Abstract: A seating unit that includes a linkage mechanism adapted to move the seating unit between extended and reclined positions, and a chassis is provided. The linkage mechanism includes a seat-mounting link, a base plate fixedly mounted to the chassis, a back-mounting bracket rotatably coupled to the seat-mounting link, a back drive link in generally laterally-spaced relation to the seat-mounting link, and a front-lift assembly that is rotatably coupled to the seat-mounting link. In operation, a rearward occupant force on the back-mounting bracket generates a rearward bias that is converted to a laterally-directed force through the back drive link to the front-lift assembly. Upon receiving this force, the front-lift assembly translates the seat-mounting link forward and upward in relation to the base plate, such that, the seat-mounting link is consistently biased in a particular inclination angle with respect to the base plate throughout adjustment.

Abstract: A powered lumbar support mechanism includes a lumbar plate having a power mechanism having connecting links connected to opposite ends of the plate. One of the connecting links is longitudinally movable to change the convexity of the outer surface of the plate to adjust the lumbar support. The power mechanism includes a housing which retains a threaded rod threaded into a worm gear mechanism held within the housing. The housing also retains a motor having a worm which drives the threaded worm gear. The housing can also incorporate a second threaded rod, threaded to a second threaded worm gear also fixed within the housing such that the end of the second threaded rod is connected to a seat support so as to allow for the adjustability of the vertical position of the lumbar mechanism.

Abstract: A wire core spool including a central axial member, a plurality of expansion swing arms, each having a proximal end and a distal end, the proximal ends pivotally attached to the central axial member, a plurality of contact members, each having a top and a bottom end, each of said contact members being pivotally attached to each of the distal ends of each of at least one of the expansion arms, a plurality of base members each attached to one of the bottom ends of said contact members, said base members disposed to support a bottom surface of a wire core, and at least one stand section fixedly attached to the bottom of the central axial element, the stand sections and base members being in spaced relation sufficient to allow passage of a binding wire therebetween, and such that said base members are disposed to rest on top of the stand sections.

Abstract: An apparatus for fully automated roll packing of compressible mattress spring assemblies, including a radially collapsible mandrel for easy removal of finished rolls. In-fed spring assemblies are precompressed prior to winding on the mandrel, which is mounted to a pivotable arm to permit controlled compression of the spring assemblies against a fixed compression roller. The apparatus further includes devices for placing the finished rolls on pallets and wrapping pallets for shipping and storage.

Abstract: A block attacher for attaching blocks to slats as stringers for pallets includes a slat dispenser disposed to dispense individual slats to a slat driver, the slat driver being selectively positionable. A first block dispenser dispenses a block to an assembly station where a position fixture is disposed to operatively cooperate with the slat driver and the block dispenser to position the dispensed block abutting the individual slat when the slat driver is in a first selected position. At least one other position fixture is disposed to operatively cooperate with the slat driver to position a second dispensed block abutting the individual slat when the slat driver is in a second selected position. The subsequent blocks may be dispensed by the same block dispenser as the first block, or by different dispensers.

Abstract: A pocketed coil spring unit and associated method of assembly combines top and bottom sheets with bonding of the sidewalls of adjacent rows of pocketed coil springs. With this combination, a posturized spring unit is produced in a commercially efficient manufacturing process. The top and bottom sheets extend perpendicularly to the rows of pocketed coil springs and the adjacent rows of pocketed coil springs are bonded on the sidewalls of the fabric pockets in the absence of the top and bottom sheets. As such, the spring unit can be customized for posturization to provide a firmer supporting foundation at the locations of the top and bottom sheets and a more individualized flexible construction in the regions of the inter-row sidewall bonding.

Abstract: A pocketed coil spring unit and associated method of assembly combines top and bottom sheets with bonding of the sidewalls of adjacent rows of pocketed coil springs. With this combination, a posturized spring unit is produced in a commercially efficient manufacturing process. The top and bottom sheets extend perpendicularly to the rows of pocketed coil springs and the adjacent rows of pocketed coil springs are bonded on the sidewalls of the fabric pockets in the absence of the top and bottom sheets. As such, the spring unit can be customized for posturization to provide a firmer supporting foundation at the locations of the top and bottom sheets and a more individualized flexible construction in the regions of the inter-row sidewall bonding.

