Modular pocketed spring construction

Abstract

The article disclosed, with method for its manufacture, is a pocketed-spring construction made by joining juxtaposed subassemblies or modules formed by the interconnection of two rows of pocketed springs at intervals of two springs or more according to the resistance to compression desired. Various module joinder techniques are shown and described.

What is claimed is:  
     
         1 . An innerspring construction comprising: 
 a continuous double row of pocketed springs comprising two connected strings of pocketed springs wherein each string includes a plurality of compartments defined between layers of a fabric strip by spaced transverse seams which also define a connecting web of fabric between successive compartments;    each of said compartments having therein a spring which is axially transverse to said strip and axially parallel to and coextensive with the other springs of said double row;    said two strings being joined together at intervals therealong;    said double row of springs having therein a connected series of modules of equal numbers of springs defined by the regular occurrence therealong of two four-spring clusters centered upon successive interstring connections having a two-spring interval between said successive connections;    the two strings of said modules having a plurality of interstring connections of their connecting webs at regular intervals of a plurality of springs between said successive interstring connections;    said modules being separable from said connected series by the severance of one connecting web between said two four-spring clusters at each occurrence thereof along said connected series, alternating between the webs of the two strings at successive such occurrences;    said construction being formed by the folding of consecutive modules upon each other in opposite directions about the non-severed web between modules as hinges;    successive juxtaposed modules being connected together remotely from said hinges, with the corresponding ends of said springs in common planes, and the ends of the connected modules aligned along opposite edges of the construction.    
     
     
         2 . The construction of  claim 1  wherein said plurality of springs between said plurality of interstring connections are two in number.  
     
     
         3 . The construction of  claim 1  wherein said plurality of springs between said plurality of interstring connections are three in number.  
     
     
         4 . The construction of  claim 1  wherein said plurality of springs between said plurality of interstring connections are more than three in number.  
     
     
         5 . The construction of  claim 1  wherein the connection of juxtaposed modules remote from said hinges is an application of adhesive to at least one module surface in contact with the juxtaposed module.  
     
     
         6 . The construction of  claim 5  wherein the adhesive is a hot-melt adhesive.  
     
     
         7 . The construction of  claim 1  wherein the connection of juxtaposed modules together remote from their hinges is an adhesive tape bridging the juxtaposed modules on exposed surfaces thereof.  
     
     
         8 . The construction of  claim 7  wherein the said tape spans a surface of said construction in a direction transverse to said modules, bridging all modules thereof adjacent to the ends of the modules.  
     
     
         9 . The construction of  claim 7  wherein the said adhesive tape spans the end surfaces of each module along said opposite edges of said construction.  
     
     
         10 . An innerspring construction comprising: 
 a continuous double row of pocketed springs comprising two connected strings of pocketed springs wherein each string includes a plurality of compartments defined between layers of a fabric strip by spaced transverse seams which also define a connecting web of fabric between successive compartments;    each of said compartments having therein a spring which is axially transverse to said strip and axially parallel to and coextensive with the other springs of said double row;    said two strings being joined together by interstring connections of the webs of the two strings at intervals of two springs therealong;    said double row of springs having defined therein a connected series of modules of equal numbers of springs by the severance of a connecting web of each string between adjacent interstring web connections and alternating between strings at regular intervals along said double row of springs;    said construction being formed by the folding of consecutive modules upon each other in opposite directions about the non-severed web between modules as hinges; and    successive folded modules being connected together remotely from said hinges, with the corresponding ends of said springs in common planes.    
     
     
         11 . A modular subassembly of pocketed springs for mattress constructions comprising a double row of pocketed springs of finite length; 
 said double row of pocketed springs comprising two connected strings of pocketed springs wherein each string includes a plurality of compartments defined between layers of a fabric strip by spaced transverse seams which also define a connecting web of fabric between successive compartments;    each of said compartments having therein a spring which is axially transverse to said strip and axially parallel to and coextensive with the other springs of said double row;    said two strings being joined together by interstring connections of the webs of the two strings between the two terminal springs of each string and at regular intervals of at least three springs therebetween.    
     
     
         12 . An innerspring construction comprising juxtaposed modular subassemblies of pocketed springs as defined by  claim 11 , wherein the end surfaces of the constituent pocketed springs thereof occupy common planes and the ends of the modular subassemblies are aligned as one edge of a rectangular array; 
 said modular subassemblies being connected together in said rectangular array by an application of adhesive to at least one of the mutually contacting surfaces of said juxtaposed assemblies;    said adhesive being applied to at least one of the two pocketed springs adjacent to each interstring connection of said module.    
     
     
         13 . An innerspring construction comprising juxtaposed modular subassemblies of pocketed springs as defined by  claim 11 , wherein the end surfaces of the constituent pocketed springs thereof occupy common planes and the ends of the modular subassemblies are aligned as one edge of a rectangular array; 
 said modular subassemblies being connected together in said rectangular array by at least two spaced adhesive tapes spanning the juxtaposed subassemblies transversely thereof in at least one of said planes.    
     
     
         14 . The innerspring construction comprising juxtaposed modular subassemblies of pocketed springs as defined by  claim 11 , wherein the end surfaces of the constituent pocketed springs thereof occupy common planes and the ends of the modular subassemblies are aligned as one edge of a rectangular array; 
 said modular subassemblies being connected together in said rectangular array by an adhesive tape spanning the end surfaces of said modules aligned along opposite edges of said array.    
     
     
         15 . A method of fabricating a pocketed spring construction from a continuous two-row strip of pocketed springs comprising two strings of said springs joined together side by side, wherein each string includes a plurality of compartments defined between layers of a fabric strip by spaced transverse seams which also define a connecting web of fabric between successive compartments; 
 each of said compartments having therein a spring which is axially transverse to said strip and axially parallel to and coextensive with the other springs of said double row;    said two strings being joined together by regular periodic interstring connections of the webs of the two strings at consecutive intervals of two springs therealong;    severing the connecting webs of each string between said consecutive interstring web connections, alternating between strings at successive periodic interstring connections along said double row of springs to form connected modules of equal numbers of springs;    folding consecutive said modules in opposite directions about the residual connecting web of the string opposite a severed web, as a hinge for folding adjacent ones of said modules in spring-to-spring contact along said modules; and    connecting adjacent modules together remotely from said hinges to secure said modules together in assembled relation with the corresponding ends of their springs in common planes.    
     
     
         16 . The method of  claim 15  wherein said two strings are further joined between said regular periodic interstring connections by further connections at intervals of at least three springs along said two-row strip.