A spring bed is provided for supporting the lumbar (lower back) curve, which provides a continuous contact on the lumbar region by preventing the lumbar curvature (hollowed space) which occurs due to the cavitation caused by the pressure on the user's buttock part on the bed. The spring bed has lower springs arranged side by side so as to take the shape of the lumbar curve on the spring bed and upper springs arranged side by side which take place on the lower springs.

Apparatus for forming a resilient unit comprises a conveyor (210) and first and second spring supply stations (212 and 214), arranged in use to deposit respectively first and second spring types (216 and 218) under compression onto the conveyor. The conveyor is arranged in use to convey a row of the springs (216, 218) in a direction shown by Arrows A4 towards pocketing station (220). At the pocketing station (220) the springs are urged from the conveyor into positions between upper and lower sheets (222 and 224), by a plurality of inserter devices (226) that move together in a reciprocating fashion in the direction of arrow A5, before retracting to the position shown. After each row of springs is inserted between the sheets (222), upper and lower computer-controlled welding tools (not shown) come together at positions P between the springs to join the sheets together, forming pockets in which the springs are encased. After each welding event the resilient unit is indexed forwards a distance equal to one pocket width in the direction of Arrows A6 by computer-controlled drive means (not shown). The next row of springs is then conveyed into position ready for insertion between the sheets of material, and the process is repeated. The two spring supply stations are arranged to supply springs that differ from one another in at least one characteristic.

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 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 or rectangular weld seams. Regardless of the shape of the weld seams, the different firmness of the different sections of the comfort layer may be due to different mini coil springs contained in the pockets. All pockets may have the same spring, the springs may be contained in different size weld seams to create pockets of different heights.

A posturized comfort layer for a bedding or seating product has different sections of different firmness due to different pocketed mini coil springs within the sections. The springs may be individually pocketed between two sheets of non-woven polypropylene fabric joined with circular or rectangular weld seams. Regardless of the shape of the weld seams, the different firmness of the different sections of the comfort layer may be due to different mini coil springs contained in the pockets. In some embodiments, all pockets may have the same spring and the springs contained in different size weld seams to create pockets of different heights.

A posturized comfort layer for a bedding or seating product has different sections of different firmness due to different pocketed mini coil springs within the sections. The springs may be individually pocketed between two sheets of non-woven polypropylene fabric joined with circular or rectangular weld seams. Regardless of the shape of the weld seams, the different firmness of the different sections of the comfort layer may be due to different mini coil springs contained in the pockets. In some embodiments, all pockets may have the same spring and the springs contained in different size weld seams to create pockets of different heights.

A pocketed spring unit comprises a plurality of strings of pocketed springs and a cover sheet, wherein each string comprises a flap of material located along an edge of the string and extending longitudinally of the string. The cover sheet is attached to the flaps at welds W.

A pocketed spring, such as that used in a mattress, comprises: a compression spring having an upper end convolution and a lower end convolution opposite the upper end convolution, and a plurality of helical intermediate convolutions between the upper end convolution and the lower end convolution; a flexible enclosure including a top wall positioned adjacent to the upper end convolution of the compression spring, a bottom wall positioned adjacent to the lower end convolution of the compression spring, and a side wall that extends from the top wall to the bottom wall; and a tension member connected to the flexible enclosure. The tension member acts in opposition to the compression spring until the pocketed spring is compressed to a point at which the tension member no longer applies any force. Thus, the pocketed spring exhibits a non-linear response when compressed.

A more versatile pocket coil mattress provides increased support in the perimeter side regions of the mattress in combination with increased support in the main sleeping area. The shape, preloading and characteristics of the pocket coil springs has changed to decrease compression per unit of force applied while still maintaining the desired user response of a pocket coiled mattress.

The present invention is a mattress comprising a first layer of cushion members secured to a layer of coil pockets. The layer of coil pockets comprises first and second coil pockets. Each of the first and second coil pockets comprise a pocket and a coil spring disposed in the pocket. The first layer of cushion members comprises an attachment member and first and second cushion members engaged with said attachment member. The attachment member is engaged with the layer of coil pockets such that the first and second cushion members act directly upon the first and second coil pockets, respectively. The first cushion member is free standing from the second cushion member thereby causing a pumping action to occur upon depression of the first cushion member and circulation of air.