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 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.

Mattress assemblies are provided that include a mattress, a mattress overlay, and a mattress cover that is comprised of a first cover and a second cover. The first cover includes a top panel, a bottom panel, and a continuous side panel that collectively define a cavity and enclose the mattress. The mattress overlay is positioned atop the mattress and the first mattress cover. The second cover, which defines a perimeter, is positioned over and is dimensionally-sized to cover the mattress overlay and at least the top panel of the first cover. The second cover can then be connected to the first cover by a fastener that extends along the perimeter of the second cover.

Mattress assemblies are provided that include a mattress, a mattress overlay, and a mattress cover that is comprised of a first cover and a second cover. The first cover includes a top panel, a bottom panel, and a continuous side panel that collectively define a cavity and enclose the mattress. The mattress overlay is positioned atop the mattress and the first mattress cover. The second cover, which defines a perimeter, is positioned over and is dimensionally-sized to cover the mattress overlay and at least the top panel of the first cover. The second cover can then be connected to the first cover by a fastener that extends along the perimeter of the second cover.

A mattress system includes a subframe having fold joints. The subframe includes a foot section, a transition section, a body section, and a head section that are separated by the fold joints. The subframe includes an upper portion and a lower portion. The mattress system further includes a first strap and a second strap. The first strap extends through the foot section from the upper portion of the subframe to a lower portion of the subframe. The second strap extends through the foot section from the lower portion of the subframe to an upper portion of the subframe such that the first and second straps form an X.

A mattress system includes a subframe having fold joints. The subframe includes a foot section, a transition section, a body section, and a head section that are separated by the fold joints. The subframe includes an upper portion and a lower portion. The mattress system further includes a first strap and a second strap. The first strap extends through the foot section from the upper portion of the subframe to a lower portion of the subframe. The second strap extends through the foot section from the lower portion of the subframe to an upper portion of the subframe such that the first and second straps form an X.