WO2018118037A1

WO2018118037A1 - Pocketed coil spring assembly

Info

Publication number: WO2018118037A1
Application number: PCT/US2016/067967
Authority: WO
Inventors: Darin T. Thomas; Hamid Ghanei
Original assignee: Sealy Technology LLC
Current assignee: Sealy Technology LLC
Priority date: 2016-12-21
Filing date: 2016-12-21
Publication date: 2018-06-28
Anticipated expiration: 2019-06-21

Abstract

A pocketed 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 pocketed coil spring assembly further includes a fabric pocket encasing the coil spring, a lower heat-conducting element positioned within the interior cavity and adjacent to the lower portion of the coil spring, an amount of phase change material positioned above and operably connected to the lower heat-conducting element, an upper heat-conducting element positioned above and operably connected to the amount of phase change material, and an amount of flexible foam positioned above and operably connected to the upper heat-conducting element. A support cushion is further provided that includes a plurality of the pocketed coil spring assemblies.

Description

POCKETED COIL SPRING ASSEMBLY

TECHNICAL FIELD

[0001] The present invention relates to pocketed coil spring assemblies. In particular, the present invention relates to pocketed coil spring assemblies that include an amount of phase change material and a heat-conducting element that collectively provide a cooling effect to an amount of flexible foam positioned above the heat-conducting element.

BACKGROUND

[0002] The effectiveness and desirability of a support cushion is partly a function of how comfortable a user is on the support cushion over an extended period of time. In this regard, some users find support cushions, and in particular mattresses, that include a visco-elastic foam to be warm after an extended period of time. One solution to this problem is the inclusion of phase change materials that absorb heat as they change from a solid to a liquid phase, i.e., melt. These phase change materials, however, may only cool for a short span of time. Thus, a support cushion that provides an extended cooling experience would be both highly desirable and beneficial.

SUMMARY

[0003] The present invention includes pocketed coil spring assemblies. In particular, the present invention includes pocketed coil spring assemblies that include an amount of phase change material and a heat-conducting element that collectively provide a cooling effect to an amount of flexible foam positioned above the heat-conducting element.

[0004] In one exemplary embodiment of the present invention, a pocketed coil spring assembly is provided that includes a coil spring having a lower portion and an upper portion which collectively define an interior cavity of the coil spring. The pocketed coil spring assembly further includes a fabric pocket that encases the coil spring, a lower heat-conducting element positioned within the interior cavity of the coil spring adjacent to the lower portion of the coil spring, an amount of phase change material positioned above and operably connected to the lower heat-conducting element, an upper heat-conducting element positioned above and operably connected to the phase change material, an amount of flexible foam positioned above and operably connected to the upper heat-conducting element, and a spacer layer positioned adjacent to the lower heat-conducting element.

[0005] The fabric pocket included in the pocketed coil spring assembly has a bottom area that covers the lower portion of the coil spring as well as a top area that covers the upper portion of the coil spring. The bottom area and the top area of the fabric pocket extend along the outside of the coil spring and form a generally cylindrical (or tubular) side surface of the fabric pocket. In this regard, the fabric pocket is preferably made of an inelastic fabric which can be joined or welded together by heat and pressure (e.g., via ultrasonic welding or by a similar thermal welding procedure) to form such a cylindrical structure. For example, suitable fabrics that can b e used for the fabric pocket can include one of various thermoplastic fibers known in the art, such as non-woven polymer-based fabric, non-woven polypropylene material, or non-woven polyester material. The top area of the fabric pocket is also connected to the bottom area of the fabric pocket within the interior cavity of the coil spring to create an upper recess that is defined by the top area of the fabric pocket and that extends into the interior cavity of the coil spring adjacent to the upper portion of the coil spring, as well as a lower recess that is defined by the bottom area of the fabric pocket and that extends into the interior cavity of the coil spring adjacent to the lower portion of the coil spring. The lower recess and the upper recess of the fabric pocket provide a suitable area into which other components of the present invention can be positioned. More specifically, the lower heat-conducting element and spacer layer are positioned in the lower recess, and the phase change material is positioned in the upper recess.

[0006] The lower heat-conducting element of the pocketed coil spring assembly includes a base plate that is positioned adjacent to the phase change material and further includes a plurality of fingers that extend downwardly from the base plate away from the phase change material. The lower heat-conducting element is made of a material with high thermal conductivity in order to dissipate heat away from the phase change material. For example, suitable materials that can be used for the lower heat-conducting element can include copper, aluminum, graphite, or any other such materials that would readily transfer heat out of the phase change material, into the base plate, and towards the plurality of fingers.

