Abstract: A suspended matrix support structure has a perimeter frame which supports a flexible matrix formed with intersecting flexible members, the ends of which are supported by the perimeter frame. Edges of the flexible members are held within channels which form a frame about the flexible matrix. In one embodiment, the perimeter frame is constructed of foam with contoured features which support the frame of the flexible matrix. The flexible members of the flexible matrix extend across the expanse within the perimeter frame to provide a flexible support structure which can be used as a mattress, mattress foundation or both in combination.

Abstract: A mattress foundation with a perimeter structure has a frame, springs mounted upon the frame, and a grid supported by the springs, and perimeter structure at a perimeter of the frame which extends from the frame to the grid, forming an exterior wall which extends from the frame to a border wire of the grid. When the perimeter structure is made of structural and reflexive material such as closed-cell foam, it co-acts with the grid and springs and provides additional support to the perimeter region of the grid and foundation. The exterior wall of the perimeter structure forms a solid surface over which padding or upholstery is placed.

Abstract: A mattress foundation with a perimeter structure has a frame, springs mounted upon the frame, and a grid supported by the springs, and perimeter structure at a perimeter of the frame which extends from the frame to the grid, forming an exterior wall which extends from the frame to a border wire of the grid. When the perimeter structure is made of structural and reflexive material such as closed-cell foam, it co-acts with the grid and springs and provides additional support to the perimeter region of the grid and foundation. The exterior wall of the perimeter structure forms a solid surface over which padding or upholstery is placed.

Abstract: A suspended matrix support structure has a perimeter frame which supports a flexible matrix formed with intersecting flexible members, the ends of which are supported by the perimeter frame. Edges of the flexible members are held within channels which form a frame about the flexible matrix. In one embodiment, the perimeter frame is constructed of foam with contoured features which support the frame of the flexible matrix. The flexible members of the flexible matrix extend across the expanse within the perimeter frame to provide a flexible support structure which can be used as a mattress, mattress foundation or both in combination.

Abstract: Devices and methods for assembly of flexible weight bearing structures such as mattress foundations using the composite material spring modules are described. The invention provides assembly jigs for dimensionally fixed attachment of spring modules to frame members, and alignment of frame members with attached spring modules for attachment to an overlying grid. The jigs comprise blocks which are suitably slidably mounted on a jig channel, which is suitably an extrusion. The blocks are fixed at a predetermined position on a jig channel and are configured to receive a portion of a frame member. Each block further has a structure for securing a spring module at a predetermined position relative to a received frame member.

Abstract: Composite material springs with integrals spacers for located between a frame attachment fitting and a spring body provide springs with an increased vertical profile for support structures with greater height. Spring elements are formed with encapsulated fibers. Attachment fittings and other structural elements such as the spacers are integrally formed by molding about the spring elements, in any suitable form for integration and assembly with spring support structure assemblies, such as a support frame on which the composite material springs are mounted, and a support structure such as a grid or wire work to which the springs are attached by the various types of attachment fittings. Direct mounting of springs to surfaces of frame members is also disclosed.

Abstract: Composite material spring modules have a fiber reinforced composite material spring body with attachment fittings integrally formed about the spring body. The attachment fittings are molded of a flexible material which dynamically responds to changes in the shape of the spring body upon deflection. Integral formation of the fittings with the spring body provides a unified single piece module which is readily attachable to any structure where spring support is desired. In one embodiment, a mounting foot is configured for mounting of the spring module directly to a planar surface of a supporting frame member by a fastener, or alternatively configured to engage with a frame member without use of a fastener. The composite material spring modules exhibit the properties of stiffness and return to uncompressed state from total depth deflection without set.

Abstract: Composite material spring modules and methods of manufacture are described having a fiber reinforced composite material spring body with attachment fittings integrally formed about the spring body. The attachment fittings are molded of a flexible material which dynamically responds to changes in the shape of the spring body upon deflection. Integral formation of the fittings with the spring body provides a unified single piece module which is readily attachable to any structure where spring support is desired. The composite material spring modules exhibit the properties of stiffness and return to uncompressed state from total depth deflection without set. The composite material spring modules with integrally formed fittings are described a mattress foundation, by attachment to high and low profile frames and to an overlying grid. Methods of manufacture of the composite material spring modules with integrally formed attachment fittings are described.

Abstract: High and low profile mattress foundation frames have perimeter and transverse members, and upper members to which spring modules are attached to support a grid over the frame, to form a flexible support surface for a mattress. In a high profile version of the frame, transverse members are oriented with a major width perpendicular to a major width of the perimeter members, to provide structural rigidity and increased height to the frame. Low profile spring modules, such as the described composite material spring modules, supported by the high profile frame form a foundation which is comparable in overall height to conventional mattress foundations which use wire-form spring modules. In a low profile version of the frame, the major widths of the perimeter and transverse members are arranged parallel, and longitudinal members are supported by the transverse members.

Abstract: A low profile composite material bedding foundation system and methods of manufacture and assembly uses spring modules made of molded composite materials and supported by inner frame members. The low-profile of the spring modules, and the composite material spring property of return to uncompressed state from total depth deflection without set, greatly decreases the height of the bedding foundation in which the spring modules are attached directly to foundation frame members. The small size and simple geometry of the spring modules is especially suited for flexible arrangement and automated assembly of low-profile foundations.

Abstract: A foundation spring module especially adapted for easy assembly in an interlocking spring and grid bedding foundation structure has a short generally vertical section which extends down from an interlockable wire grid-engaging horizontal top portion to position an upper end of each of two contiguous legs of the spring away from the area of intersection of the top portion and legs of the spring with the wire grid to greatly ease manipulation and assembly of the spring into the interlocked position in the wire grid of the foundation structure.

Abstract: An improved steel span for use in mattress foundations has increased strength and rigidity characteristics achieved by a longitudinal ridge formed in a center section of the span between vertical legs of the span. The central location of the ridge in the cross-section of the span centers and thereby improves precise formation of symmetrical halves of the span which in turn insures accurate alignment of opposing spring-receiving slots formed in the vertical legs. Widened horizontally disposed base sections at the bottom of the vertical legs further increase rigidity and provide a greater surface area for attachment of the spans to a foundation frame.