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.

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 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.

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.

A pocket spring mattress for use in a bedding or seating product is disclosed. The mattress comprises a plurality of interconnected coil springs enclosed in continuous covers forming strings of pockets accommodating the coil springs. Adjacent coil springs within each string are spaced apart by an interjacent separation distance, said separation distance exceeding at least 20 percent of the diameter of the largest one of the spiral turns of the adjacent coil springs. Further, the pocket spring mattress further comprises a cushioning pad located above the upper end of each coil spring, wherein the covers provides first compartments enclosing the coil springs, and second compartments enclosing the cushioning pads, said first and second compartments being separated from each other. The cushioning pads each have a length extension in the longitudinal direction of the strings exceeding the diameter of the largest one of the spiral turns of the corresponding coil spring.

A three-layered topper for a bedding or seating product has a first piece of foam, a second piece of foam and a pocketed spring comfort layer therebetween. The pocketed spring comfort layer has individually pocketed mini coil springs. At least one of the foam pieces may be infused with metallic particles to improve thermal conductivity. Alternatively, at least one of the foam pieces may be infused with microencapsulated phase change materials to improve heat absorption. At least one of the foam pieces may have a coating to further improve thermal conductivity or heat absorption.

Compressible mattress assemblies for bed in a box applications consist of a first polymeric foam layer and a second polymeric foam layer, wherein the first polymeric foam layer has a thickness less than the second polymeric foam layer and has a property and/or a foam material that is different from the second polymeric foam layer. In other embodiments, the compressible mattress assemblies consist of a pocketed microcoil array intermediate the first and second polymeric foam layers.

Disclosed are a welding apparatus and manufacturing method for a multilayer pocket spring string, and a manufacturing device for a pocket spring mattress. The welding apparatus may include: at least one first welding module configured for welding cloth, so that an accommodating cavity for accommodating a spring is separated to form at least two layers of first cavities; at least one first driving mechanism configured for driving the first welding module to move along a layer-column direction of the first cavity; a second welding module configured for welding the cloth, so that the cloth forms the accommodating cavities arranged at intervals; and at least two spring conveying mechanisms arranged at intervals, the spring conveying mechanism is configured for clamping and conveying the spring into the corresponding first cavity.

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 comfort layer for a bedding or seating product has liquid pods sandwiched between plies of fabric. The plies of fabric are joined with seams thereby creating pockets, at least one liquid pod being inside each pocket. Each seam joining opposed plies of fabric around each of the liquid pods of the comfort layer may be segmented or solid, depending upon the fabric and type of seam.