[0007] Similarly, the upper heat-conducting element includes a base plate that is positioned adjacent to the phase change material and further includes a plurality of fingers that extend from the base plate away from the phase change material. Also similar to the lower heat-conducting element, the upper heat-conducting element is made of a material with high thermal conductivity such as copper, aluminum, or graphite, but in the case of the upper heat-conducting element, this is to direct heat towards the phase change material rather than away from the phase change material. In particular, the upper heat-conducting element is positioned between the phase change material and the flexible foam such that the plurality of fingers of the upper heat- conducting element extend from the base plate into the flexible foam, but do not extend all of the way through the flexible foam. The plurality of fingers of the upper heat-conducting element therefore more readily transfer heat out of the flexible foam, towards the base plate, and into the phase change material.

[0008] The flexible foam included in the pocketed coil spring assembly is generally comprised of a type of foam having a density suitable for supporting and distributing pressure from a user's body, or portion thereof, resting on the pocketed coil spring assembly. The flexible foam is also comprised of a two-part polyurethane foam that can be dispensed as a liquid foam precursor directly onto the upper heat-conducting element such that the flexible foam is operably connected to the upper heat-conducting element and surrounds each of the plurality of fingers of the upper heat-conducting element. The flexible foam also has a relatively low thermal conductivity such that the flexible foam acts substantially as an insulator.

[0009] By comparison, the spacer layer included in the pocketed coil spring assembly is generally comprised of a highly-porous material suitable for allowing heat to readily dissipate away from the plurality of fingers of the lower heat-conducting element. Such porous materials include, but are not limited to: convoluted foam, extruded filaments, spacer fabrics, and the like. In some embodiments, the spacer layer surrounds the plurality of fingers of the lower heat- conducting element and substantially fills the lower recess of the fabric pocket, but in other embodiments the spacer layer may fill only a portion of the lower recess. Regardless, because of the highly porous spacer layer, the area surrounding the fingers of the lower heat-conducting element generally has higher thermal conductivity as compared to the area surrounding the fingers of the upper heat-conducting element. [0010] In another embodiment of the present invention, a support cushion in the form of a mattress is provided that comprises a spring core including of a plurality of the pocketed coil spring assemblies substantially similar to the pocketed coil spring assemblies described above, except that the spacer layer is in the form of a continuous layer that spans across the plurality of pocketed coil spring assemblies. That is to say, the spacer layer is positioned below the spring core and adjacent to the lower heat-conducting elements of each of the plurality of pocketed coil spring assemblies. The exemplary mattress further includes a fan operably connected to the spacer layer and configured to draw an amount of air through the spacer layer. In this way, the fan provides forced convection of heat away from the lower heat conducting elements by way of the air moving through the spacer layer, which, in turn, allows for a greater cooling effect in the mattress. The exemplary mattress also has an upper body supporting layer positioned above the spring core adjacent to the top surface of the flexible foam and a lower foundation layer positioned below the spacer layer. A side panel extends between the upper body supporting layer and the lower foundation layer around the entire periphery of the spring core and spacer layer.

[0011] Further features and advantages of the present invention will become evident to those of ordinary skill in the art after a study of the description, figures, and non -limiting examples in this document.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is a partial side view of an exemplary pocketed coil spring assembly made in accordance with the present invention with a portion of the fabric pocket removed; and

[0013] FIG. 2 is a perspective view of an exemplary support cushion in the form of a mattress made in accordance with the present invention and with a portion of the mattress removed to show a plurality of the pocketed coil spring assemblies of FIG. 1 positioned in the interior of the mattress.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0014] The present invention includes pocketed coil spring assemblies. In particular, the present invention includes pocketed coil spring assemblies that include an amount of phase change material and a heat-conducting element that collectively provide a cooling effect to an amount of flexible foam positioned above the heat-conducting element.

[0015] Referring first to FIG. 1, in one exemplary embodiment of the present invention, a pocketed coil spring assembly 10 is provided that includes a coil spring 20 having a lower portion 22 and an upper portion 24 which collectively define an interior cavity 28 of the coil spring 20. The pocketed coil spring assembly 10 further includes a fabric pocket 30 that encases the coil spring 20, a lower heat-conducting element 40 positioned within the interior cavity 28 of the coil spring 20 adjacent to the lower portion 22 of the coil spring 20, an amount of phase change material 60 positioned above and operably connected to the lower heat-conducting element 40, an upper heat-conducting element 50 positioned above and operably connected to the phase change material 60, an amount of flexible foam 62 positioned above and operably connected to the upper heat-conducting element 50, and a spacer layer 70 positioned adjacent to the lower heat-conducting element 40.

[0016] Referring still to FIG. 1, the coil spring 20 included in the pocketed coil spring assembly 10 is made of a continuous wire that extends from a lower end convolution at the lower portion 22 of the coil spring to an upper end convolution at the upper portion 24 of the coil spring 20. In the coil spring 20, there are three intermediate convolutions that helically spiral between the lower end convolution and the upper end convolution, such that the coil spring 20 is made of a total of five convolutions or turns. Of course, various other springs, such as coil springs having a different number of convolutions, could also be used in an exemplary pocketed coil spring assembly without departing from the spirit and scope of the present invention.

