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 spring unit containing a spring system used in bed, armchair and sofa like constructions and realizing different hardness and comfort levels in different areas of the constructions and having a soft spring forming a soft comfort area of low hardness of the spring unit, a medium hard spring providing gradual transition between soft comfort areas of the spring unit and hard comfort areas with a spring a having number of convolution different from the soft spring and of the same wire diameter, and a hard spring providing hard comfort area of the spring unit by a spring having number of convolution different from the soft spring and medium hard spring and of the same wire diameter as the medium hard spring and soft spring.

Mattress coverings are manufactured utilizing conventional equipment and using a dummy mattress core. The mattress coverings include a zippered access on the bottom panel, for example, where the dummy core can be removed after the mattress covering is completed. When shipped to a regional assembly facility the zippered access is utilized for insertion of a select mattress core that corresponds to the size of the dummy mattress core about which the mattress covering was assembled. The zippered access is zipped shut and the mattress is ready for sale, transport, and use. Great efficiencies are available where the mattress cover is assembled in a first location, shipped to a sale and use location and also regionally close to where mattress cores are manufactured, and the mattress covers are assembled with cores into mattresses.

The invention relates to a mattress (1, 1′, 2, 3) having at least one first layer (10, 20, 30), a second layer (12, 22, 32) and a third layer (14, 24, 34), the second layer (12, 22, 32) comprising spring elements (16, 26, 36) and being interposed between the first layer (10, 20, 30) and the third layer (14, 24, 34). The thickness (a.sub.1, a.sub.2, a.sub.3, d.sub.1, d.sub.2, d.sub.3, . . . , d.sub.10) of the third layer (14, 24, 34) varies locally to an extent that exceeds the extent defined by a surface structure of the third layer (14, 24, 34) on its exterior surface (17).

A mattress includes a base layer having a first surface and a second surface arranged opposite to the first surface. The base layer defines a plurality of slots extending from the first surface to the second surface and arranged in a plurality of rows in a staggered arrangement. The mattress also includes a plurality of hoop assemblies arranged inside the plurality of the slots. Each hoop assembly includes a hoop arranged vertically inside the slot and a central axis of the hoop extends substantially horizontally and parallel to the first surface. The hoop is configured to compress under a load.

A pocketed spring assembly comprises a plurality of parallel strings of individually pocketed springs. Each string is joined to at least one adjacent string. Each string comprises one piece of fabric joined to itself to create first and second opposed plies on opposite side of coil springs. The plies are joined by transverse seams to form a plurality of pockets along a length of the string. At least one spring is positioned in each of the pockets. The piece of fabric is a non-woven ultrasonically weldable fabric made with fiber made with at least some used or recycled material or content.

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.

Mattress assemblies include a hybrid posture support system that provide an end user with improved posture support during use, among other advantages. The hybrid posture support system includes a top foam layer including first and second foam portions that are spaced apart and generally correspond to a head/shoulder region and a foot region, respectively, a pocketed microcoil array underlying the top foam layer that is intermediate the first and second foam portions; and an underlying foam layer. The hybrid posture support system can be used in any mattress assembly including mattresses having a coil spring innercore or a foam innercore.