Abstract: A clip for use in a hinged border wire assembly, such as a border wire assembly used in a mattress, joins border wire portions together in a manner that permits one border wire section to rotate with respect to the other. This permits folding of a large border wire of the type that would be used on a king-size mattress, for example, in order to pass the mattress through small areas such as doors and stairways. The disclosed embodiment has two border wire sections which are generally U-shaped and which abut along portions formed at the ends of each U. The clip has a pair of adjacent sleeves within which respective abutting border wire portions are received. A barb is formed inwardly of a sleeve to secure the barbed sleeve in place on its border wire portion while allowing the other abutting portion to rotate within its sleeve in hinged fashion.

Abstract: A spring coil has an open-ended terminal convolution which is connected to the body of the coil through a gradient arm. The gradient arm can be readily varied in length in manufacture to alter the compression and thereby the firmness of the spring coil. Offset portions are advantageously formed on terminal convolutions with a major straight part which is outwardly spaced from minor straight parts. This provides a three point engagement for the offset portion when connected to a border wire with a border wire helical spring. The offset portions of the spring coils have inside and outside shoulders adjacent their ends. The pitch of cross-helicals which join overlapped offset portions is chosen so that a cross-helical simultaneously engages the outside shoulders of one of a pair of overlapped offset portions to firmly hold the spring coil against rotation. The cross-helical preferably also catches the inside shoulders of the other overlapped portion to additionally hold that spring coil against rotation.

Abstract: An apparatus particularly suited for measuring the shape or contour of a surface under load, such as a mattress, is comprised of a humanoid having body limb extremities which are movable in a manner similar to the movement of comparable human extremities. Sensors are placed at joints, such as the knees and hips, to measure the amount of relative movement, i.e. deflection, that occurs at these joints when the humanoid is placed upon a mattress surface. The sensors provide an indication of the shape or contour of the mattress surface by correlation of the relative movement that occurs at these joints caused by the underlying mattress shape. In its preferred form, a movable frame is provided to raise and lower the humanoid in relation to the mattress surface to be tested. A "spine" is also advantageously provided with associated sensors to measure deflection, and thus surface contour, in the lower torso/abdominal region.

Abstract: A spring assembly for an innerspring unit, particularly an innerspring mattress, is provided wherein at least a pair of springs are restricted about their adjacent offset portions of adjacent terminal convolutions in one surface of the assembly so that hinging action between the adjacent offset portions is allowed only to a maximum angle of deflection between the offset portions and thereafter, upon further loading, the pair of springs provide a greater resistance to loading than would be realized without restriction of their adjacent offset portions. Also provided is an improved coil spring for such a spring assembly.

Abstract: An improved mattress includes a composite made of a layer of a fire retardant material capable of providing a heat barrier bonded to a layer of high tensile strength material, such as fiberglass fabric. The composite encloses at least most and generally practically all of the flammable ingredients of the mattress. When exposed to a fire, the fire retardant material chars, thereby creating a heat shield that protects the inside of the mattress while the high tensile strength material holds the mattress together and prevents the mattress from bursting open thereby exposing the flammable ingredients thereof to the fire.The composite of the present invention is made by bonding a fire-retardant material capable of providing a heat barrier to a high tensile strength material.

Abstract: A mattress cover is provided which includes facing panel and a heat panel overlying at least a portion of the facing panel. The heat panel has an upper section, a backing section, and means for generating heat, the heat generating means being disposed between the upper and backing sections. Also provided is means for fastening the facing panel to the heat panel comprising at least one complementary pair of interlocking members comprising a first and a second locking member, the first locking member being secured to the facing panel, the second locking member being secured to the heat panel, and the first and second locking members being adjustable between an interlocked position, bridging the facing and heat panels, to an open position. The mattress cover is also provided with means for securing the facing panel to a mattress core. Also provided is a mattress construction having a mattress core and a facing panel and having said mattress cover secured to the facing panel.

Abstract: An improved mattress innerspring unit is provided which includes a plurality of rows of coil springs and a plurality of cross helicals which extend transversely of the rows of coil springs, lacing together adjacent terminal convolutions of the coil springs, wherein a welding means is provided to eliminate the tendency of the cross helicals to spin-out of the unit. Also provided is a method of constructing an innerspring unit which includes welding an end revolution of a cross helical to another component of the unit or to an adjacent cross helical revolution.

Abstract: An improved mattress innerspring unit is provided including cross helicals which extend transversely of the rows of coil springs and lace together adjacent terminal convolutions of the springs in a row and a retention and support strip which overlies the terminal convolutions of the springs in a row of the unit, the retention and support strip and the helicals being crimped together and otherwise secured about the interlaced portions of the coil springs. The cross helicals are prevented from spinning out of the unit and the unit is firmed, particularly in the area close to the retention and support strip. Preferably, retention and support strips are provided along both the top and bottom terminal convolutions of the coil springs of at least one row near each of the two longitudinal edges of the innerspring unit.

Abstract: A frame for a box spring unit utilizing torsion bar springs comprises a generally rectangular wood frame member and a plurality of parallel transverse metal slats secured to the frame member, the metal slats being adapted to precisely position and firmly secure the base of the torsion bar spring to the metal slat.