[0017] Referring still to FIG. 1, the fabric pocket 30 included in the pocketed coil spring assembly 10 has a bottom area 31 that covers the lower portion 22 of the coil spring 20 as well as a top area 33 that covers the upper portion 24 of the coil spring 20. In the exemplary pocketed coil spring assembly 10 shown in FIG. 1, the bottom area 31 and the top area 33 of the fabric pocket 30 extend along the outside of the coil spring 20 and form a generally cylindrical (or tubular) side surface 36 of the fabric pocket 30. In this regard, the fabric pocket 30 is preferably made of an inelastic fabric which can be joined or welded together by heat and pressure (e.g., via ultrasonic welding or by a similar thermal welding procedure) to form such a cylindrical structure. For example, suitable fabrics that can be used for the fabric pocket 30 can include one of various thermoplastic fibers known in the art, such as non-woven polymer-based fabric, non- woven polypropylene material, or non-woven polyester material.

[0018] With further respect to the fabric pocket 30 and referring still to FIG. 1, which shows a portion of the side surface 36 of the fabric pocket 30 removed to reveal the coil spring 20 and the interior of the pocketed coil spring assembly 10, the top area 33 of the fabric pocket 30 is connected to the bottom area 31 of the fabric pocket 30 within the interior cavity 28 of the coil spring 20. The top area 33 of the fabric pocket 30 can be connected to the bottom area 31 of the fabric pocket 30 by any number of means, including a tuft, a staple, a weld, glue, stitches, clamps, hook-and-loop fasteners, and the like. By connecting the top area 33 of the fabric pocket 30 to the bottom area 31 of the fabric pocket 30 within the interior cavity 28 of the coil spring 20, however, not only is it possible to impart a desired level of pre-compression, stability, and/or stretchability to the pocketed coil spring assembly 10, but the connection of the top area 33 of the fabric pocket 30 to the bottom area 31 of the fabric pocket 30 also creates an upper recess 34 that is defined by the top area 33 of the fabric pocket 30 and that extends into the interior cavity 28 of the coil spring 20 adjacent to the upper portion 24 of the coil spring 20, as well as a lower recess 32 that is defined by the bottom area 31 of the fabric pocket 30 and that extends into the interior cavity 28 of the coil spring adjacent to the lower portion 22 of the coil spring 20.

[0019] In the exemplary embodiment shown in FIG. 1 , the top area 33 of the fabric pocket 30 is connected to the bottom area 31 of the fabric pocket 30 about half of the way up the height of the coil spring 20 such that the lower recess 32 and the upper recess 34 extend into the interior cavity 28 of the coil spring 20 to about half of the height of the coil spring 20. Furthermore, the connection between the top area 33 and the bottom area 31 of the fabric pocket 30 is generally centered in the interior cavity 28 of the coil spring 20 such that the upper recess 34 and the lower recess 32 each have a substantially symmetrical shape. In this way, it is contemplated that the connection between the top area 33 of the fabric pocket 30 and the bottom area 31 of the fabric pocket 30 is substantially circular such that the lower recess 32 and the upper recess 34 are formed in the shape of a truncated cone. However, it is of course appreciated that depending on how the top area 33 of the fabric pocket 30 is joined to the bottom area 31 of the fabric pocket 30, the lower recess 32 and the upper recess 34 can also be formed with a different shape. For example, by changing the shape of the connection to a square or rectangle, the recesses could be formed in the shape of a truncated pyramid or by increasing the size of the connected portion within the interior cavity 28 of the coil spring 20, the recesses could be formed in the shape of a cylinder. Regardless of the particular shape of the lower recess 32 and the upper recess 34, by joining the top area 33 of the fabric pocket 30 to the bottom area 31 of the fabric pocket 30, the lower recess 32 and the upper recess 34 provide a suitable area into which other components of the present invention can be positioned. More specifically, in the exemplary embodiment shown in FIG. 1, the lower heat-conducting element 40 and spacer layer 70 are positioned in the lower recess 32, and the phase change material 60 is positioned in the upper recess 34.

[0020] Referring still to FIG. 1, the phase change material 60 included in the pocketed coil spring assembly 10 is typically comprised of substances having a high heat of fusion and that store or release heat as the substances oscillate between solid and liquid forms (i.e., phase change materials). As a result of applying heat to the phase change material 60, the phase change material 60 included in the upper recess 34 of the fabric pocket 30 changes from solid to liquid form (i.e., melts) while continually absorbing heat and maintaining a steady temperature until all of the phase change material 60 has been transformed from a solid to a liquid form. When the heat source is removed from the phase change material 60, the phase change material 60 will then revert back to solid form (i.e., re-solidify) and give off the heat which caused it to initially melt. As mentioned above, the phase change material 60 is positioned in the upper recess 34 defined by the fabric pocket 30, and more specifically, in the exemplary embodiment shown in FIG. 1, the phase change material 60 substantially fills all of the upper recess 34. In this way, it is contemplated that the phase change material 60 is typically directly dispensed into the upper recess 34, and therefore the fabric pocket 30, or at least the portion defining the upper recess 34, is comprised of a material that will prevent the liquid phase of the phase change material 60 from penetrating the fabric pocket 30.

