospheric pressure, at room temperature.

[00133] While I have described the various preferred embodiments of this invention, persons skilled in this art will appreciate that other semi-impermeable and non-permeable fabric materials may be used in the practice of this invention. Similarly, such persons will appreciate that each pocket can contain any number of coil springs or other type of spring, made of any desired material. Persons skilled in the art may further appreciate that segments of the weld seams may be sewn, glued or otherwise adhered or bonded. Therefore, I do not intend it to be limited except by the scope of the following attached Claims.

Claims (30)

1. Comfort Layer, configured to overlay spring core of bed product or seat cushion, said comfort layer comprising: an array of interconnected mini pocket springs, each mini coil spring of which is contained within a fabric pocket between the first and second pieces of fabric, each of said pieces of fabric comprising multiple layers and being impervious to air flow, each pocket having weld seams comprising linear weld segments joining the first and second pieces of fabric of the pocket , each weld seam having openings between the linear weld segments through which air can flow between adjacent pockets at the corners of the pockets; characterized in that when a load is placed on the comfort layer, the compression rate of at least some of the mini coil springs within some of the pockets of the comfort layer being slowed by the rate at which air escapes through openings, the Compression rate of mini coil springs is slowed by the size of the openings. 2. Comfort Layer, according to Claim 1, characterized in that at least one of the fabric pieces comprises three layers. 3. Comfort Layer, according to Claim 1, characterized in that each of the fabric pieces comprises three layers. 4. Comfort Layer, according to Claim 1, characterized in that said linear weld segments are of the same size. 5. Comfort Layer, configured to overlay bed or seat product spring core, said comfort layer comprising: an array of mini coil springs; a first piece of fabric on one side of the mini coil spring array; a second piece of fabric on the other side of the mini coil spring array, the first and second piece of fabric being joined with weld seams around each of the mini coil springs to create individual pockets containing the mini coil springs, each one of the fabric pieces comprising multiple layers and being impervious to air flow, each of the weld seams comprising linear weld segments with openings therebetween at the corners of the weld seams; characterized in that when at least some of the mini coil springs in at least some of the pockets are subjected to an air load that moves between the pockets through the openings between the linear weld segments of the weld seams and exits the perimeter pockets into the atmosphere, the compression rate of the mini helical springs is slowed by the size of the gaps between the linear weld segments of the weld seams. 6. Comfort Layer, according to Claim 5, characterized in that each of the fabric pieces comprises three layers. 7. Comfort Layer, according to Claim 5, characterized in that at least one of the fabric pieces comprises three layers. 8. Comfort Layer, according to Claim 5, characterized in that said linear weld segments are of the same size. 9. Comfort Layer, according to Claim 5, characterized in that each of the fabric pieces comprises at least one airtight layer. 10. Comfort Layer, configured to overlay bed or seat product spring core, said comfort layer comprising: mini coil springs; a first piece of fabric on one side of the mini helical springs; a second piece of fabric on the other side of the mini coil springs, the first and second pieces of fabric being joined with weld seams comprising linear weld segments around each of the mini coil springs to create individual pockets containing the mini coil springs helical, each pocket having openings between adjacent linear weld segments at the corners of the pocket and each of the fabric pieces comprising multiple layers including at least one air flow impermeable layer, characterized in that when at least some of the pockets are subjected to a charge of air that moves between the pockets through the openings between the first and second pieces of fabric, the compression rate of the mini coil springs is slowed by the size of the openings between the linear weld segments of the weld seams. 11. Comfort Layer, according to Claim 10, characterized in that each of the fabric pieces includes a sound attenuating layer. 12. Comfort Layer, according to Claim 10, characterized in that each of the fabric pieces comprises three layers. 13. Comfort layer according to Claim 10, characterized in that each of the fabric pieces comprises at least one layer of non-woven material. 14. Comfort Layer, according to Claim 10, characterized in that at least one of said first and second layers of fabric has three layers. 15. Comfort Layer according to Claim 10, characterized in that at least some of said mini coil springs have a barrel shape. 16. Comfort Layer, according to Claim 10, characterized in that said linear weld segments are of the same size. 17. Comfort Layer, according to Claim 14, characterized in that said three layers comprise a protective layer, an airflow impervious layer and a sound attenuation layer. 18. Comfort Layer, according to Claim 17, characterized in that said protective layer comprises a non-woven polypropylene material. 19. Comfort Layer, according to Claim 17, characterized in that said layer impervious to air flow comprises a layer of thermoplastic polyurethane film. 20. Comfort Layer, according to Claim 17, characterized in that said sound attenuation layer comprises a fiber layer. 