Abstract: A bed construction having a one-sided mattress assembly supported on a rigid foundation. The one-sided mattress assembly includes a core of pocketed coil springs having a layer of resiliently compressible material covering the upper surface thereof and having a bottom surface constructed of a substantially rigid material without a compressible layer. The core of coil springs is attached to the bottom surface around its periphery. The foundation has a rigid inner construction and a noncompressible top layer. The bed construction reduces the amount of compressible padding in the mattress by one-half and consequently the mattress is capable of exhibiting a substantial reduction in the amount of permanent deflection in use.

Abstract: A cover for a tight top mattress includes an upper panel, a lower panel and a border panel. A zipper connects the border panel to either the upper or lower panel. At least one of the upper of lower panels is a quilted foam and fabric assembly which is dimensioned and configured as a pillow top. The upper, lower and border panels define an enclosure for closely fitting and receiving the mattress.

Abstract: A one-sided mattress assembly includes a core of pocketed coil springs having a layer of resiliently compressible material covering the upper surface thereof and having a bottom surface constructed of a substantially rigid material without a compressible layer. The core of coil springs is preferably attached to the bottom surface only around its periphery. By such a construction the amount of compressible padding is reduced by one-half and consequently the mattress is capable of exhibiting a substantial reduction in the amount of permanent deflection in use. Maintenance of the mattress such as by rotating or turning the mattress over is also avoided.

Abstract: A mattress assembly includes a mattress core formed as a unitary assembly from one or more resiliently compressible materials and defining a generally planar deck surface. A pillow top layer assembly extends coextensively with the deck surface and includes a quilt panel which forms an envelope with the core. A plurality of closely spaced coil springs are positioned within the envelope. The springs retain nearly all of the their resilience over the life of the mattress assembly, thus, providing for continued comfort to the user over an extended period of time.

Abstract: A unitary mattress assembly comprises a plurality of coil springs interarranged to define a single innerspring core having a generally rectangular shape in plan. The core has a first portion which is sized to accommodate a first sleeping person and comprises coil springs having a first preselected compressive strength. Adjacent to the first portion is a second core portion sized to accommodate another sleeping person and having coil springs of a different compressive strength than the springs of the first portion. By the foregoing construction, a mattress may be manufactured having a single innerspring core but having two regions of differing firmness to suit the particular preferences of two people.

Abstract: A quilted border winder apparatus, a quilted border system and a method of making quilted borders that includes two machine halves in which a number of independent wind-up stations are radially mounted and longitudinally spaced about the axis of a main shaft for each half and in which each wind-up station is connected to the shaft by an arm. Each machine half contains an identical shaft and the two shafts are parallel, but are laterally offset one from the other. Each wind-up station is driven by an electric motor utilizing a gear box and a chain/sprocket assembly that is connected to the wind-up station through the interior of the connecting arm.

Abstract: A structural frame having laterally extending L-shaped braces for reinforcing resilient and non-resilient bedding foundations.

Abstract: Methods and apparatus are provided for forming strings of springs enclosed within pockets having flat overlapping side seams avoiding problems with false loft in mattress construction.

Abstract: An apparatus for assembling innerspring constructions from rows or strings of pocketed coil springs comprises a generally planar support surface with a pressure plate mounted parallel to and above the support surface. The apparatus includes a bonding material applicator for applying bonding material to a first row of pocketed coil springs retained by the pressure plate. A pusher bar assembly is provided for pushing a second row of coil springs into intimate contact with the first row whereupon the two rows become bonded. The pusher bar assembly includes a pusher fixture having two opposed sides, each with differently spaced dividers for receiving rows of springs having differing diameters. The pusher fixture is manually rotatable to employ a desired set of dividers depending on the size of the coils being assembled.

Abstract: An innerspring construction comprises a first elongate string of pocketed coil springs with each coil having a longitudinal axis lying in a first plane and a first elongate tube of fabric having first transverse seams spaced along the length of the tube to define individual coil spring pockets. The tube is alternately bent proximate the first seams such that every other first seam lies on the same side of the first plane. A second elongate string of pocketed coils in which each coil has a longitudinal axis lying in a second plane has a second elongate tube of fabric with second transverse seams spaced along the length of the tube to define individual coil pockets. The second elongate string is attached to the first elongate string by bonds formed between circumferentially abutting surfaces on the coil pockets of the first and second tubes of fabric. The resulting construction provides for reduced tendency for leaning coils and permits greater innerspring firmness for a given coil wire diameter.

