Abstract: A mattress employs a high density, high ILD convoluted polyurethane foam topper as a major transition layer over the supporting surfaces of an innerspring assembly in order to provide a smooth transition from the support characteristics of the padding and upholstery layers to the innerspring assembly. A high density, high ILD foam material of substantial thickness is positioned between a padding or insulating layer over the innerspring assembly and overlying upholstery, with convolutions in the high density transition layer oriented to extend away from the innerspring assembly. The high density transition layer dominates or masks the support characteristics of the innerspring assembly so that the perception of stiffness or board-like feel of an innerspring is greatly reduced upon initial loading of the mattress.

Abstract: A method of manufacture and formation of mattress foundation corner guards made of formable metal, including the steps of manufacturing guards in a flat planar configuration with attachment tabs extending from a bottom edge of the sidewall and in the same plane as the sidewall, and forming the guard about the rounded corner of a mattress foundation by positioning the sidewall of the guard at a midpoint of a radiused corner of intersecting side walls of a mattress foundation and the bending the side wall to generally conform to the radiused vertical wall of the mattress foundation corner, whereupon the corner guard side wall remains in a curved configuration which generally conforms to the radiused corner, and bending the attachment tabs about a bottom edge of the mattress foundation to lie flush against a bottom surface of the mattress foundation, and fastening the attachment tabs to the bottom of the foundation.

Abstract: An elongate member of resilient material for use in the innerspring of a mattress, cushion or the like, is inserted between adjacent springs rows with its major cross-sectional axis extending perpendicular to the support surface. The cross-section of the resilient member is such that it increases from a minimum at or near the ends of a major axis to a maximum along a minor axis. The method of making the resilient member further contemplates matching the combination of cross-section and type of resilient material to the spring rate of the springs between which the member extends. When placed as a beam between springs defining the innerspring perimeter and interior springs adjacent thereto, this arrangement results in an assembly with a border of greater firmness, without a significantly harsh transition between compression of the border area and the innerspring interior area.

Abstract: Internal mattress wall structures interlockingly engageable with mattress innerspring assemblies provide a structurally integrated resilient mattress support edge to which the mattress padding and upholstery is integrally attached. The wall structures include a main body section with a vertically oriented wall surface and a plurality of parallel flanges which mechanically engage the innerspring assembly by compression fit between the intermediate and terminal convolutions of the perimetrical coils of the innerspring assembly. Corner structures contiguous with side and end wall structures form a contiguous smooth side wall with support characteristics comparable to an innerspring assembly.

Abstract: A low profile composite material bedding foundation system and methods of manufacture and assembly uses spring modules made of molded composite materials and supported by inner frame members. The low-profile of the spring modules, and the composite material spring property of return to uncompressed state from total depth deflection without set, greatly decreases the height of the bedding foundation in which the spring modules are attached directly to foundation frame members. The small size and simple geometry of the spring modules is especially suited for flexible arrangement and automated assembly of low-profile foundations.

Abstract: An innerspring assembly, such as for use in a mattress, comprises a plurality of coil springs defining upper and lower terminal convolutions and body portions therebetween. Adjacent coil springs are attached together at the body portions thereof with the terminal convolutions being unattached to one another, so that the terminal convolution can move independently of one another.

Abstract: An elongate member of resilient material for use in the innerspring of a mattress, cushion or the like, is inserted between adjacent springs rows with its major cross-sectional axis extending perpendicular to the support surface. The cross-section of the resilient member is such that it increases from a minimum at or near the ends of a major axis to a maximum along a minor axis. The method of making the resilient member further contemplates matching the combination of cross-section and type of resilient material to the spring rate of the springs between which the member extends. When placed as a beam between springs defining the innerspring perimeter and interior springs adjacent thereto, this arrangement results in an assembly with a border of greater firmness, without a significantly harsh transition between compression of the border area and the innerspring interior area.

Abstract: A protective and decorative mattress foundation curved corner guard is mold formed in a curved configuration with a wall portion of the guard having a radius of curvature approximately equal to a radius of curvature of rounded corners of a mattress foundation to which the corner guard is to be attached. Raised areas in the form of indicia are mold formed to protrude from a front surface of the curved wall. Edges of the raised areas are bevelled to allow mold pieces to be withdrawn from the front surface of the curved wall without damage to the molded guard. When mold formed of a suitable plastic material, the curved corner guard, including the curved wall and raised indicia thereon, can be metal plated and polished.

Abstract: A laminated support pad includes layers of material having different density in which voids are formed to extend through at least partial cross-sections of at least two adjacent layers to form regions of the pad having different support characteristics determined by the placement and extent of the voids in the laminated layers. Lamination of a layer of high density material on top of a layer of relatively low density material produces a relatively firm pad having varying degrees of firmness dependent upon the placement and extent of the voids. Conversely, lamination of layer of low density material on a top surface of a layer of relatively high density material produces a relatively soft pad also having varying degrees of firmness dependent upon the placement and extent of the voids. The pad can be cut to conform to conventional mattress sizes, and the regions formed in areas of the pad which correspond to the weight bearing requirements for optimum support of the human body in prone positions.

Abstract: A display device for illustrating the internal construction of a conventional bedding system displayed on the sales floor of a store is adapted to be superposed on a corner of the displayed bedding system. The novel display device comprises three generally-planar members, one planar member corresponding with the horizontally-disposed body-receiving surface of the mattress and the other two generally-planar members corresponding to the two side surfaces of the bedding system forming the corner on which the display device is superposed. On each of the three generally-planar members of the device is a different picture, each picture portraying the likeness of the individual components of the innerspring assembly of the mattress on which the display device is superposed in such a way that these likeness simulate in two dimensions the structures and arrangement of the corresponding components in the innerspring assembly of the mattress.

Abstract: A generally dish-shaped or conical-like head member with clips for securely engaging a typical wire grid used in cushions, seats, and bedding products is disclosed, as well as a similar member using cooperating lobe and trough pairs to hold a grid wire therebetween to fix a spring device in place.

Abstract: A foot member is disclosed for use in attaching a spring device to a rail for cushions, seats, or foundations for a bedding product. The foot member can straddle and snap into a frame rail, or be stapled or otherwise affixed to a frame rail.

Abstract: A pneumatic and load-supporting spring device for use in bedding, cushions and the like. The disclosed embodiments have tubular telescoping members that are biased apart by either an elastomer located in the overlapping region, or a helical spring located within the pneumatic cylinder formed by the tubes. A conical or dish-shaped head element with clips for securely engaging a typical wire grid found in many bedding products is also disclosed, as well as a dish-shaped head element using cooperating lobe and trough pairs to hold a grid wire therebetween to fix a spring device in place. A foot element is also disclosed for use in attaching a spring device on the base frame of a typical bedding product. The foot element can straddle and snap into a metal frame rail, or be stapled to a frame rail.

Abstract: A rhomboid-shaped member of resilient material for use in the innerspring of a mattress, cushion or the like, is inserted between adjacent springs rows with its major cross sectional axis extending perpendicular to the support surface. When placed as a beam between springs defining the innerspring perimeter and interior springs adjacent thereto, this arrangement results in an assembly with a border of greater firmness, without a significantly harsh transition between compression of the border area and the innerspring interior area.