Posturized Pocketed Spring Comfort Layer

Abstract

A posturized comfort layer for a bedding or seating product has different sections of different firmness due to different mini coil springs within the sections. The springs may be individually pocketed between two sheets of non-woven polypropylene fabric joined with circular seams or rectangular seams. Each circular seam joins opposed pieces of fabric around one of the mini coil springs with curved segments. Alternatively, rectangular seams join opposed pieces of fabric around each of the mini coil springs with linear segments. Regardless of the shape of the seams, the different firmness of the different sections of the comfort layer may be due to the mini-coil springs contained in the pockets.

We claim: 
     
         1 . A comfort layer configured to overlay a core of a bedding or seating product, said comfort layer comprising:
 a matrix of interconnected mini pocketed springs, each mini coil spring being contained within a pocket, said pocket having a weld seam around the pocket joining first and second pieces of fabric of the pocket, each weld seam having multiple weld segments;   said comfort layer having a center section and a perimeter section surrounding the center section, the mini pocketed springs within the pockets of the perimeter section being made of thicker wire than the wire from which the mini pocketed springs within the pockets of the center section.   
     
     
         2 . The comfort layer of  claim 1  wherein the weld seams are circular and the weld segments of the pocket are curved. 
     
     
         3 . The comfort layer of  claim 1  wherein the weld seams are rectangular and the weld segments of the pocket are straight. 
     
     
         4 . The comfort layer of  claim 1  wherein weld segments of said weld seams of said pockets are evenly spaced from each other. 
     
     
         5 . The comfort layer of  claim 1  wherein at least some of said mini coil springs have a barrel shape. 
     
     
         6 . The comfort layer of  claim 1  wherein the mini coil springs have a uniform diameter. 
     
     
         7 . A comfort layer configured to overlay a core of a bedding or seating product, said comfort layer comprising:
 a matrix of mini coil springs;   a first piece of fabric on one side of the matrix of mini coil springs;   a second piece of fabric on another side of the matrix of mini coil springs, the first and second pieces of fabric being joined with weld seams comprising weld segments around each of the mini coil springs to create gaps between the first and second pieces of fabric and individual pockets which contain the mini coil springs;   said comfort layer having different sections of different firmness due, at least in part, to the out-of-pocket height of the mini coil springs.   
     
     
         8 . The comfort layer of  claim 7  wherein said weld seams are circular and the weld segments are curved and the same size. 
     
     
         9 . The comfort layer of  claim 7  wherein said weld segments of said weld seams of said pockets are the same size. 
     
     
         10 . The comfort layer of  claim 7  wherein each of said mini coil springs has the same shape. 
     
     
         11 . The comfort layer of  claim 7  wherein at least some of said mini coil springs have a barrel shape. 
     
     
         12 . The comfort layer of  claim 7  wherein at least one of said pieces of fabric comprises at least one layer of non-woven fabric material. 
     
     
         13 . The comfort layer of  claim 7  wherein said mini coil springs in a relaxed condition are approximately 0.5 to 3.0 inches tall. 
     
     
         14 . The comfort layer of  claim 7  wherein at least some of said mini coil springs have a uniform diameter. 
     
     
         15 . A comfort layer configured to overlay a core of a bedding or seating product, said comfort layer comprising:
 mini coil springs;   a first piece of fabric on one side of the mini coil springs;   a second piece of fabric on another side of the mini coil springs, the first and second pieces of fabric being joined with weld seams comprising weld segments around each of the mini coil springs to create gaps between the weld segments and individual pockets which contain the mini coil springs;   said comfort layer having different sections of different firmness due, at least in part, to the number of convolutions of the mini coil springs within the sections.   
     
     
         16 . The comfort layer of  claim 15  wherein the weld seams are circular and the weld segments are curved. 
     
     
         17 . The comfort layer of  claim 15  wherein the weld seams are rectangular and the weld segments are straight. 
     
     
         18 . The comfort layer of  claim 15  wherein the gaps are the same size. 
     
     
         19 . The comfort layer of  claim 15  wherein the gaps are different sizes. 
     
     
         20 . The comfort layer of  claim 15  wherein at least some of said mini coil springs have a barrel shape.