Sealy Technology, LLC

Other

Larry K DeMoss

Brian M Manuszak

Darin T Thomas

Kevin Tar

James A Beamon

Morrison J Just

Daniel W Green

David J Pleiman

Randy Sizemore

Bruce G Barman

Herman F Fisher

Joseph Truskolasky

Dan Olsen

Christina Pollock

Stephen Wallace

Christopher J Kennedy

Mark J Reisz

Abed Khaskia

Wesley D Ballew

Julian Thomas Young

Christopher Dean Page

Allen M Platek

Timothy Michael Witherell

David Michael Moret

Alan Letton

Julius Nagy

Mark A Delahanty

Kevin M Tar

Mark A Sarvary

Present embodiments provide various open coil spring assemblies which perform like an encased spring assembly. The embodiments have elastic lacings or connections which connect springs to springs or springs to lacings. Various spring embodiments are provided as well as various arrangements for the elastic lacings. All of these features improve compliance and stability while reducing motion transfer.

Open coil spring assemblies

A pocket coil spring assembly is provided that includes a coil spring having an upper portion and a lower portion collectively defining an interior cavity of the coil spring. The pocket coil spring assembly further includes a fabric pocket encasing the coil spring with a top area covering the upper portion of the coil spring and a bottom area covering the lower portion of the coil spring. A discrete amount of flexible foam is poured on the top of the fabric pocket such that a top surface of the flexible foam extends above the coil spring. A mattress assembly is further provided that includes the flexible foam dispensed in continuous or discrete amounts between rows of pocket coil springs.

Pocket coil spring assembly including flexible foam

A coil-in-coil spring is provided that exhibits a variable and non-linear loading response upon compression. The spring comprises a continuous wire including a first spring portion having a first spring constant, a second spring portion having a second spring constant less than the first spring constant, and a third spring portion having a third spring constant less than the first spring constant and less than the second spring constant. In the coil-in-coil spring, the first spring portion forms an outer coil of the coil-in-coil spring and the second spring portion, the third spring portion, or both the second spring portion and the third spring portion are positioned within the first spring portion and form an inner coil of the coil-in-coil spring. A multi-coil spring is also provided that includes an outer coil, an intermediate coil positioned within the outer coil, and an inner coil positioned with the intermediate coil.

Coil-in-coil springs with non-linear loading responses and mattresses including the same

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.

Coil-in-coil spring with variable loading response and mattresses including the same

A mattress assembly is provided that includes a mattress core having a bottom surface and a top surface opposite the bottom surface, and a mattress topper positioned adjacent to the top surface of the mattress core. The mattress topper includes a plurality of coil springs, an upper fabric layer extending above the plurality of coil springs, and a lower fabric layer extending below the plurality of coil springs. The lower fabric layer is connected to the upper fabric layer around each coil spring such that the upper fabric layer and the lower fabric layer collectively form a fabric pocket encasing each coil spring. The mattress topper further includes a padded layer positioned atop the upper fabric layer, with the padded layer connected to the upper fabric layer by ultrasonic welds and/or tufts. Methods of producing a mattress topper for connection to a mattress core are further provided.

Mattress assembly with a mattress topper that includes pocketed coil springs and methods of producing the same

A pocketed spring, such as that used in a mattress, comprises: a compression spring having an upper end convolution and a lower end convolution opposite the upper end convolution, and a plurality of helical intermediate convolutions between the upper end convolution and the lower end convolution; a flexible enclosure including a top wall positioned adjacent to the upper end convolution of the compression spring, a bottom wall positioned adjacent to the lower end convolution of the compression spring, and a side wall that extends from the top wall to the bottom wall; and a tension member connected to the flexible enclosure. The tension member acts in opposition to the compression spring until the pocketed spring is compressed to a point at which the tension member no longer applies any force. Thus, the pocketed spring exhibits a non-linear response when compressed.

Non-linear springs and mattresses including the same

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.

Coil springs with non-linear loading responses and mattresses including the same

A pocketed spring, such as that used in a mattress, comprises: a compression spring having an upper end convolution and a lower end convolution opposite the upper end convolution, and a plurality of helical intermediate convolutions between the upper end convolution and the lower end convolution; a flexible enclosure including a top wall positioned adjacent to the upper end convolution of the compression spring, a bottom wall positioned adjacent to the lower end convolution of the compression spring, and a side wall that extends from the top wall to the bottom wall; and a tension member connected to the flexible enclosure. The tension member acts in opposition to the compression spring until the pocketed spring is compressed to a point at winch the tension member no longer applies any force. Thus, the pocketed spring exhibits a non-linear response when compressed.

A coil-in-coil spring is provided that exhibits a variable and non-linear loading response. The spring includes a first spring portion having a first spring constant, a second spring portion having a second spring constant less than the first spring constant, and a third spring portion having a third spring constant less than the first spring constant and less than the second spring constant. The first spring portion forms an outer coil of the coil-in-coil spring and the second spring portion, the third spring portion, or both the second spring portion and the third spring portion are positioned within the first spring portion and form an inner coil of the coil-in-coil spring. A multi-coil spring is also provided that includes an outer coil, an intermediate coil positioned within the outer coil, and an inner coil positioned with the intermediate coil.

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Greensboro, NC, United States of America

Larry K DeMoss