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.

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.

A comfort layer for a bedding or seating product has slow-acting pockets characterized by the individual springs of the comfort layer being pocketed with either semi-impermeable or impermeable fabric. Each seam joining opposed plies of fabric around each of the coil springs of the comfort layer may be segmented, allowing air to flow between the segments, thereby increasing the luxury “feel” of the comfort layer. The method of making the comfort layer includes compressing the springs and creating pockets with a welding horn and an anvil.

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 foam core for a mattress including a supporting layer for supporting the vertebral column, the supporting layer including an upper part and a lower part. Different body support regions are provided in the upper part along the longitudinal direction of the foam core, a plurality of the body support regions having at least one recess in the material of the foam core. At least one reserve region is provided in the lower part and has at least one recess in the material of the foam core. The foam core is formed such that the reserve region is not substantially deformed in case of a load on the upper part above the reserve region if the load is below a predetermined limit pressure, and that in case of a load above the predetermined limit pressure, the reserve region is deformed. A mattress having such a foam core is furthermore shown.

A flippable mattress includes a first memory foam layer, a second memory foam layer, a core layer disposed therebetween and a transition layer between each foam layer and the core. The first memory foam layer has a thickness, and the second memory foam layer has a thickness that is greater than the thickness of the first memory foam layer. The first transition layer has an IFD less than that of the second transition layer. The mattress is flippable between a first orientation in which the first memory foam layer is above the core layer and the second memory foam layer, and a second orientation in which the second memory foam layer is above the core layer and the first memory foam layer.

Components of a pocket-sprung-mattress sub-assembly having individual metal springs retained within a matrix of fabric pockets are separated. A rotatable tearing drum 405 is driven by a drive motor 406. Tearing devices 407 are arranged to pull metal springs from a pocket-sprung-mattress sub-assembly during the rotation of the tearing drum 405. A feeding assembly 408 compressors an end portion of the mattress sub-assembly and moves this end portion continually to bring an end of the mattress sub-assembly into contact with the rotating tearing devices 407.

A method and apparatus for deconstructing a mattress of the type having steel coil springs held within fabric pockets. The apparatus includes a frame and an opener mechanism mounted to the frame and operable for opening a plurality of fabric pockets at a first end thereof to create an opening in the first end of the fabric pockets and expose the steel coil springs contained therewithin. A gripper mechanism is provided for gripping the plurality of fabric pockets at a second end thereof, opposite the first end. An extractor mechanism is mounted to the frame for extracting the steel coil springs from the fabric pockets through the openings formed in the first end of the fabric pockets.

Hybrid coil and air chamber assemblies for cushioning supports generally include pressurized air chambers that are positioned intermediate strings of pocketed coils. In this manner, the coils and air chambers can move independently but can be made to cooperate to provide firmness control, contouring and/or support of a user thereof. Air pressure within the air chambers can be independently adjusted to manipulate firmness and/or contour properties in specific zones defined by the presence and location of the air chambers, e.g., pressure of the air chambers corresponding to the lumbar region can be adjusted to eliminate high pressure points. Still further, the pressure within the air chambers can be automatically adjusted to different applied loads as a function of movement. Also disclose are processes for adjusting a mattress including the hybrid coil and air assemblies.