Abstract: An encapuslated spring for use with mattresses, cushions, or the like, including a spring enclosed within flexible sheet material, the material being formed in a tubular configuration such that its longitudinal edges are in a flat overlap configuration. The flat overlap configuration reduces a phenomenon known as false loft.

Abstract: An improved method and apparatus for constructing an improved pocketed coil string, in which a tube of fabric is formed, a transverse seam is provided across the tube, a partially compressed coil spring is inserted adjacent to the seam, and a second seam is provided, thus encapsulating the spring. The fabric is guided around the outer surface of a tubular mandrel, thus forming a tube, and the spring is inserted into the mandrel such that as the spring exits the opposite side of the mandrel, it is within the tube of fabric. Excessive spring compression is avoided.

Abstract: A convertible bed assembly is provided which is movable between a seating position and a bed position. The assembly includes foot, intermediate and head support sections, the latter being fixedly mounted to a frame assembly. The three sections are arranged in telescoping relation such that all may fit within the frame assembly. The foot and intermediate sections are both pivotably mounted with respect to the frame assembly. An inclined or curved rear wall is provided to urge a mattress supported by the sections downwardly as it is moved in the direction of the head support section. As the mattress moves in this direction, it is folded into a seating position including a seat portion and a back portion.

Abstract: An innerspring construction including adhered strings of pocketed coil springs is provided together with a method of manufacture. Each string is defined by a series of coil springs connected and encased by a fabric cover. The strings are connected to each other by an adhesive applied between the lines of tangency of adjacent coil springs. A method is provided for assembling such a construction. A hot melt adhesive applicator traverses a string of pocketed coil springs depositing a precise amount of adhesive on each coil jacket. A second string is positioned on the first and pressure applied thereto. The applicator then traverses the second string in the same manner as the first. For purposes of efficiency, it may traverse the second string in the opposite direction from which it originally moved with respect to the first. The sequence is repeated until an innerspring construction of desired size is created.

Abstract: A method and apparatus are provided for assembling innerspring constructions from rows of pocketed coil springs. The apparatus includes a surface for supporting the rows and a pressure plate which compresses them slightly while holding them in straight lines. After each row is positioned between the surface and the plate, a hot melt applicator is passed thereby and deposits a selected amount of bonding material to the fabric encasing each coil spring. New rows are pushed into contact with the treated rows and each displaces them by about one coil spring diameter. A plurality of rows are maintained under compression at all times to insure they remain in alignment with adequate frictional contact therebetween. A bar having markings corresponding to each pocketed coil spring within a row is mounted to the apparatus. A beam switch or the like is provided for detecting these markings and actuating the applicator at a selected time as it passes each spring.

Abstract: An apparatus for manufacturing pocketed coil springs is provided. The apparatus includes a pair of weld heads and an adjustment assembly for moving the heads longitudinally or transversely from each other. The relative position of the weld lines in a fabric passing beneath the heads can accordingly be set with precision. This is accomplished by rotating one of the heads about two axes, one extending through the head and a second axis extending parallel to the first at a selected distance therefrom.

Abstract: A spring assembly is provided including a plurality of interconnected longitudinal blocks of pocketed coil springs. Each block includes a pair of interconnected strips of pocketed springs which are preferably arranged in a square array. Each pair of strips is tightly encased by a flexible cover. The covers are connected to each other along longitudinal hinge lines which allows the assembly to bend easily in at least one direction.

Abstract: A boxspring is provided with stop members for limiting the amount the springs therein can be compressed. The stop members may be light weight hollow cylindrical members fitted within or about a selected number of springs. Supporting braces having a height sufficient to prevent overstressing of the springs when compressed may also be employed. The braces also have the advantage of providing additional stiffness to the boxspring frame. Areas of the boxspring most vulnerable to damage are protected by selective positioning of the stop members.

Abstract: An ultrasonic separation apparatus is disclosed which provides simultaneous cutting and sealing of thermoplastic materials. Both relatively thin and thick materials may be cut and sealed. The apparatus includes a cutting mechanism having a cutting blade mounted for oscillatory movement along its longitudinal axis. Cutting takes place at a controlled rate to allow sufficient time for simultaneous sealing to occur. The apparatus may be particularly adapted for cutting strings of pocketed coil springs to length.

