A pocketed spring assembly comprises a plurality of parallel strings of individually pocketed springs. A dimensionally stabilizing substrate is secured to at least some of the strings on one of the top and bottom surfaces of the strings. A scrim sheet is secured to at least some of the strings on an opposed surface of the strings to maintain the positions of the strings. The dimensionally stabilizing substrate is laterally rigid enough to maintain length and width dimensions of the coil spring assembly. However, the dimensionally stabilizing substrate is flexible enough to allow the pocketed spring assembly to be roll packed for shipping.

A pocketed spring assembly comprises a plurality of parallel strings of individually pocketed springs. A dimensionally stabilizing substrate is secured to at least some of the strings on one of the top and bottom surfaces of the strings. A scrim sheet is secured to at least some of the strings on an opposed surface of the strings to maintain the positions of the strings. The dimensionally stabilizing substrate is laterally rigid enough to maintain length and width dimensions of the coil spring assembly. However, the dimensionally stabilizing substrate is flexible enough to allow the pocketed spring assembly to be roll packed for shipping.

A pocketed spring assembly comprises parallel strings, each string joined to at least one adjacent string. At least some of the strings have springs of different gauge wire and some of the pockets of the strings having springs of different gauge wire are spliced together. At least some of the strings have springs of different geometries and some of the pockets of the strings having springs of different geometries are spliced together. At least some strings may have end sections with springs different than a middle section therebetween, the springs of the end sections being firmer than the springs of the middle section.

A coil-in-coil spring is provided that exhibits a variable loading response as the spring is compressed. The coil-in-coil spring comprises a continuous wire forming’ an inner coil having a substantially conical shape and an outer coil extending around the inner coil and having a substantially cylindrical shape. The inner coil includes a plurality of helical convolutions with diameters that progressively decrease as the plurality of helical convolutions extend from a lower end of the coil-in-coil spring to an upper end convolution of the inner coil. The inner coil also has an uncompressed height that is about 75% of the uncompressed height of the outer coil, A mattress is further provided and includes the coil-in-coil springs arranged in a matrix.

A coil-in-coil spring is provided that exhibits a variable loading response as the spring is compressed. The coil-in-coil spring comprises a continuous wire forming’ an inner coil having a substantially conical shape and an outer coil extending around the inner coil and having a substantially cylindrical shape. The inner coil includes a plurality of helical convolutions with diameters that progressively decrease as the plurality of helical convolutions extend from a lower end of the coil-in-coil spring to an upper end convolution of the inner coil. The inner coil also has an uncompressed height that is about 75% of the uncompressed height of the outer coil, A mattress is further provided and includes the coil-in-coil springs arranged in a matrix.

A pocketed spring assembly comprises parallel strings, each string joined to at least one adjacent string. At least some of the strings have springs of different gauge wire and some of the pockets of the strings having springs of different gauge wire are spliced together. At least some of the strings have springs of different geometries and some of the pockets of the strings having springs of different geometries are spliced together. At least some strings may have end sections with springs different than a middle section therebetween, the springs of the end sections being firmer than the springs of the middle section.

A mattress assembly is provided that includes a mattress core having a bottom surface and a top surface opposite the bottom surface, and a mattress topper positioned adjacent to the top surface of the mattress core. The mattress topper includes a plurality of coil springs, an upper fabric layer extending above the plurality of coil springs, and a lower fabric layer extending below the plurality of coil springs. The lower fabric layer is connected to the upper fabric layer around each coil spring such that the upper fabric layer and the lower fabric layer collectively form a fabric pocket encasing each coil spring. The mattress topper further includes a padded layer positioned atop the upper fabric layer, with the padded layer connected to the upper fabric layer by ultrasonic welds and/or tufts. Methods of producing a mattress topper for connection to a mattress core are further provided.

A mattress assembly is provided that includes a mattress core having a bottom surface and a top surface opposite the bottom surface, and a mattress topper positioned adjacent to the top surface of the mattress core. The mattress topper includes a plurality of coil springs, an upper fabric layer extending above the plurality of coil springs, and a lower fabric layer extending below the plurality of coil springs. The lower fabric layer is connected to the upper fabric layer around each coil spring such that the upper fabric layer and the lower fabric layer collectively form a fabric pocket encasing each coil spring. The mattress topper further includes a padded layer positioned atop the upper fabric layer, with the padded layer connected to the upper fabric layer by ultrasonic welds and/or tufts. Methods of producing a mattress topper for connection to a mattress core are further provided.

A pocketed spring assembly comprises a plurality of parallel strings of individually pocketed springs. A dimensionally stabilizing substrate is secured to at least some of the strings on one of the top and bottom surfaces of the strings. A scrim sleet is secured to at least some of the strings on an opposed surface of the strings to maintain the positions of the strings. The dimensionally stabilizing substrate is laterally rigid enough to maintain length and width dimensions of the coil spring assembly. However, the dimensionally stabilizing substrate is flexible enough to allow the pocketed spring assembly to be roll packed for shipping.

A pocketed spring assembly comprises a plurality of parallel strings of individually pocketed springs. A dimensionally stabilizing substrate is secured to at least some of the strings on one of the top and bottom surfaces of the strings. A scrim sleet is secured to at least some of the strings on an opposed surface of the strings to maintain the positions of the strings. The dimensionally stabilizing substrate is laterally rigid enough to maintain length and width dimensions of the coil spring assembly. However, the dimensionally stabilizing substrate is flexible enough to allow the pocketed spring assembly to be roll packed for shipping.