Sealy Technology, LLC

Said A Dimitry

William Freeman

Bruce G Barman

Extruded foam reinforcement pieces are described for assembly in connection with innerspring assemblies and mattresses. The pieces have optimized cross-sectional configurations which can be consistently extruded in continuous strands which are then cut to length according to the type and size of innerspring assembly. The pieces are configured to engage various components of the innerspring, including spring coils, spaces between spring coils, and framing borderwires. The foam reinforcement pieces facilitate attachment and alignment of overlying material such as padding and upholstery and function to improve the support characteristics of an innerspring. Various embodiments of extruded foam reinforcement pieces include a support element configured to attach about the exterior of a single coil at a corner of an innerspring; a relatively short span side wall support which engages vertically between coils adjacent a vertical side wall of the innerspring; and a tapered edge structure configured to fit over side edges of an innerspring, with padding and upholstery attachable over each of the various foam reinforcement structures to improve the form and strength of an innerspring assembly.

Extruded foam reinforcement structures for innerspring assemblies and mattresses

A cavitated pad and innerspring assembly combination, for use in mattresses, furniture, or other cushioned flexible support structures, wherein coils of the innerspring assembly have terminal convolutions which extend beyond the coil body and are not connected to adjacent coils. A cavitated pad has openings in which the terminal convolutions fit, and the pad overlies the coil bodies. In one embodiment, the cavitations extend either partially or entirely through the pad. Upholstery is attached over the pad. The combination of coils with terminal convolutions positioned within the cavitations in the pad provides a dampened or attenuated dual spring rate support surface with controlled lateral deflection of the terminal convolutions.

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Westlake, OH, United States of America

Said A Dimitry