Advanced conformance encased coil spring units
View Patent ↗Encased coil units with advance conforming properties have various interconnections and structures between individually encased or wrapped coils. In the various embodiments, encasement structures between coils such as closure or attachment of sheet material or fabric, which encase the coils, are configured to allow and enhance independent movement of coils with respect to adjacent coils and remote coils of the unit. Modifications in the sheet material or fabric which encases the coils include variations in the points of connection or disconnection between adjacent coils, proximate to top ends of the coils to allow more freedom of movement of the top or upper ends of the coils and with respect to adjacent coils, and to reduce load transfer or cratering of the coil springs about the locus of the force vector.
1. An advanced conformance encased coil spring unit comprising: a plurality of coils arranged in any array of rows and columns, each coil being individually covered in an encasement material and attached to each adjacent coil in each column creating a continuous strand of coils, each row of coils being attached by one or more connection points between the encasement material to each adjacent continuous strand of coils; a subset of the continuous coil strands having a partial slit between two center vertically adjacent coils, the partial slit proximate to an upper portion of the two center vertically adjacent coils, the subset also having fewer connection points between each pair of horizontally adjacent coils than the remaining horizontally adjacent coils; wherein the subset of the continuous coil strands does not include coils proximate to an outer perimeter of the encased coil spring unit.
2. The advanced conformance encased coil spring unit of claim 1 , wherein the subset of the continuous coil strands have three connection points between each pair of horizontally adjacent coils.
3. The advanced conformance encased coil spring unit of claim 2 , wherein the remaining coils have four connection points between each pair of horizontally adjacent coils.
4. The advanced conformance encased coil spring unit of claim 1 , wherein the one or more connection points are glue.
5. The advanced conformance encased coil spring unit of claim 1 , wherein the one or more connection points are welded.
6. The advanced conformance encased coil spring unit of claim 1 , wherein the subset of the continuous coil strands does not include the first three coils on opposing ends of two adjacent center horizontal rows of the unit.
7. The advanced conformance encased coil spring unit of claim 1 , wherein the encasement material is polyester.
8. The advanced conformance encased coil spring unit of claim 1 , wherein the encasement material contains acrylic.
9. The advanced conformance encased coil spring unit of claim 1 , wherein the encasement material is coated with silicone.
10. An advanced conformance encased coil spring unit comprising:
a plurality of encased coils arranged in rows and columns, the coils in each column encased in a continuous coil strand and the coils in each row being attached by two or more connection points;
a portion of the plurality of encased coils located in the same horizontal row, having a partial separation between at least one vertically adjacent coil and having fewer connection points between at least one horizontally adjacent coil than the other coils;
wherein the partial separations is not co-located with the connection points between the encased coils.
11. The advanced conformance encased coil spring unit of claim 10 , wherein the portion of the plurality of encased coils include coils located in two adjacent center rows of the unit.
12. The advanced conformance encased coil spring unit of claim 10 , wherein the portion of the plurality of encased coils does not include coils located at the perimeter edge of the unit.
13. The advanced conformance encased coil spring unit of claim 10 , wherein the plurality of encased coils are coil-in-coil coils.
14. The advanced conformance encased coil spring unit of claim 10 . wherein the partial separation is proximate to an upper region of the coils and the connection points are proximate to a lower region of the coils.