Abstract: A foundation unit which can be relaxed in a compact configuration for shipping and which can be then elevated to an expanded state for completion. The foundation unit includes a rectangular grid wire top bearing structure, a rigid bottom substructure, and a series of spaced, parallel intermediate rows of wire supports. The wire supports are oriented in pairs, with the bottom attachment segments of the wire supports being adjacent one another and secured to the bottom substructure. The top attachment segments of the wire supports are spaced from one another such that the wire supports of each pair form a generally V-shaped configuration. The wire supports are sandwiched between spaced longitudinal grid wires of the top bearing structure so that, prior to being secured to the bottom substructure, the wire supports are pivotally secured to the top bearing structures so that the foundation unit can be selectively relaxed for storage or shipping.

Abstract: A wire support member for a foundation unit, the resulting foundation unit, and a method of fabricating the foundation unit. The wire support member comprises a pair of parallel wire elements arranged in mirror image with a transverse link extending between and joining the wire elements. A dimple is formed in the top of each of the wire elements to form an engagement location to accommodate and seat a grid wire extending transverse to the wire support member. The foundation unit is comprised of a series of the wire support members installed in a flat grid wire top bearing structure and affixed to a rigid bottom substructure. The foundation unit is formed by inserting a wire support member at an oblique angle to the grid wire top bearing structure with the wire elements straddling a pair of longitudinal grid wires and with one wire element being located on one side of a transverse grid wire and with the other wire element being located on the other side of the transverse grid wire.

Abstract: A drop-in spring assembly unit and method of manufacture of furniture. The assembly unit includes a plurality of spring elements coupled together by unique individual grid inserts, a wire base that may be customized to customer specifications and a border wire surrounding the top perimeter of the unit. The grid inserts are assembled prior to assembly of the drop-in unit and are coupled to spring elements by cushion clips.

Abstract: An edge support system for a mattress foundation. The edge support system includes a pair of torsion elements, each including a central torsion segment, with the torsion segments being secured to one another, and with the torsion elements being formed as mirror images of one another, with legs being attached to the top and bottom border members of the mattress foundation. A secondary expansion spring is connected between the attached torsion segments and an intermediate rod located midway between the border members of the foundation. The gauge of the wire forming the torsion elements and the strength of the expansion spring determine the amount of support by the edge support system. A plurality of the system can be spaced about the periphery of the foundation to provide greater firmness in areas needing enhanced stiffness.

Abstract: A machine for inserting foam cores within the coil springs of a mattress or similar device having a series of spiral coil springs. The machine has a series of hollow receptacles for accommodated the cores above and aligned with one row of coil springs of the mattress. Beneath the mattress, a series of grippers is located in alignment with the receptacles. When actuated, the grippers rise through the coil springs, grip the bottom of each foam core, and return through the coils, placing each core in the center of each of the coils of the row of coils. The mattress is then indexed, and the process repeated for the next row of coils.

Abstract: A spring element for a foundation unit and a foundation unit employing the spring element. The foundation unit is of the type having a top wire grid structure and a wooden bottom structure, with a plurality of the spring elements being disposed in space relationship between the grid structure and the bottom substructure. The spring elements include spaced support legs extending from a top portion, with the legs converging toward one another. Each leg has a series of spaced support segments, with the support segments lying generally in a single plane and extending oppositely from one another in a zig-zag fashion between the top portion and an attachment segment. Torsion segments are located between adjacent support segments, with the torsion segments extending generally perpendicular to the plane of the support legs. Suitable links are used to interconnect each torsion segment with its adjacent support segments of each support leg.

Abstract: A foundation unit which can be collapsed for compact shipping and which later can be elevated to a fully expanded state. The foundation unit includes a rectangular, grid wire top bearing structure, a rigid bottom substructure, and a series of spaced, parallel rows of support members extending between the top bearing structure and the bottom substructure. The support members are hingedly secured to the top bearing structure and the bottom substructure to permit reduction of the foundation unit to the collapsed state with the elements of the rows of support members lying essential prone. In the elevated state, each of the rows of support members is composed at least in part of a plurality of spring wire segments comprising a pair of generally flat support elements forming a generally V-shaped configuration.

Abstract: A foundation unit having a top bearing grid structure secured to a bottom substructure by intermediate support elements. The grid structure comprises a series of spaced longitudinal and transverse spring elements, each spring element being formed to permit elastic elongation thereof. Elastic elongation is accomplished by a series of V-shaped segments in each of the spring elements, the segments being located at the intersections of the spring elements and being joined by a clip. The support elements comprise wire elements which are L-shaped and which are composed of two planar portions connected at right angles to one another. The wire elements are located in transverse rows with the orientation of the wire elements in each row being opposite to the orientation of the wire elements in the adjacent row so that loads applied to the foundation unit are balanced.