[0021] Referring still to FIG. 1, the lower heat-conducting element 40 of the pocketed coil spring assembly 10 includes a base plate 42 that is positioned adjacent to the phase change material 60 and further includes a plurality of fingers 44 that extend downwardly from the base plate 42 away from the phase change material 60. The lower heat-conducting element 40 is made of a material with high thermal conductivity in order to dissipate heat away from the phase change material 60, as further discussed below. For example, suitable materials that can be used for the lower heat-conducting element 40 can include copper, aluminum, graphite, or any other such materials that would readily transfer heat out of the phase change material 60, into the base plate 42, and towards the plurality of fingers 44. To this end, the base plate 42 of the lower heat- conducting element 40 is substantially the same size and shape as the connection between the top area 33 of the fabric pocket 30 and the bottom area 31 of the fabric pocket 30 in order to maximize the thermal connection between the phase change material 60 and the base plate 42 of the lower heat-conducting element 40. In the exemplary embodiment shown in FIG. 1, the fingers 44 are substantially pin shaped extensions that are equally spaced across the surface of the base plate 42, but, other configurations of the fingers are also contemplated including, for example, fingers having alternative shapes such as plates, fins, coils, loops, and the like.

Regardless of the shape and position of the plurality of fingers 44, each finger 44 is configured to draw heat away from the base plate 42 and provide a greater surface area for that heat to dissipate away from the lower heat-conducting element 40.

[0022] Much like the lower heat-conducting element 40, the upper heat-conducting element 50 includes a base plate 52 that is positioned adjacent to the phase change material 60 and further includes a plurality of fingers 54 that extend from the base plate 52 away from the phase change material 60. Also similar to the lower heat-conducting element 40, the upper heat- conducting element 50 is made of a material with high thermal conductivity such as copper, aluminum, or graphite, but in the case of the upper heat-conducting element 50, this is to direct heat towards the phase change material 60 rather than away from the phase change material 60, as further discussed below. In particular, the upper heat-conducting element 50 is positioned between the phase change material 60 and the flexible foam 62 such that the plurality of fingers 54 of the upper heat-conducting element 50 extend from the base plate 52 into the flexible foam 62. The plurality of fingers 54 therefore more readily transfer heat out of the flexible foam 62, towards the base plate 52, and into the phase change material 60. The base plate 52 of the upper heat-conducting element 50 is substantially the same size and shape as the upper surface of the phase change material 60 in order to maximize the thermal conductivity between the base plate 52 of the upper heat-conducting element 50 and the phase change material 60. For example, in the exemplary embodiment shown in FIG. 1, the upper surface of the phase change material 60 as well as the base plate 52 are both circular. As also shown in the exemplary embodiment shown in FIG. 1, the fingers 54 are substantially pin shaped extensions that are equally spaced across the surface of the base plate 52, but other configurations of the fingers are also

contemplated including, for example, fingers having alternatives shapes such as plates, fins, coils, loops, and the like. Additionally, as shown in FIG. 1, the fingers 54 extend into the flexible foam 62 but do not extend all of the way through the flexible foam 62. Regardless of the shape and position of the plurality of fingers 54, each finger 54 is configured to provide an increased surface area for heat to dissipate from the flexible foam 62 and into the base plate 52 of the upper heat-conducting element 50.

[0023] Referring still to FIG. 1, the flexible foam 62 included in the pocketed coil spring assembly 10 is generally comprised of a type of foam having a density suitable for supporting and distributing pressure from a user's body, or portion thereof, resting on the pocketed coil spring assembly 10. Such flexible foams include, but are not limited to: latex foam; reticulated or non-reticulated visco-elastic foam (sometimes referred to as memory foam or low -resilience foam); reticulated or non -reticulated non-visco-elastic foam; high-resilience polyurethane foam; expanded polymer foams (e.g., expanded ethylene vinyl acetate, polypropylene, p olystyrene, or polyethylene); and the like. In the exemplary embodiment shown in FIG. 1, the flexible foam 62 is comprised of a two-part polyurethane foam that can be dispensed as a liquid foam precursor directly onto the upper heat-conducting element 50 such that the flexible foam 62 is operably connected to the upper heat-conducting element 50 and surrounds each of the plurality of fingers 54 of the upper heat-conducting element 50. In particular, as shown in FIG. 1, the flexible foam 62 is formed into a small, substantially spherical ball with a top surface 64 having a convex shape that is positioned above the plurality of fingers 54 of the upper heat-conducting element 50, but it is appreciated that varying the method of application or composition of the liquid foam precursor would result in a different shape of the flexible foam 62.

