In order to manufacture an innerspring unit (31) comprising pocketed springs and having an increased stability at its edge regions, in a first step, an innerspring main body (30) comprising a plurality of first strings (14) of pocketed springs is provided. In a subsequent second step, at least one second string (13c, 13d) of pocketed springs is attached to a lateral surface of the innerspring main body (30), so that the at least one second string (13c, 13d) of pocketed springs extends in a longitudinal direction of the innerspring main body (30). The springs (13) of the at least one second string (13c, 13d) 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 (30). The at least one second string (13c, 13d) of pocketed springs forms together with the innerspring main body (30) the innerspring unit (31).

Furniture is assembled from elastic modules enabling rapid and convenient assembly and disassembly. The elastic module has a spring, an outer covering layer, and an end member attached to an end face of the outer covering layer. A mattress includes a plurality of individual spring assemblies (145), with each spring assembly including at least one spring (134) and a spring cap (144, 150, 161, 164, 171, 184, 194, 204). Each spring cap has at least one first attachment fitting (168, 178, 174, 186, 196) and at least one second attachment fitting (169, 180, 176, 187) with each first attachment fitting engageable into or onto and removable from a second attachment fitting of an adjoining spring cap. The spring assemblies are attached to each other via the first and second attachment fittings, forming the individual spring assemblies into a spring core. A top pad is positioned on top of the spring core.

Methods and systems for no-glue pocketed spring unit construction. Rows of pocketed springs modules, comprising more than two pocketed springs surrounding a central hole, can be automatically loaded onto an assembler; pocketed spring-surrounded openings can be automatically aligned with welding phalanges; and probe/anvil welding pairs can be inserted into modules in different rows of modules, closed around polymer pocket fabric, and activated to weld rows of modules together without glue; without a user manually loading rows of modules onto the assembler.

A mattress assembly includes a base layer, a coil layer disposed over the base layer, an upper layer disposed over the coil layer, and an elastomeric cushioning element disposed over the upper layer. The coil layer may include a plurality of pocketed coils. Furthermore, the elastomeric cushioning element may have a thickness within a range of about 2.0 inches to about 4.5 inches. Furthermore, the elastomeric cushioning element may form between about 15.0% and about 32.0% of an overall thickness of the mattress assembly. A method of forming a mattress assembly includes disposing a coil layer over a base layer, disposing an upper layer over the coil layer, disposing an elastomeric cushioning element over the upper layer, and disposing an outer covering over at least the upper layer.

A spring is provided that exhibits a variable and non-linear loading response upon compression. The spring comprises a continuous wire having a lower end convolution, an upper end convolution, and a plurality of helical intermediate convolutions. The upper end convolution, the lower end convolution, and the helical intermediate convolutions each have a respective diameter, with the continuous wire further defining a pitch between the various convolutions. In the spring, one or more of the diameters of the convolutions or one or more of the pitches varies along the length of the continuous wire such that the spring exhibits a non-linear loading response upon compression. A mattress is further provided and includes a plurality of the springs arranged in a matrix.

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.

A pocket spring mattress (1) comprising a plurality of double layer spring units (7) arranged in rows and columns to form a rectangular shaped mattress is provided. Each double layer spring unit (7) comprises a first pocket spring unit (2a) arranged axially onto a second pocket spring unit (2b), and each spring unit (2a, 2b) comprises a number of springs (3a-b, 4a-b) and a fabric pocket (6) enclosing the springs (3a-b, 4a-b). The springs (3a-b, 4a-b) comprises reference springs (3a-b) having a first spring constant and frame springs (4a-b) having a second spring constant being greater than the first spring constant, and frame springs (4a-b) are arranged in at least one of the first and second pocket spring units (2a, 2b) of at least one outermost row or column of the double layered spring units (7) in a configuration such that the edge of the mattress (1) is reinforced.

A mattress includes a plurality of layers vertically stacked to one another, the plurality of layers comprising a first layer; a second layer; and a third layer. The first layer comprises a plurality of openings defined therein being operably in fluidic communication with a plurality of fans for providing air circulation to a user through the mattress. The second layer is disposed between the first layer and the third layer and comprises an array of springs.

A sleeping system includes a comfortable layer comprising a plurality of pressure relief springs and a supporting layer arranged under the comfortable layer. The supporting layer includes a plurality of supporting springs corresponding to the plurality of pressure relief springs, each of the plurality of supporting springs is connected with one of the plurality of pressure relief springs to constitute a pair of spring, the supporting springs and the supporting springs forms a plurality of pairs of springs arranged along a length direction and a width direction, each pair of spring has a same size, and a ratio of a length of the supporting spring to a length of the pressure relief spring varies smoothly along the length direction of the sleeping system.

A comfort layer for a bedding or seating product has fast-acting pockets characterized by the individual mini springs of the comfort layer being pocketed with permeable fabric having apertures therein. Apertures in the fabric facilitate airflow through the fabric. The permeable fabric is specifically structured to facilitate airflow while minimizing noise. Each seam joining opposed pieces of fabric around each of the mini coil springs of the comfort layer may be segmented, allowing air to flow between the segments.