POCKET COIL SPRING ASSEMBLY INCLUDING FLEXIBLE FOAM
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.
1 . A mattress assembly, comprising:
a spring core having a first support surface and a second support surface opposite the first support surface, the spring core including:
a plurality of coil springs positioned in a matrix and extending in rows from a first end of the mattress assembly to a second end of the mattress assembly, each coil spring having an upper portion and a lower portion, the upper portion and the lower portion collectively defining a height of each coil spring,
a plurality of fabric pockets, each fabric pocket encasing one of the plurality of coil springs, and each fabric pocket including a top area covering the upper portion of each coil spring and a bottom area covering the lower portion of each coil spring, and
a plurality of amounts of a flexible foam each having a top surface and each positioned between the rows of the coil springs.
2 . The mattress assembly of claim 1 , wherein the first support surface comprises the top surface of the plurality of amounts of the flexible foam and the upper portion of each coil spring.
3 . The mattress assembly of claim 1 , further comprising an upper continuous sheet covering the upper portion of each coil spring.
4 . The mattress assembly of claim 3 , wherein the flexible foam is positioned atop the upper continuous sheet.
5 . The mattress assembly of claim 3 , wherein for each fabric pocket, a portion of the upper continuous sheet forms the top area of the fabric pocket.
6 . The mattress assembly of claim 5 , further comprising a lower continuous sheet covering the lower portion of each coil spring.
7 . The mattress assembly of claim 6 , wherein for each fabric pocket, a portion of the lower continuous sheet forms the bottom area of the fabric pocket.
8 . The mattress assembly of claim 1 , wherein each of the plurality of amounts of the flexible foam is a continuous amount of flexible foam extending between the rows of coil springs.
9 . The mattress assembly of claim 1 , wherein each of the amounts of the flexible foam is a plurality of discrete amounts of flexible foam positioned between the rows of the coil springs.
10 . The mattress assembly of claim 9 , wherein each of the plurality of discrete amounts of the flexible foam has a convex top.
11 . The mattress assembly of claim 1 , further comprising an upper body supporting layer positioned adjacent to the first support surface of the spring core; and
a lower foundation layer positioned adjacent to the second support surface of the spring core.