21. Method for Manufacturing Comfort Layer, for bed or seat product, which comfort layer is composed of slow and gentle compression, when a load is applied to the product, the method comprising: forming a continuous blanket of individually bagged mini helical springs , each of the individually bagged mini coil springs containing a mini coil spring contained within an individual pocket of fabric, the individual pocket being formed by joining together several pieces of fabric with linear welded seams that intersect around one of the mini springs helical, with each piece of fabric being impervious to airflow through the fabric, with opposing pieces of fabric being joined along linear weld segments with openings between adjacent linear weld segments; and cutting the continuous blanket of individual mini pocket coil springs to a desired size to create a comfort layer, characterized in that when a load is placed on the comfort layer, the rate of deflection of the comfort layer being retarded by the rate in As air passes through the openings of the linear weld seams without passing through the fabric pieces, the openings enlarge as they are subjected to load, allowing air to exit the comfort layer pockets at a desired rate. 22. Method for manufacturing comfort layer, according to Claim 21, characterized in that the comfort layer further consists of the recovery rate of the comfort layer to its original height, after removal of the load from the comfort layer being delayed by rate at which air returns between segments of the weld seams to the pockets, the openings decreasing in width upon removal of the load, allowing air to enter the comfort layer pockets at a desired rate only through the openings. 23. Method for manufacturing comfort layer, according to Claim 21, characterized in that the weld seams are configured to allow air to pass through the openings between the segments of the weld seams at a desired rate. 24. Method for manufacturing comfort layer, according to Claim 21, characterized in that the fabric is a three-layer fabric. 25. Method for Manufacturing Comfort Layer, for bed or seat product, the comfort layer of which is composed of slow and gentle compression, when a load is applied to the product, the method comprising: forming a continuous blanket of individually bagged mini helical springs , each of the individually bagged mini coil springs comprising a mini coil spring contained within an individual pocket of fabric, the fabric pocket being formed by joining together several pieces of fabric with intersecting linear welded seams around one of the mini springs helical springs, each of the fabric pieces comprising multiple layers, at least one of the layers being impervious to airflow, the opposing fabric pieces being joined along linear weld segments to create individual pockets around each mini helical spring with openings between adjacent linear weld segments; and cutting the continuous blanket of individual mini pocket coil springs to a desired size to create a comfort layer, characterized in that when a load is placed on the comfort layer, the rate of deflection of the comfort layer being retarded by the rate in As air passes through the openings of the linear weld seams without passing through the fabric pieces, the openings widen as they are subjected to load, allowing air to exit the comfort layer pockets at a desired rate only through the gaps. 26. Method for manufacturing comfort layer, according to Claim 25, characterized in that the comfort layer further consists of the rate of recovery of the comfort layer to its original height after removal of the load from the comfort layer being retarded by the rate in which air returns between segments of the weld seams to the pockets, the openings decreasing in width as the load is removed, allowing air to enter the comfort layer pockets at a desired rate only through the openings without passing through the parts of fabric. 27. Method for manufacturing comfort layer, according to Claim 26, characterized in that the weld seams are configured to allow air to pass through the openings between the segments of the weld seams at a desired rate. 28. Method for Manufacturing Comfort Layer, for bed or seat product, which comfort layer is composed of slow and gentle compression, when a load is applied to the product, the method comprising: forming a continuous blanket of individually bagged mini helical springs , each of the individually bagged mini coil springs comprising a mini coil spring contained within an individual pocket of fabric, the fabric pocket being formed by joining together several pieces of fabric with intersecting linear weld seams surrounding one of the mini coil springs , each of the fabric pieces comprising multiple layers, at least one of the layers being impervious to airflow, the opposing fabric pieces being joined along linear weld segments with openings between adjacent linear weld segments; and cutting the continuous blanket of individual mini pocket coil springs to a desired size to create a comfort layer, characterized in that when a load is placed on the comfort layer, the rate of deflection of the comfort layer being retarded by the rate in which air passes through the openings of the linear weld seams without passing through the fabric pieces, the openings widen as they are subjected to load, allowing air to exit the comfort layer pockets at a desired rate only through the openings, where the heavier the load, the wider the openings. 29. Method for manufacturing comfort layer, according to Claim 28, characterized in that the comfort layer further consists of the rate of recovery of the comfort layer to its original height after removal of the load from the comfort layer being retarded by the rate in which air returns between segments of the weld seams to the pockets, the openings decreasing in width as the load is removed, allowing air to enter the comfort layer pockets at a desired rate only through the openings without passing through the parts of fabric. 30. Method for manufacturing comfort layer, according to Claim 26, characterized in that the weld seams are configured to allow air to pass through the openings between the segments of the weld seams at a desired rate.