Spring core with integrated cushioning layer
A spring core is provided that includes a plurality of coil springs having an upper portion and a lower portion that collectively define an interior cavity. The spring core further includes a continuous upper fabric layer that covers each coil spring and defines a recess in the interior cavity of each coil spring. A cushioning layer is positioned atop the continuous upper fabric layer and extends into the recess in the interior cavity of each coil spring. A mattress assembly is further provided that includes the spring core, an upper body supporting layer, and a lower foundation layer. Methods of producing a spring core are further provided.
1. A method of producing a spring core, comprising the steps of:
providing an array of coil springs, each coil spring having an upper end convolution and defining an interior cavity;
covering the array of coil springs with a continuous upper fabric layer to define a recess in the interior cavity of each coil spring, an intermediate recess between each coil spring, or both the recess in the interior cavity of each coil spring and the intermediate recess between each coil spring; and
dispensing a foam precursor onto the continuous upper fabric layer such that, upon curing the foam precursor, a cushioning layer is formed atop and bonded to the continuous upper fabric layer and extends below the upper end convolution of each coil spring.
2. The method of claim 1 , wherein the step of dispensing the foam precursor onto the continuous upper fabric layer comprises pouring the foam precursor onto the continuous upper fabric layer as the array of coil springs is moved linearly.
3. The method of claim 1 , further comprising the step of smoothing the foam precursor, such that, upon curing, the cushioning layer has a substantially planar top surface.
4. The method of claim 1 , further comprising the step of advancing the array of coil springs through an infrared curing oven subsequent to dispensing the foam precursor onto the continuous upper fabric layer.
5. The method of claim 1 , further comprising the step of planarizing the cushioning layer subsequent to curing the foam precursor such that the cushioning layer has a substantially planar top surface.
6. The method of claim 1 , wherein each coil spring includes a lower portion with a lower end convolution, and further comprising, prior to dispensing the foam precursor, the step of covering the lower portion of each coil spring with a continuous lower fabric layer to define the intermediate recess.
7. The method of claim 6 , further comprising, prior to dispensing the foam precursor, the step of connecting the continuous lower fabric layer to the continuous upper fabric layer around each coil.
8. The method of claim 7 , wherein, upon dispensing the foam precursor onto the continuous upper fabric layer, the cushioning layer extends into the intermediate recess.
9. The method of claim 6 , further comprising connecting the continuous lower fabric layer to the continuous upper fabric layer in the interior cavity of each coil to define a recess.
10. The method of claim 9 , wherein, upon dispensing the foam precursor onto the continuous upper fabric layer, the cushioning layer extends into the interior cavity.
11. A spring core, comprising:
a plurality of coil springs, each coil spring having an upper portion with an upper end convolution and a lower portion with a lower end convolution;
a continuous upper fabric layer covering the upper end convolution of each coil spring;
a continuous lower fabric layer covering the lower end convolution of each coil spring; and
a cushioning layer defined by a precursor that is poured on to the continuous upper fabric layer wherein the precursor forms the cushioning layer and bonds to the continuous upper fabric layer, the cushioning layer being positioned atop the continuous upper fabric layer and extending below the upper end convolution of the plurality of coil springs.
12. The spring core of claim 11 , wherein the continuous upper fabric layer is connected to the continuous lower fabric layer between each coil spring to thereby define an intermediate recess between each coil spring, and the cushioning layer extends into the intermediate recess.
13. The spring core of claim 11 , wherein the upper portion and the lower portion of each coil spring collectively define an interior cavity of each coil spring, wherein the continuous upper fabric layer is connected to the continuous lower fabric layer within the interior cavity of each coil spring to thereby define a recess in the interior cavity of each coil spring, and wherein the cushioning layer extends into the recess of each coil spring.
14. The spring core of claim 11 , further comprising a second cushioning layer positioned below the continuous lower fabric layer and extending above the lower end convolution of the plurality of coil springs.