Abstract: A method of packaging a resiliently compressible article comprises the steps of inserting the article into a tube of deformable material such that excess material is provided at the ends of the tube. A first end of the tube is then sealed closed. Air is then evacuated from the tube through the second end thereby deforming the tube around the article and causing the article to compress. While a vacuum is maintained in the tube, the second end of the tube is sealed closed. A containment sleeve is fitted over the sealed tube to maintain the article in a compressed state. When the article is unpackaged, the containment sleeve is severed and the tube is allowed to expand in a gradual controlled fashion by the bleeding of air back into the tube.

Abstract: Methods and apparatus are provided for forming strings of springs enclosed within pockets having flat overlapping side seams avoiding problems with false loft in mattress construction.

Abstract: A method and apparatus for manufacturing mattresses, including the steps of forming a coil spring from wire, conditioning said coil spring to reduce stresses formed therein, placing said coil spring within pockets to create elongate strings of pocketed coil springs, attaching said elongate strings to create innerspring constructions.

Abstract: A knock down mattress system comprises a generally rectangular box-like shell having a bottom panel, a top panel and side panels interposed therebetween. A plurality of generally elongate bolsters are dimensioned and configured to be positioned within the shell in abutment with the side panels thereof. Each bolster comprises a casing containing resiliently compressible, pocketed coil springs, thereby providing a firm but compliant perimeter around the bed. The bolsters are maintained in proper position within the shell by straps which cooperate with loops formed in the bottom panel of the shell. By this configuration, the bolsters define an interior bounded space within the shell to contain a water mattress, an air mattress or other suitable mattress member. Because the bed system comprises an assembly of discrete pieces, it can be shipped conveniently to the customer in disassembled form and is readily assembled at final destination.

Abstract: A method and apparatus for manufacturing mattresses, including the steps of forming a coil spring from wire, conditioning said coil spring to reduce stresses formed therein, placing said coil spring within pockets to create elongate strings of pocketed coil springs, attaching said elongate strings to create innerspring constructions.

Abstract: Improvements to a method and apparatus are disclosed for making a series of coil springs pocketed within individual pockets in an elongate fabric strip comprised of two overlying plies capable of being welded together. Improvements include improvements to fabric tracking and folding, fabric handling along the fabric path, and various direct-drive configuration eliminating the need for pneumatic cylinders.

Abstract: An improved innerspring construction such as a mattress or box spring unit which includes improved edge support characteristics. A torsion edge support unit is disclosed which may be placed about the periphery of an innerspring construction with a minimum of interference with more interiorly-positioned coil springs.

Abstract: A method is provided which provides an improved manner in which to manufacture innerspring constructions including individual springs. A rotating bristled brush is used to urge individual springs along a path from one position to another.

Abstract: A bed foundation comprises a pair of parallel spaced side rails with ends connected by corner braces to the ends of parallel, spaced cross rails thereby defining a rectangular box frame. Upwardly facing edges of the cross rails and side rails lie in a common plane. A pair of generally planar top panels are positioned on the frame with their peripheral edges flush with the outer edges of the frame. The corner braces extend above the plane defined by the upwardly facing edges of the rails providing lips which cooperate with corners of the panels to retain the panels immovable on the frame. A third panel may be positioned between the pair of panels and a clip engages both an edge of the third panel and the upwardly facing edge of a cross rail to retain the third panel immovable relative to the frame.

Abstract: A method of packaging a resiliently compressible article comprises the steps of inserting the article into a tube of deformable material such that excess material is provided at the ends of the tube. A first end of the tube is then sealed closed. Air is then evacuated from the tube through the second end thereby deforming the tube around the article and causing the article to compress. While a vacuum is maintained in the tube, the second end of the tube is sealed closed. A containment sleeve is fitted over the sealed tube to maintain the article in a compressed state. When the article is unpackaged, the containment sleeve is severed and the tube is allowed to expand in a gradual controlled fashion by the bleeding of air back into the tube.