In order to manufacture an innerspring unit comprising pocketed springs and having an increased stability at its edge regions, in a first step, an innerspring main body comprising a plurality of first strings of pocketed springs is provided. In a subsequent second step, at least one second string of pocketed springs is attached to a lateral surface of the innerspring main body, so that the at least one second string of pocketed springs extends in a longitudinal direction of the innerspring main body. The springs of the at least one second string of pocketed springs have a spring characteristic or a spring geometry different from the springs of the plurality of first strings of the innerspring main body. The at least one second string of pocketed springs forms together with the innerspring main body the innerspring unit.

In order to manufacture an innerspring unit comprising pocketed springs and having an increased stability at its edge regions, in a first step, an innerspring main body comprising a plurality of first strings of pocketed springs is provided. In a subsequent second step, at least one second string of pocketed springs is attached to a lateral surface of the innerspring main body, so that the at least one second string of pocketed springs extends in a longitudinal direction of the innerspring main body. The springs of the at least one second string of pocketed springs have a spring characteristic or a spring geometry different from the springs of the plurality of first strings of the innerspring main body. The at least one second string of pocketed springs forms together with the innerspring main body the innerspring unit.

Methods and systems for no-glue pocketed spring unit construction. Rows of pocketed springs, preferably arranged into modules of more than two pocketed springs surrounding a central hole, are ultrasonically welded together when paired vibrating probes and anvils press layers of pocketed spring fabric from the rows of pocketed springs together and a welding pulse is transmitted to the vibrating probe.

Methods and systems for no-glue pocketed spring unit construction. Rows of pocketed springs, preferably arranged into modules of more than two pocketed springs surrounding a central hole, are ultrasonically welded together when paired vibrating probes and anvils press layers of pocketed spring fabric from the rows of pocketed springs together and a welding pulse is transmitted to the vibrating probe.

An apparatus and method are provided for a pocketed spring seating unit to be incorporated into a couch or sofa. The pocketed spring seating unit comprises a spring array that includes a multiplicity of pocketed springs disposed in a spring layer arrangement. Each of the pocketed springs comprises an independently operable coil spring covered with a flexible wrap. An envelope comprising insulating materials surrounds the spring array. The spring array and the envelope are attached to a rigid platform that is disposed below the envelope. The rigid platform has a length and width that match a seating area of the couch or sofa and is configured such that the pocketed spring seating unit may be laid into an upholstery frame of the couch or sofa. An exterior cloth material overlays one or more exterior surfaces of the pocketed spring seating unit.

An apparatus and method are provided for a pocketed spring seating unit to be incorporated into a couch or sofa. The pocketed spring seating unit comprises a spring array that includes a multiplicity of pocketed springs disposed in a spring layer arrangement. Each of the pocketed springs comprises an independently operable coil spring covered with a flexible wrap. An envelope comprising insulating materials surrounds the spring array. The spring array and the envelope are attached to a rigid platform that is disposed below the envelope. The rigid platform has a length and width that match a seating area of the couch or sofa and is configured such that the pocketed spring seating unit may be laid into an upholstery frame of the couch or sofa. An exterior cloth material overlays one or more exterior surfaces of the pocketed spring seating unit.

A bedding or seating product comprises a pocketed spring assembly comprising a plurality of parallel strings of individually pocketed springs. The strings of springs may extend from head-to-foot or side-to-side of the product. Adjacent individually pocketed springs are separated from each other by at least one separating seam. Each of the separating seams comprises a pair of Y-shaped or U-shaped seams which may be joined together or spaced apart.

A bedding or seating product comprises a pocketed spring assembly comprising a plurality of parallel strings of individually pocketed springs. The strings of springs may extend from head-to-foot or side-to-side of the product. Adjacent individually pocketed springs are separated from each other by at least one separating seam. Each of the separating seams comprises a pair of Y-shaped or U-shaped seams which may be joined together or spaced apart.

A high tension coil spring structure for a bed mattress includes spring bodies and exposed wiring portions which absorb an external load. Diameter-increasing portions (A) are formed on at least one of upper and/or lower end wiring portions (14, 14′) of body wiring portions (12), and provide spaces in which upper and/or lower exposure start wiring portions (16-5, 16-5′) move upward and downward. Rigid support ends (18) are formed on at least one of the body wiring portions (12) and upper and lower exposed wiring portions (16, 16′), and absorb a compressive load. The diameter-increasing portions and the rigid ends of the coil spring structure fundamentally prevent noise caused by friction between the exposed wiring portions and surrounding wiring portions when the exposed wiring portions are compressed and significantly increase the elasticity of the exposed wiring portions.

A customizable mattress includes a chassis defining a cavity. A spring pack is removably positioned within the cavity. A top pad removably covers at least a portion of the spring pack. In some embodiments, kits and methods of use are provided.