[0024] With respect to hardness, the flexible foam 62 included in the pocketed coil spring assembly 10 can, in some embodiments, have a hardness of at least about 10 N to no greater than about 80 N, as measured by exerting pressure from a plate against a sample of the material to a compression of at least 40% of an original thickness of the material at approximately room temperature (i.e., 21°C to 23°C), where the 40% compression is held for a set period of time as established by the International Organization of Standardization (ISO) 2439 hardness measuring standard. In some embodiments, the flexible foam 62 included in the pocketed coil spring assembly 10 has a hardness of about 10 N, about 20 N, about 30 N, about 40 N, about 50 N, about 60 N, about 70 N, about 80 N, about 90 N, about 100 N, about HO N, about 120 N, about 130 N, about 140 N, about 150 N, about 160 N, about 170 N, about 180 N, about 190 N, or about 200 N, to provide a desired degree of comfort and body-conforming or supporting qualities. [0025] With respect to density, the flexible foam 62 included in the pocketed coil spring assembly 10 can, in some embodiments, also have a density that assists in providing a desired degree of comfort and body-conforming qualities, as well as an increased degree of material durability. In some embodiments, the density of the flexible foam 62 included in the pocketed coil spring assembly 10 has a density of no less than about 30 kg/m³ to no greater than about 150 kg/m³. In some embodiments, the density of the flexible foam 62 included in the pocketed coil spring assembly 10 is about 15 kg/m³, about 20 kg/m³, about 25 kg/m³, about 30 kg/m³, about 40 kg/m 3 , about 50 kg/m 3 , about 60 kg/m 3 , about 70 kg/m 3 , about 80 kg/m 3 , about 90 kg/m 3 , about 100 kg/m³, about 110 kg/m³, about 120 kg/m³, about 130 kg/m³, about 140 kg/m³, or about 150 kg/m³. Of course, the selection of a flexible foam having a particular density will affect other characteristics of the foam, including its hardness, the manner in which the foam responds to pressure, and the overall feel of the foam, but it should be appreciated that a flexible foam having a desired density and hardness can readily be selected for a particular pocketed coil spring assembly or application as desired.

[0026] The flexible foam 62 used in the exemplary pocketed coil spring assembly 10 shown in FIG. 1 typically has a relatively low thermal conductivity such that the flexible foam 62 acts substantially as an insulator. By comparison, and referring still to FIG. 1, the spacer layer 70 included in the pocketed coil spring assembly 10 is generally comprised of a highly porous material suitable for allowing heat to readily dissipate away from the plurality of fingers 44 of the lower heat-conducting element 40. Such porous materials include, but are not limited to: convoluted foam, extruded filaments, spacer fabrics, and the like. In the exemplary embodiment shown in FIG. 1, the spacer layer 70 surrounds the plurality of fingers 44 of the lower heat- conducting element 40 and substantially fills the lower recess 32 of the fabric pocket 30, but in other embodiments the spacer layer 70 may fill only a portion of the lower recess 32. In any event, because of the highly porous spacer layer 70 the area surrounding the fingers 44 of the lower heat-conducting element 40 has a higher thermal conductivity as compared to the area surrounding the fingers 54 of the upper heat-conducting element 50, as further discussed below.

[0027] Referring still to FIG. 1, in operation, the pocketed coil spring assembly 10 provides a cooling effect at the top surface 64 of the flexible foam 62. In particular, when a user's body or portion thereof, rests on the pocketed coil spring assembly 10, the heat of the user's body is absorbed by the flexible foam 62 which then gradually heats up. The upper heat-conducting element 50 with its plurality of fingers 54 helps direct some of the heat absorbed by the flexible foam 62 into the phase change material 60. As mentioned above, the phase change material 60 is capable of absorbing heat and maintaining a steady temperature until all of the phase change material 60 has been transformed from a solid to a liquid form. Since the flexible foam 62 is thermally connected to the phase change material 60 by way of the upper heat-conducting element 50, the flexible foam 62 is therefore also maintained at or near the same temperature of the phase change material 60 until all of the phase change material 60 has been transformed from a solid to a liquid form.

[0028] As also mentioned above, upon removing the source of heat (i.e., the user's body or portion thereof positioned on the pocketed coil spring assembly 10), the phase change material 60 will begin to revert back to solid form and give off the heat that caused it to initially melt. It is contemplated that the heat released by the phase change material 60 will be directed not only back through the upper heat-conducting element 50, but also through the lower heat-conducting element 40. However, it is contemplated that the lower thermal conductivity of the flexible foam 62 positioned adjacent to the upper heat-conducting element 50 will slow the heat transfer through the upper heat-conducting element 50 such that a larger portion of the heat given off of the phase change material 60 will transfer through the lower heat-conducting element 40. That is to say, the flexible foam 62 acts as an insulator that slows the transfer of heat through the upper heat-conducting element 50 so that more heat will transfer through the lower heat-conducting element 40 than the upper heat-conducting element 50 due to the higher thermally conductivity of the spacer layer 70. Since more heat from the phase change material 60 transfers through the lower heat-conducting element 40 into the spacer layer 70 than through the upper heat- conducting element 50 into the flexible foam 62, the pocketed coil spring assembly 10 provides a net cooling effect at the top surface 64 of the flexible foam 62.

