Abstract: A modular sleep system has a foundation unit, an support unit having an innerspring and a support surface covered with a friction material, and a comfort unit having compressible material encapsulated in a woven upholstery material which is engaged by the friction material on the support surface of the support unit to prevent lateral movement or sliding of the comfort unit relative to the support unit, without any fasteners between the support unit and the comfort unit. The comfort unit can be lifted vertically off of the support unit without release or use of any fasteners, to be turned over, fluffed or exchanged for a different comfort unit having different layers of internal materials, feature layers, and support characteristics.

Abstract: A selectively contoured single unibody foam piece for use as a layer in a cushioned load bearing structure has a first zone with a first surface topography having distinct support properties from a second zone with a second surface topography. The zones of differing topography are formed in the surface of a single, unibody piece of foam by applicable foam cutting techniques. Patterned removal of foam material from a single piece creates zones with different density, ILD or other load bearing properties with different support and feel characteristics. A single unibody component in a responsive flexible support structure has distinct zones with distinct support characteristics, the zones corresponding in location with the anticipated loads and loading patterns of a flexible support device in use.

Abstract: Machinery for automated manufacture of formed wire structures such as innerspring assemblies for mattresses and seating and flexible support structures includes one or more coil formation devices configured to produce generally helical spring coils having a terminal convolution which extends beyond an end of the coil; a conveyor system having a plurality of flights slidably mounted upon a continuous track and connected to a chain and driven by an index driver; a coil transfer machine which removes a row of coils from the conveyor and inserts the coils into an innerspring assembler; and an innerspring assembler. A coil forming block on a coiler machine has a cavity in which a terminal convolution of the coil is formed, and from which the coil is cut by a cutter which extends into the cavity.

Abstract: An attachment gusset with ruffled corners and method and machinery for manufacture provides a gusset formed of a continuous strip of material which is pleated at corners or turns in direction of the gusset to form ruffles which are attached to an adjacent layer of material. The ruffled gusset lies substantially flat against adjacent layers of material to which it is attached in a pressed state, and can be expanded to accommodate dimensional structures, such as cushioned pads. The number and spacing of pleats can be adjusted according to the radius of the corners or turns in the gusset. In a method of construction of the gusset, the pleats are formed as the material to which the gusset is attached is turned relative to the sewing point of attachment.

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: Extruded foam reinforcement pieces are described for assembly in connection with innerspring assemblies and mattresses. The pieces have optimized cross-sectional configurations which can be consistently extruded in continuous strands which are then cut to length according to the type and size of innerspring assembly. The pieces are configured to engage various components of the innerspring, including spring coils, spaces between spring coils, and framing borderwires. The foam reinforcement pieces facilitate attachment and alignment of overlying material such as padding and upholstery and function to improve the support characteristics of an innerspring.

Abstract: A machine for automatically producing a mattress border with handles sewn to the border material. Border material is pre-fed from a selected spool, screened for splice avoidance and measured. Handle material is fed from a selected spool mounted in a multiple handle material spool magazine mounted on rails, fed into a handle folding assembly, and cut to length. Ends of the handle material are folded under by the handle folding assembly and the handle then transferred in a folded condition from the handle folding assembly to a correct position on the border material. A double frame handle press holds each folded end of the handle material in place as each end is maneuvered under a sewing head needle to apply a stitch pattern to secure the folded ends to the border material. The double frame handle press is translated separately from the carriage assembly which travels in the sew pattern, to position the other end of the handle under the sewing needle.

Abstract: Machinery for automated manufacture of formed wire structures such as innerspring assemblies for mattresses and seating and flexible support structures includes one or more coil formation devices configurable to produce generally helical spring coils having a terminal convolution which extends beyond an end of the coil; a conveyor system having a plurality of flights slidably mounted upon a continuous track and connected to a chain and driven by an index driver; a coil transfer machine which removes a row of coils from the conveyor and inserts the coils into an innerspring assembler; an innerspring assembler having first and second sets of coil-engaging dies in a parallel arrangement, each set of dies having an upper row positioned over a lower row, the dies being mounted upon carrier bars which are vertically translated within the innerspring assembler to diverge the upper and lower dies of a set to allow positioning of a row of uncompressed coils between the upper and lower dies, and to converge the upper a

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 cavitated pad and innerspring assembly combination, for use in mattresses, furniture, or other cushioned flexible support structures, wherein coils of the innerspring assembly have terminal convolutions which extend beyond the coil body and are not connected to adjacent coils. A cavitated pad has openings in which the terminal convolutions fit, and the pad overlies the coil bodies. In one embodiment, the cavitations extend either partially or entirely through the pad. Upholstery is attached over the pad. The combination of coils with terminal convolutions positioned within the cavitations in the pad provides a dampened or attenuated dual spring rate support surface with controlled lateral deflection of the terminal convolutions.