Abstract: A wire support member for a foundation unit. The support member is composed of a continuous, planar wire element, comprising parallel upper and lower attachment segments and a sinuous central segment extending between the upper and lower segments. The central segment is composed of a series of C-shaped curved portions. A series of the support members can be used in rows to form a foundation unit, and the members can be located perpendicular to one another at the corners of a foundation unit in order to form a corner support.

Abstract: A foundation unit which, when assembled, can be collapsed for compact storage and shipping and later can be elevated to a fully expanded state. The foundation unit includes a rectangular, grid wire top bearing structure, a rigid bottom substructure such as a wooden frame, and a series of spaced, parallel rows of substantially flat support members extending between the top bearing structure and the bottom substructure. The support members are hingedly secured to the top bearing structure and bottom substructure to permit reduction of the foundation unit to the collapsed state with the rows of support members lying essentially prone. In the elevated state, the foundation unit includes stabilizers which are oppositely reactive and which prevent relative longitudinal translation between the top and bottom of the foundation unit.

Abstract: A spring foundation unit having one or more pairs of inner border members on the top and bottom surfaces of the unit. In a conventional fashion, the spring unit has a plurality of transverse rows and longitudinal columns of coil springs, and top and bottom perimeter border wires extending along the outer periphery of the unit and attached to outer coil springs of the transverse rows and longitudinal columns. The inner border members have side elements extending parallel to opposed sides of the unit, with one or more spring widths separating the side elements from the perimeter of the unit. Each side element has a free end which is attached to an end section of the perimeter border wire, and a cross-connecting element interconnecting the opposite ends of the opposed side elements of each inner border member. In one embodiment of the invention, the cross-connecting elements of each pair of inner border members are straight and have at least one spring width separating them.

Abstract: The entire assembly includes an upper supporting panel, a base, and spring body means between the panel and base. The panel comprises a rectangular border frame and a grid made up of a series of grid wires extending longitudinally and another series extending laterally to define rows of rectangular openings serving as spring seats. The spring body means comprise coil spring bodies and attachment heads made up of single lengths of wire. The heads are bent to U-shape with a rectangular pattern similar in size and shape to the spring seats, and portions are offset to resiliently grip the grid wires defining a selected spring seat above and below the grid and lock the head in place. The rectangular engagement of the spring components with the spring seats prevents rotation in their mountings.

Abstract: The invention pertains to a wooden frame structure for a box spring. Two spaced, parallel, upright members form elongated side rails which are initially held together by a base slat extending between the side rails at either end thereof, the base slats being affixed to the bottom of the side rails in recesses therein. Above each base slat, an end slat is installed extending between the side rails, each end slat having a formation such as a tenon formed on either end thereof which engages a corresponding formation such as a mortise formed in each side rail. Normally, at least one center slat, depending on the ultimate frame dimension, lies on its side between the end slats with each end of the center slat lying on a portion of the top of one of the base slats. A plurality of upright cross slats extends between the side rails, and similar to the end slats, each cross slat has a tenon formed in either end thereof which interlockingly engages a corresponding mortise formed in each side rail.

Abstract: A coil spring supporting grid structure of the type used to reinforce the top surface of a box spring foundation unit is provided with formations on the longitudinal and transverse wires thereof, enabling a snap-in interconnection with a plurality of coil springs to form a spring unit assembly. Each coil spring convolute engaged by the grid structure is supported on a pair of upwardly extending formations from a pair of spaced parallel first wires and is locked in place by means of two downwardly depending formations from a pair of spaced parallel second wires which extend transversely with respect to the first wires to form the grid.

Abstract: A box spring mattress is supported a predetermined distance above a floor by a bed base including panels connected at their ends to form a rectangular frame and a pair of cross-supports resting crosswise on the edges of an opposed pair of notched panels. Each cross-support has a generally flat surface which is generally parallel to the floor and on which the box spring rests, and a downwardly pointing brace. The braces nest in the notches in the panels and the support surfaces are essentially flush with the unnotched portion off the notched edges of the panels. Each brace includes notches which lockingly connect with the notches in the panels so that the cross-supports cannot move laterally relative to the base. There are stop members at the opposed ends of each cross-support for restricting the lateral movement of the box spring relative to the base.