[0029] Referring now to FIG. 2, in another embodiment of the present invention, a support cushion 100 is further provided that is in the form of a mattress and that includes a plurality of the pocketed coil spring assemblies 110 made in accordance with the present invention. In particular, the support cushion 100 comprises a spring core 112 including of a plurality of the pocketed coil spring assemblies 110 substantially similar to the pocketed coil spring assemblies 10 described above with reference to FIG. 1. In particular, each of the pocketed coil spring assemblies 110 of the spring core 112 shown in FIG. 2 includes a coil spring 120 with a lower portion 122 and an upper portion 124 that collectively define an interior cavity 128 of the coil spring 120 and a fabric pocket 130 with a bottom area 131 that covers the lower portion 122 of the coil spring 120 and a top area 133 that covers the upper portion 124 of the coil spring 120, similar to the pocketed coil springs assemblies 10 described above with reference to FIG. 1 .

[0030] As shown in FIG. 2, the spring core 112 also includes an upper continuous sheet 138 which extends across the upper portion 124 of each of the plurality of coil springs 120, and a lower continuous sheet 139 which extends across the lower portion 122 of each of the plurality of coil springs 120. The upper continuous sheet 138 is connected to the lower continuous sheet 139 around and between each of the plurality of coil springs 120, such that the upper continuous sheet 138 and the lower continuous sheet 139 collectively form the fabric pocket 130 that encases each of the coil springs 120. Specifically, a portion of the upper continuous sheet 138 forms, at least in part, the top area 133 of the fabric pocket 130 that covers the upper portion 124 of the coil spring 120 of each of the plurality of pocketed coil spring assemblies 110. Similarly, a portion of the lower continuous sheet 139 forms, at least in part, the bottom area 131 of the fabric pocket 130 that covers the lower portion 122 of the coil spring 120 of each of the plurality of pocketed coil spring assemblies 110. The upper continuous sheet 138 is also connected to the lower continuous sheet 139 within the interior cavity 128 of the coil spring 120 forming the lower recess 132 and the upper recess 134 substantially similar to the lower recess 32 and the upper recess 34 described above with reference to FIG. 1.

[0031] As also shown in FIG. 2, and similar to the pocketed coil spring assembly 10 shown in FIG. 1, each pocketed coil spring assembly 110 in the spring core 112 of FIG. 2 further includes a lower heat-conducting element 140 with a base plate 142 and plurality of fingers 144 positioned in the lower recess 132 of each fabric pocket 130, an amount of phase change material 160 positioned within the upper recess 134 of each fabric pocket 130, an upper heat- conducting element 150 with a base plate 152 and plurality of fingers 154 positioned above and operably connected to the phase change material 160, and an amount of flexible foam 162 positioned above and operably connected to the upper heat-conducting element 150 where the flexible foam 162 has a top surface 164 that is positioned above the plurality of fingers 154 of the upper heat-conducting element 150. [0032] The mattress 100 shown in FIG. 2 further includes a spacer layer 170 similar to the spacer layer 70 described above with respect to FIG. 1 but the spacer layer 170 in FIG. 2 is a continuous layer that spans across the plurality of pocketed coil spring assemblies 110. That is to say, the spacer layer 170 is positioned below the spring core 112 and adjacent to the lower heat- conducting elements 140 of each of the plurality of pocketed coil spring assemblies 110. Similar to the spacer layer 70 described above with respect to FIG. 1, the spacer layer 170 included in the mattress 100 of FIG. 2 is generally comprised of a highly porous material suitable for allowing heat to readily dissipate away from the lower heat-conducting elements 140 of the plurality of pocketed coil spring assemblies 110, but the spacer layer 170 in FIG. 2 also acts as a support layer within the mattress 100.

[0033] The exemplary mattress 100 further includes a fan 172 operably connected to the spacer layer 170 and configured to draw an amount of air through the spacer layer 170. In this way, the fan 172 provides forced convection of heat away from the lower heat conducting elements 140 by way of the air moving through the spacer layer 170 which will allow for a greater cooling effect in the mattress 100. The fan 172 shown in FIG. 2 is positioned to the side of the spacer layer 170 but it is contemplated that one or more fans could also be positioned below the spacer layer, or any other position which would allow the fan to draw an amount of air through the spacer layer 170. Of course, it is also contemplated that in some embodiments of the present invention, there are no fans and the heat is drawn from the lower heat conducting elements 140 into the spacer layer 170 by passive convection and/or conduction of the heat.

[0034] Of course, it should be understood that each of the plurality of pocketed coil spring assemblies 110 included in the mattress 100 shown in FIG. 2 provides a cooling effect at the top surface 164 of the flexible foam 162 in substantially the same manner as the pocketed coil spring assembly 10 shown in FIG. 1 and as described above, except that the fan 172 operably connected to the spacer layer 170 in the mattress 100 helps dissipate heat more readily through the spacer layer 170, thus improving the overall cooling effect in the mattress 100 shown in FIG. 2.

