Resilient unit and method of manufacture

Abstract

A resilient unit (180), such as for a mattress, comprises a folded pad containing rows of resilient elements (120) in discrete pockets formed between superposed sheets of material joined at locations between adjacent resilient elements. Between at least some adjacent resilient elements the sheets form a gusset (160) which acts as a hinge when the pad is folded to form the resilient unit.

1 . A resilient unit comprising a folded pad containing rows of resilient elements in discrete pockets formed between superposed sheets of material joined at locations between adjacent resilient elements, wherein between at least some adjacent resilient elements the sheets form a gusset which acts as a hinge when the pad is folded to form the resilient unit. 
     
     
         2 . A unit according to  claim 1 , wherein the pad comprises a plurality of gussets, each between adjacent pairs of resilient elements in a longitudinal direction of the pad. 
     
     
         3 . A unit according to  claim 1  or  2 , wherein successive gussets are located on alternate sides of the folded pad. 
     
     
         4 . A unit according to any of the preceding claims, wherein at least some of the resilient elements have axes that extend between gussets. 
     
     
         5 . A unit according to any of the preceding claims, wherein at least some of the resilient elements have axes that are aligned in a substantially parallel fashion in the folded pad. 
     
     
         6 . A unit according to any of the preceding claims, wherein the sheets are joined at two or more spaced locations between adjacent resilient elements to form the gusset. 
     
     
         7 . A unit according to any of the preceding claims, wherein a single resilient element is located between successive gussets. 
     
     
         8 . A unit according to any of the preceding claims, wherein a plurality of resilient elements are located between successive gussets in the pad. 
     
     
         9 . A unit according to any of the preceding claims, wherein the resilient elements comprise springs. 
     
     
         10 . A unit according to any of the preceding claims wherein the resilient elements comprise coil springs, which of metal wire. 
     
     
         11 . A unit according to any of the preceding claims, wherein for at least some of the springs the axial length of the spring exceeds the maximum diameter of the spring. 
     
     
         12 . A unit according to any of the preceding claims, wherein for at least some of the springs the axial length of the spring is substantially equal to, or less than, the maximum diameter of the spring. 
     
     
         13 . A unit according to any of the preceding claims, wherein in the folded pad at least some adjacent resilient elements are attached together. 
     
     
         14 . A unit according to  claim 13 , wherein the adjacent elements are attached together along an axially extending surface of the resilient elements in the folded pad. 
     
     
         15 . A unit according to any of the preceding claims, wherein the folded pad is held in its folded configuration by a retention member. 
     
     
         16 . A unit according to  claim 15 , wherein the retention member comprises a frame or envelope. 
     
     
         17 . A unit according to  claim 15  or  16 , wherein the retention member comprises a loop or band passing around the folded pad to prevent it from unfolding. 
     
     
         18 . A unit according to any of the preceding claims, wherein the folded pad is held in its folded configuration by its attachment to a cover sheet or sheets. 
     
     
         19 . A unit according to  claim 18 , wherein the cover sheet or sheets cover one or both sides of the folded pad. 
     
     
         20 . A unit according to  claim 18  or  19 , wherein the or each cover sheet is attached to the folded pad by adhesive or by welding to one or more positions. 
     
     
         21 . A unit according to any of  claims 18  to  20 , wherein the or each cover sheet is attached to one or more gussets of the pad. 
     
     
         22 . A unit according to any of the preceding claims, wherein the folded pad is retained in a folded configuration by a case or bag. 
     
     
         23 . A unit according to  claim 22 , wherein the case or bag includes padding or cushioning material. 
     
     
         24 . A unit according to any of the preceding claims, wherein the unit comprises a fan-folded, accordion-folded, concertina-folded or pleated pad. 
     
     
         25 . A unit according to any of the preceding claims, wherein the pad is folded upon itself first one way and then the other such that alternate gussets are located at first one side then the other side of the folded unit. 
     
     
         26 . A unit according to any of the preceding claims, wherein in the folded unit at least some rows of resilient elements comprise a first plurality of springs and a second plurality of springs superposed on, and/or axially adjacent, the first plurality. 
     
     
         27 . A unit according to  claim 26 , wherein the first and second pluralities of springs differ in one or more characteristics including, but not limited to: length, diameter, stiffness, shape, number of coils and gauge of spring material. 
     
     
         28 . A unit according to any of the preceding claims, wherein the sheets of material on opposed sides of the unit differ from one another in respect of at least one characteristic from a group including optical, thermal, tactile, structural, chemical and physical. 
     
     
         29 . A resilient pad for forming a resilient unit, the pad comprising plural rows of resilient elements in discrete pockets formed between superposed sheets of material joined at locations between adjacent resilient elements, wherein between at least some adjacent resilient elements the sheets form a gusset which acts as a hinge between resilient elements either side of the gusset when the pad is folded to form a resilient unit. 
     
     
         30 . A method of making a resilient unit, the method comprising forming a resilient pad by encasing a plurality of resilient elements in discrete pockets between superposed sheets of material joined at locations between the resilient elements, forming between at least some of the resilient elements a gusset, and fan-folding the pad upon itself using the gussets as hinges, such that alternate gussets become located on opposed sides of the folded unit and axes of at least some of the resilient units become substantially parallel. 
     
     
         31 . A mattress comprising a resilient unit according to any of  claims 1  to  28  or made by a method according to  claim 30 .