Abstract: A spring assembly including a helical coil formed from a multi-strand cord.

Abstract: A suspended matrix support structure has a perimeter frame which supports a flexible matrix formed with intersecting flexible members, the ends of which are supported by the perimeter frame. Edges of the flexible members are held within channels which form a frame about the flexible matrix. In one embodiment, the perimeter frame is constructed of foam with contoured features which support the frame of the flexible matrix. The flexible members of the flexible matrix extend across the expanse within the perimeter frame to provide a flexible support structure which can be used as a mattress, mattress foundation or both in combination.

Abstract: A one-sided mattress construction includes a spring assembly with asymmetric spring coils. Only the bottom portion of each spring coil is attached, either to adjacent spring coils or to a bottom surface of the mattress. The top portion of each spring may have a narrowing taper that permits the top to move independent of other adjacent springs.

Abstract: A mattress foundation with a perimeter structure has a frame, springs mounted upon the frame, and a grid supported by the springs, and perimeter structure at a perimeter of the frame which extends from the frame to the grid, forming an exterior wall which extends from the frame to a border wire of the grid. When the perimeter structure is made of structural and reflexive material such as closed-cell foam, it co-acts with the grid and springs and provides additional support to the perimeter region of the grid and foundation. The exterior wall of the perimeter structure forms a solid surface over which padding or upholstery is placed.

Abstract: A one-sided mattress construction includes a spring assembly with asymmetric spring coils. Only the bottom portion of each spring coil is attached, either to adjacent spring coils or to a bottom surface of the mattress. The top portion of each spring may have a narrowing taper that permits the top to move independent of other adjacent springs.

Abstract: A mattress foundation with a perimeter structure has a frame, springs mounted upon the frame, and a grid supported by the springs, and perimeter structure at a perimeter of the frame which extends from the frame to the grid, forming an exterior wall which extends from the frame to a border wire of the grid. When the perimeter structure is made of structural and reflexive material such as closed-cell foam, it co-acts with the grid and springs and provides additional support to the perimeter region of the grid and foundation. The exterior wall of the perimeter structure forms a solid surface over which padding or upholstery is placed.

Abstract: A one-sided mattress construction includes a spring assembly with asymmetric spring coils. Only the bottom portion of each spring coil is attached, either to adjacent spring coils or to a bottom surface of the mattress. The top portion of each spring may have a narrowing taper that permits the top to move independent of other adjacent springs.

Abstract: A suspended matrix support structure has a perimeter frame which supports a flexible matrix formed with intersecting flexible members, the ends of which are supported by the perimeter frame. Edges of the flexible members are held within channels which form a frame about the flexible matrix. In one embodiment, the perimeter frame is constructed of foam with contoured features which support the frame of the flexible matrix. The flexible members of the flexible matrix extend across the expanse within the perimeter frame to provide a flexible support structure which can be used as a mattress, mattress foundation or both in combination.

Abstract: A spring assembly including a helical coil formed from a multi-strand cord.

Abstract: A one-sided mattress construction includes a spring assembly with asymmetric spring coils. Only the bottom portion of each spring coil is attached, either to adjacent spring coils or to a bottom surface of the mattress. The top portion of each spring may have a narrowing taper that permits the top to move independent of other adjacent springs.

Abstract: A bedding system that provides ease of handling and transport and reduces storage space, and includes a foundation in the form of a shell comprising a top panel and a side panel, a mattress having a transport size to fit inside the shell so that the foundation and mattress can be transported as a single unit having the outside dimensions of the foundation. When in set up as a bed, the mattress is placed on the top panel of the foundation. A bracing system is provided that attaches to the sidewalls of the foundation to provide a foundation sufficiently strong to support a mattress and one or more users.

Abstract: A mattress having a border rod assembly and at least one central spring core. The border rod assembly having individual border rods and corner pieces fitting together to create a contiguous border around and attached to the central spring core. A resilient, polymer material is used for at least one of the individual border rods. Border rod assemblies serve a dual purpose in mattress construction, acting both as a frame to which fabrics and foams may be attached and as a support structure for the central spring core, eliminating unsightly sagging and bowing at the mattress edge. Using resilient materials for the border rods allows the mattress to be used interchangeably with adjustable and non-adjustable foundations, while retaining the rigidity and desirable structural aspects of standard steel border rod mattresses.

Abstract: An apparatus and method for winding strings of pocketed coils onto a spool. The coil spooling apparatus includes a feed mechanism and a spooler. The feed mechanism includes buffer rollers and an adjustable hollow feed arm. The feed arm terminates adjacent to the spooler. The spooler includes a spool with a horizontally or vertically oriented spool core, a drive mechanism, and a turntable base with a pallet. The drive mechanism powers the rotation of the spool core. The rotation of the spooler winds the string of pocketed coils received from the feed mechanism. The feed mechanism buffers the tension and directs the string of pocketed coils along the horizontal and vertical axis. After the desired size of wound package is reached, the rotation of the spooler ceases. The completed wound package can then be lifted while attached to the spool through the use of a fork lift. The vertical spools can be stored and transported in a vertical position since the core base is flat.

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: A tire sheet component is cut and applied to a drum with a retractable applier having a cutter and anvil member for cutting the sheet component at a first position spaced from the drum. Vacuum means are provided for holding the cut leading end on the anvil as it is moved to a second position where the anvil is moved towards the drum to press the leading end portion of the sheet component against the drum with a stitcher roll. The anvil is then moved in a sweeping motion to stitch the leading end against the drum. The drum is rotated a predetermined amount and the sheet is stitched to the drum with a second stitcher roll. The sheet component is cut at the first position providing a trailing end which is then stitched to the drum as it is rotated the final amount.