Abstract: An apparatus is provided for transferring a wood frame or the like from a first surface to a second surface. The apparatus includes a pivotably mounted frame assembly having a pair of projecting transfer arms. The transfer arms are provided with a clamping mechanism for clamping the wood frame therebetween at the first surface. It is transferred to the second surface by rotating the frame assembly about its pivot axis and then releasing the clamping mechanism when the frame is at or just above the second surface. The clamping mechanism includes at least one structure which is pivotably mounted to the end of one of the transfer arms and movable in the direction of the other of the two arms.

Abstract: A coil spring construction is provided for incorporation within a mattress or cushion. The construction includes a plurality of independently mounted pocketed coil springs. Resilient stabilizers are provided between the springs to maintain their axial positions. The spring pockets are formed by the sealing of first and second sheets to each other in a substantially circular configuration about the axis of each spring. Spring height is determined by the inside diameter of the seal.

Abstract: A stabilized mattress border is provided which eliminates undesirable leaning. The border defines a center compartment within which air, flotation, or spring mattress inserts may be positioned. It includes a pair of rows of pocketed coils and a flat wire positioned above and between the rows. The flat wire is attached to the upper convolutions of each of the coils and exerts an inward force upon the entire mattress border. Additional border wires are provided near the exterior corners of the mattress border as well as inside the innermost row of pocketed coils. The appropriate padding and upholstery define the compartment within which the border coils and wires are positioned.

Abstract: The pocketed upholstery springs of the disclosed assembly, made from strips of pocketed springs and intended for use in mattresses or cushions, are connected together in "square" array, i.e., each spring disposed in mutually perpendicular rows, by connecting the pocket sheeting of adjacent strips together between adjacent springs of each strip, the firmness of the assembly being increased by the nature of the interstrip connection, namely, an elongated connection centered at mid-height of the spring coils.

Abstract: A mattress is provided having a continuous border portion having a removable and reversible pillow top fastened thereto. The border portion has a large cavity disposed therein to receptably receive a core mattress. Differing core mattresses can be inserted into the cavity to modify the degree of firmness of the overall mattress. The border portion is further internally provided with supporting means such as coil springs disposed therein. The reversible pillow top provides further versatility in providing a variety of sleeping surfaces.

Abstract: 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 thermally welded together. The fabric strip is fed along a guide path during which compressed coil springs are inserted between the piles with the axes of the springs substantially normal to the planes of the plies, whereafter the fabric plies are thermally welded together longitudinally and transversly to form a series of connected pocketed springs. After thermal welding, the pocketed springs are passed through a turner assembly during which the coil springs are reoriented within the fabric pockets to positions wherein the axes of the springs are transverse to the fabric strip.

Abstract: A mattress construction in which the firmness of the top surface is selectively adjustable. A mattress body provides the primary support for a person lying on top thereof. A removable pillow top covers the mattress body, and is removably fastened thereto along its peripheral edges. A relatively thin fluid inflatable cushion is positioned beneath the removable top such that the pressure in the cushion can be varied to alter the firmness of the mattress top surface.

Abstract: A thermally controlled mattress construction including a mattress body designed to support a person lying on top thereof. A removable pillow top for the mattress body, removably fastened along the peripheral edges, incorporates a thermally controlled liner as an integral but removable part thereof. The liner is removably fastened to the bottom of the top surface by a fastener extending along the lower peripheral edge of the pillow top, and also the pillow top is removably fastened to the mattress body by a fastener extending along its peripheral edge. This arrangement provides for removal of the liner for repair of maintenance or other reasons. In one embodiment, the thermally controlled liner includes an electrical heater, which can incorporate two separately controllable heaters, one for each half side of the mattress. In a second embodiment, the thermally controlled liner includes therein an array of tubing, through which either heated or cooled fluid is pumped to selectively heat or cool the pillow top.

Abstract: A base frame for a box-spring which is reinforced by longitudinal beams secured to the upper surfaces of the cross slats within the spring assembly.

Abstract: A flotation mattress is provided including a retractable valve for draining and filling said mattress. The valve includes an elongated neck portion including at least one port which may be extended from the mattress to facilitate the draining and filling operations. The valve may similarly be retracted within the mattress for storage. Upon retraction, the elongated neck portion defines a well a collapsible hose adapted to be secured to said at least one port for draining and filling the mattress may be stored. A cover is provided to protect the valve when recessed in the mattress.

Abstract: An apparatus for the manufacture of mattress cores of cloth-pocketed wire springs comprising a support on a frame for holding an assembly of such springs. The support is reciprocated relative to the frame on a linear bearing mechanism by a fluid actuated cable cylinder.