[0035] Referring still to FIG. 2, the exemplary mattress 100 further comprises an upper body supporting layer 180 positioned above the spring core 112 adjacent to the top surface 164 of the flexible foam 162 and a lower foundation layer 182 positioned below the spacer layer 170. A side panel 184 extends between the upper body supporting layer 180 and the lower foundation layer 182 around the entire periphery of the spring core 112 and spacer layer 170.

[0036] In the exemplary embodiment shown in FIG. 2, the upper body supporting layer 180 is comprised of a visco-elastic foam; however, it is contemplated that the upper body supporting layer 180 can also be comprised of some combination of foam, upholstery, and/or other soft, flexible materials known in the art. Furthermore, the upper body supporting layer 180 can be comprised of multiple layers of material configured to improve the comfort or support of the upper body supporting layer 180. In contrast to the upper body supporting layer 180, the lower foundation layer 182 is generally comprised of a piece of wood, or other similarly rigid member, and is configured to support the plurality of pocketed coil spring assemblies 110.

[0037] In some embodiments of the support cushion 100 of the present invention, the spring core 112 can be characterized as comprising an upper comfort layer and a lower support layer positioned below the upper comfort layer. The upper comfort layer includes the upper heat- conducting elements 150 with the base plate 152 and plurality of fingers 154 as well as the flexible foam 162 positioned above and operably connected to the base plate 152 and

surrounding each of the plurality of fingers 154 of the upper heat-conducting element 150. The lower support layer includes the phase change material 160 positioned adjacent to and operably connected to the bottom side of the base plate 152 of the upper heat-conducting element. In some further embodiments, the lower support layer further includes the coil springs 120 having an upper portion 124 and a lower portion 122 which collectively define the interior cavity 128 of the coil spring and the fabric pocket 130 encasing the coil spring 120 with the phase change material 160 positioned in the interior cavity 128 of the coil spring 120. The lower support layer can, in some embodiments, further include the lower heat-conducting elements 140 positioned in the interior cavity 128 of the coil springs 120 and operably connected to the phase change material 160 with the base plate 142 of the lower heat-conducting element 140 positioned adjacent to the phase change material 160 and the plurality of fingers 144 extending away from the base plate 142. The lower support layer can also, in some embodiment, further include the spacer layer 170, or a portion thereof, positioned below and operably connected to the lower heat-conducting element 140 such that the plurality of fingers 144 of the lower heat-conducting element extend away from the base plate 142 and into the spacer layer 170.

[0038] In an exemplary method of manufacturing a support cushion such as the support cushion 100 shown in FIG. 2, a plurality of pocketed coil springs arranged in a matrix are first provided. In particular, the plurality of coil springs 120 shown in FIG. 2 along with the upper continuous sheet 138 and lower continuous sheet 139 connected around and between each of the plurality coil springs 120 is first provided. This matrix of pocketed coil springs accordingly has a lower recess 132 and an upper recess 134 extending into the interior cavity 128 of each coil spring 120. A lower heat-conducting element 140 is then positioned within each lower recess 132 with the plurality of fingers 144 extending downward. An amount of phase change material 160 is then dispensed inside each upper recess 134 and allowed to harden. After the phase change material 160 is dispensed into the upper recess 134, an upper heat-conducting element 150 is positioned on top of the phase change material 160 with the plurality of fingers 154 of the upper heat-conducting element 150 facing upward and away from the phase change material 160. A liquid foam precursor is then injected onto each of the upper heat-conducting elements 150 such that the resulting flexible foam 162 covers the plurality of fingers 154 of the upper heat-conducting element 150. The structure at this point is the spring core 112 shown in FIG. 2 and described above which includes the plurality of pocketed coil spring assemblies 110 with lower heat-conducting elements 140, phase change material 160, upper heat-conducting elements 150, and flexible foam 162. The spring core 112 is then positioned on top of the spacer layer 170 such that the plurality of fingers 144 of the lower heat-conducting elements 140 extend into the spacer layer 170 as shown in FIG. 2. Finally, the upper body supporting layer 180, the lower foundation layer 182, and side panel 184 are positioned and secured around the spring core 112 and spacer layer 170 forming the support cushion 100.

[0039] One of ordinary skill in the art will recognize that additional embodiments are also possible without departing from the teachings of the present invention or the scope of the claims which follow. This detailed description, and particularly the specific details of the exemplary embodiments disclosed herein, is given primarily for clarity of understanding, and no

unnecessary limitations are to be understood therefrom, for modifications will become apparent to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the claimed invention.

