Partially foam encased pocketed spring assembly
A partially foam encased pocketed spring assembly is made in a fully automated assembly machine. A first foam rail is introduced into the assembly machine and glued to upper and lower substrate webs. A first string of pocketed springs is then glued to a side surface of the first foam rail between upper and lower substrate webs and glued to the upper and lower substrate webs. Additional strings are joined together to create a pocketed spring interior. A second foam rail is then introduced into the assembly machine and glued to an outer string and to the upper and lower substrate webs to create a core. Third and fourth foam rails are glued to the core.
1 . A partially foam encased pocketed spring assembly comprising:
a lower fabric substrate sheet;
an upper fabric substrate sheet;
first and second foam rails glued to the upper and lower fabric substrate sheets at opposed ends of the partially foam encased pocketed spring assembly;
a first string of pocketed springs glued to a side surface of the first foam rail and extending parallel to the first and second foam rails;
a last string of pocketed springs glued to a side surface of the second foam rail;
interior strings of pocketed springs glued to each other between the first and last strings of pocketed springs; and
third and fourth foam rails glued to the upper and lower fabric substrate sheets on opposed sides of the partially foam encased pocketed spring assembly, wherein each of the foam rails is made of polyurethane foam.
2 . The partially foam encased pocketed spring assembly of claim 1 , wherein the lower fabric substrate sheet is thicker than the upper fabric substrate sheet.
3 . The partially foam encased pocketed spring assembly of claim 1 , wherein at least two of the foam rails have the same cross-sectional configuration.
4 . The partially foam encased pocketed spring assembly of claim 1 , wherein each of the foam rails has the same cross-sectional configuration.
5 . The partially foam encased pocketed spring assembly of claim 1 , wherein the lower fabric substrate sheet has a different thickness than the upper substrate sheet.
6 . The partially foam encased pocketed spring assembly of claim 1 , wherein each of the third and fourth foam rails is glued to the first and second foam rails.
7 . The partially foam encased pocketed spring assembly of claim 1 , wherein an end surface of each of the first, last and interior strings is glued to the third and fourth foam rails.
8 . A partially foam encased pocketed spring assembly comprising:
a lower fabric substrate sheet;
first and second foam rails glued to the lower fabric substrate sheet;
a pocketed spring interior comprising separate strings of pocketed springs glued to each other and to the lower fabric substrate sheet, a first string of pocketed springs being glued to a side surface of the first foam rail and a last string of pocketed springs being glued to a side surface of the second foam rail, the strings extending parallel to the first and second foam rails; and
third and fourth foam rails glued to the lower fabric substrate sheet, wherein each of the foam rails is made of polyurethane foam.
9 . The partially foam encased pocketed spring assembly of claim 8 , wherein each of the third and fourth foam rails is glued to the first and second foam rails.
10 . The partially foam encased pocketed spring assembly of claim 8 , further comprising an upper fabric scrim sheet, wherein the lower substrate sheet is thicker than the upper fabric scrim sheet.
11 . The partially foam encased pocketed spring assembly of claim 8 , wherein at least two of the foam rails has the same cross-sectional configuration.
12 . The partially foam encased pocketed spring assembly of claim 8 , wherein each of the foam rails has the same cross-sectional configuration.
13 . The partially foam encased pocketed spring assembly of claim 8 , wherein each of the strings is the same length along with the first and second foam rails.
14 . The partially foam encased pocketed spring assembly of claim 8 , wherein an end surface of each of the first and second foam rails is glued to the third and fourth foam rails.
15 . A partially foam encased pocketed spring assembly comprising:
a lower fabric substrate sheet;
an upper fabric substrate sheet;
first and second foam rails attached to the lower fabric substrate sheet and upper fabric substrate sheet;
a pocketed spring interior comprising strings of pocketed springs glued to each other, a first string of pocketed springs being attached to the lower fabric substrate sheet and the upper fabric substrate sheet and a last string of pocketed springs being attached to the lower fabric substrate sheet and the upper fabric substrate sheet, the strings extending parallel to the first and second foam rails; and
third and fourth foam rails attached to the lower fabric substrate sheet and the upper fabric substrate sheet, each of the third and fourth foam rails being attached to the first and second foam rails, wherein each of the foam rails is made of polyurethane foam and the first string of the pocketed spring interior is glued to a side surface of the first foam rail and the last string of the pocketed spring interior is glued to a side surface of the second foam rail.
16 . The partially foam encased pocketed spring assembly of claim 15 , wherein the lower fabric substrate sheet is thicker than the upper fabric substrate sheet.
17 . The partially foam encased pocketed spring assembly of claim 15 , wherein each of the foam rails has the same cross-sectional configuration.
18 . The partially foam encased pocketed spring assembly of claim 15 , wherein the upper and lower fabric substrate sheets are the same thickness.
19 . The partially foam encased pocketed spring assembly of claim 15 , wherein each of the strings is the same length as the first and second foam rails.
20 . A partially foam encased pocketed spring assembly comprising:
a lower fabric substrate sheet;
first and second foam rails attached to the lower fabric substrate sheet;
a pocketed spring interior comprising strings of pocketed springs glued to each other, a first string of pocketed springs being attached to the lower fabric substrate sheet and a last string of pocketed springs being attached to the lower fabric substrate sheet, the strings extending parallel to the first and second foam rails; and
third and fourth foam rails to the lower fabric substrate sheet, each of the third and fourth foam rails being attached glued to the first and second foam rails, wherein each of the foam rails is made of polyurethane foam and the first string of the pocketed spring interior is glued to a side surface of the first foam rail and the last string of the pocketed spring interior is glued to a side surface of the second foam rail.