Abstract: A system and method for manufacturing pocketed compound nested coil springs includes inserting a compressed, preferably pocketed, smaller coil spring into a horizontally oriented larger coil spring either prior to compressing and inserting the outer coil spring into pocket material or after the larger coil spring has been pocketed thereby requiring the first spring to be inserted into and through an opening in the pocket material.

Abstract: A bedding product comprising a collapsible spring assembly, a pad covering the spring assembly and a fabric covering encasing the padded spring assembly. The spring assembly comprises a plurality of collapsible spring modules connected to a plurality of spaced parallel connecting rods and locking means to hold the assembly in an expanded condition and prevent its collapse. The parallel connecting rods are located between border rods in the top and bottom planes of the assembly. Each of the spring modules comprises four individual wires joined together with helical lacing wire wrapped around a center section of each of the wires. The center sections of the wires define an axis about which each of the wires are capable of rotational movement. Upon the collapse of the assembly, each of the spring modules collapses rotating around the axis of the module. The assembly is held in an expanded condition by a plurality of locking rods, pieces of plastic mesh or other locking means.

Abstract: A method of manufacturing a pocketed coil spring assembly comprising vertically spacing two sheets of fabric apart so that the sheets are generally parallel to one another. The sheets are then attached together along one end edge and rows of coil springs are inserted between the sheets. After each row of coil springs is inserted between the sheets, the sheets are attached together along transversely extending lines of attachment in alternative planes of the pocketed coil spring assembly. These steps of inserting rows of coil springs and attaching the sheets together in alternative planes occurs sequentially until an appropriate length of the assembly is obtained.

Abstract: A spring assembly comprising a frame, a plurality of rails secured to the frame and a plurality of spaced springs secured to the rails. Each of the rails has a generally U-shaped cross-section and comprises a bottom and two sidewalls. Each sidewall has an inwardly projecting detent creating a receptacle underneath the detent adapted to receive and hold a spring. Each of the springs has a substantially planar lower portion which is generally S-shaped and adapted to be positioned in the receptacles of the sidewalls of the rail and rotated into a snap-fit locked position. In this locked position, the detents of the sidewalls hold the lower portion of the spring against the bottom of the rail and prevent lateral or vertical movement of the spring.

Abstract: A spring assembly comprising a frame, a plurality of metal rails secured to the frame and a plurality of spaced spring modules secured to the rails. Each of the rails comprises a top portion and two sidewalls extending downwardly from the top portion and terminating in outwardly extending flanges. The sidewalls define a throat proximate the flanges. The spring module has at least one mounting foot comprising two opposed leg portions joined together by a connecting portion, each of the leg portions having a notch therein for engagement with a slot in the planar upper portion of the rail. The connection portion of the mounting foot is engagable with the throat defined by the sidewalls of the rail so as to inhibit lateral movement of the mounting foot within the rail.

Abstract: A sofa sleeper foldable sofa bed assembly having pivotally interconnected head, body, intermediate and foot frame sections which are extendable to form a bed and foldable to form a sofa seat. Each frame section has a pair of opposed side rails and the head and foot frame sections have end rails connecting the opposed side rails. The frame further comprises a cross rail extending between opposed side rails of the intermediate frame section. In one preferred embodiment, a floating cross tube is spaced from and generally parallel the cross rail. The floating cross tube has two ends, each end of which is secured to the cross rail by a rigid wire hook. A plurality of transversely spaced longitudinally extending sinuous wire springs extend between the cross rail and the end rail of the foot section of the frame in one embodiment of this invention and between the floating cross tube and the end rail of the foot frame section in a second embodiment of the invention.

Abstract: A two position linkage mechanism for reclining an item action furniture between a fully upright position and a "TV" position. In the fully upright position, a footrest portion of the mechanism is fully retracted and a backrest portion of the mechanism is disposed at a first angle relative to a seat portion of the linkage. In the "TV" position, the footrest portion of the mechanism is fully extended, the seat portion of the mechanism moves forwardly, and the backrest portion of the linkage is disposed at a second, "opened up" or larger angle relative to the seat portion of the linkage.