Claims

CLAIMS What is claimed is:

1 . A pocketed coil spring assembly, comprising:

a coil spring having an upper portion and a lower portion, the upper portion and the lower portion collectively defining an interior cavity of the coil spring;

a fabric pocket encasing the coil spring;

a lower heat-conducting element positioned within the interior cavity and adjacent to the lower portion of the coil spring;

an amount of phase change material positioned above and operably connected to the lower heat-conducting element;

an upper heat-conducting element positioned above and operably connected to the amount of phase change material; and

an amount of flexible foam positioned above and operably connected to the upper heat- conducting element.

2. The pocketed coil spring assembly of claim 1, wherein the fabric pocket defines an upper recess extending into the interior cavity of the coil spring, and wherein the phase change material is positioned in the upper recess.

3. The pocketed coil spring assembly of claim 1, wherein the fabric pocket defines an upper recess extending into the interior cavity of the coil spring adjacent to the upper portion of the coil spring and a lower recess extending into the interior cavity of the coil spring adjacent to the lower portion of the coil spring, and

wherein the phase change material is positioned in the upper recess and the lower heat- conducting element is positioned in the lower recess.

4. The pocketed coil spring assembly of claim 1, wherein the upper heat-conducting element includes a base plate positioned between the phase change material and the flexible foam and a plurality of fingers extending from the base plate into the flexible foam.

5. The pocketed coil spring assembly of claim I , wherein the lower heat-conducting element includes a base plate positioned adjacent to the phase change material and a plurality of fingers extending downwardly from the base plate.

6. The pocketed coil spring assembly of claim 1, further comprising a spacer layer positioned adjacent to the lower heat-conducting element.

7. The pocketed coil spring assembly of claim 6, further comprising a fan operably connected to the spacer layer, the fan for drawing an amount of air through the spacer layer.

8. The pocketed coil spring assembly of claim 6, wherein the lower heat-conducting element includes a base plate positioned between the phase change material and the spacer layer and a plurality of fingers extending away from the base plate and into the spacer layer.

9. The pocketed coil spring assembly of claim I, wherein the upper heat-conducting element, the lower heat-conducting element, or both the upper heat-conducting element and the lower heat-conducting element are comprised of a material selected from the group consisting of copper, aluminum, and graphite.

1 0. The pocketed coil spring assembly of claim 1 , wherein the fabric pocket is comprised of a non-woven textile.

1 1. The pocketed coil spring assembly of claim I, wherein the flexible foam is comprised of a visco-elastic foam.

12. The pocketed coil spring assembly of claim 6, wherein the spacer layer is comprised of a porous material.

13. The pocketed coil spring assembly of claim 12, wherein the porous material is selected from the group consisting of convoluted foam, extruded filaments, and spacer fabrics.

14. A support cushion, comprising:

a spring core including a plurality of pocketed coil springs, each pocketed coil spring having

a fabric pocket encasing the coil spring, a lower heat-conducting element positioned within the interior cavity and adjacent to the lower portion of the coil spring,

an amount of phase change material positioned above and operably connected to the lower heat-conducting element,

an upper heat-conducting element positioned above and operably connected to the amount of phase change material, and

an amount of flexible foam positioned above and operably connected to the upper heat-conducting element; and

an upper body supporting layer positioned above the spring core; and

a lower foundation layer positioned below the spring core.

1 5. The support cushion of claim 14, wherein the fabric pocket defines an upper recess extending into the interior cavity of the coil spring adjacent to the upper portion of the coil spring and a lower recess extending into the interior cavity of the coil spring adjacent to the lower portion of the coil spring, and

16. A support cushion, comprising:

an upper comfort layer including

an upper heat-conducting element having a base plate and a plurality of fingers extending upwardly from the base plate, and

an amount of flexible foam positioned above and operably connected to the base plate, the amount of flexible foam surrounding each of the plurality of fingers of the upper heat- conducting element, and

a lower support layer positioned below the upper comfort layer, the lower support layer including an amount of phase change material positioned adjacent to and operably connected to a bottom side of the base plate of the upper heat-conducting element.

17. The support cushion of claim 16, wherein the lower support layer further comprises: a coil spring having an upper portion and a lower portion, the upper portion and the lower portion collectively defining an interior cavity of the coil spring; and

a fabric pocket encasing the coil spring;

wherein the phase change material is positioned in the interior cavity of the coil spring.

18. The support cushion of claim 17, wherein the lower support layer further comprises a lower heat-conducting element positioned in the interior cavity of the coil spring and operably connected to the amount of phase change material.

19. The support cushion of claim 18, wherein the fabric pocket defines an upper recess extending into the interior cavity of the coil spring adjacent to the upper portion of the coil spring and a lower recess extending into the interior cavity of the coil spring adjacent to the lower portion of the coil spring, and

20. The support cushion of claim 18, wherein the lower support layer further comprises a spacer layer positioned below and operably connected to the lower heat-conducting element.

2 1 . The support cushion of claim 20, wherein the lower heat-conducting element includes a base plate positioned adjacent to the phase change material and a plurality of fingers extending away from the base plate and into the spacer layer.