Abstract: A molded foam-encased integrated flexible support device includes an innerspring positioned upon a three-dimensional thermoplastic foam deck as a flexible foundation, and a molded foam encasement which structurally integrates the foam deck with the innerspring by attachment to perimeter coils of the innerspring. A sculpted foam topper is adhesively bonded to a support surface of the foam-encased innerspring, forming a unitized mattress or support structure with fully integrated innerspring and internal and external foam components. The sculpted foam topper is designed with varying contours and densities to provide the desired support and feel characteristics for different comfort profiles. The foam encased innerspring with internal three-dimensional foam structures is upholstered for use as a mattress, seating, or other flexible support structure.

Abstract: Asymmetric spring components for mattress and other flexible support structures, in the form of helical coil springs with turns in the coil body having varying pitch angles and radii, and a single support end for use in a one sided innersprings in one-sided mattresses. The coil springs are asymmetric about an axis of the coil or a horizontal reference plane, or both, and with ends of the coil springs shaped and sized differently to accommodate different mounting and support arrangements. Asymmetric coil springs can be contained in individual pockets or strings of pockets and arranged together to form an asymmetric pocketed coil innerspring for use in a one-sided mattress.

Abstract: A mattress package with a full perimeter protection and handling piece combines a barrier layer which encapsulates a mattress with a perimeter piece attached about a perimeter of the mattress proximate to the border of the mattress and preferably extending over the adjacent major surfaces of the mattress over the barrier layer. The perimeter piece provides increased strength and protection to the package about the entire perimeter of the mattress, and provides a grip for handling of the mattress which evenly distributes stresses on the package to prevent breach or failure of the package. The perimeter piece can be positioned underneath or on top of a barrier layer.

Abstract: Three-dimensional unitized thermoplastic foam structures are made by thermoplastic welding of different foam components. The unitized foam structures may include a planar base to which other foam components are welded to project from the base and provide a flexible three-dimensional structure. The thermal bonding or welding of the thermoplastic foam components creates a unitized structure which is both flexible and load bearing. For mattress and seating applications, the welded foam structures may be combined with an innerspring, and certain of the foam components of the structure may mechanically engage parts of the innerspring. The preferred foam deck has first and second panels interconnected by one or more webs. One or more foam decks may be employed. Other foam components may be attached to the foam decks or other components. The utilized foam structures can be employed as single or double-sided mattresses, seating structures or other flexible support structures.

Abstract: An apparatus and device for fusing two or more foam components together by thermal welding, has an interface blade adapted for placement at an interface of foam components to be fused together, and a nozzle proximate to the interface blade for distributing a heated gas at the interface of the foam components. The nozzle may be located in a shroud proximate to the interface blade. An automated foam welding apparatus has a platform for supporting foam components or other components, a clamp for applying pressure to one or more of the foam components, and one or more welding heads mounted upon a track for translation proximate to the foam components to be welded together, the welding heads having an interface blade and a heated gas distribution nozzle, and optionally a trimmer for trimming excess material from one or more of the foam components. A hand-held foam welding device is also described.

Abstract: An apparatus and device for fusing two or more foam components together by thermal welding, the apparatus and device comprising an interface blade adapted for placement at an interface of foam components to be fused together, and a nozzle proximate to the interface blade for distributing a heated gas at the interface of the foam components. The nozzle may be located in a shroud proximate to the interface blade. An automated foam welding apparatus has a platform for supporting foam components or other components, a clamp for applying pressure to one or more of the foam components, and one or more welding heads mounted upon a track for translation proximate to the foam components to be welded together, the welding heads having an interface blade and a heated gas distribution nozzle, and optionally a trimmer for trimming excess material from one or more of the foam components. A hand-held foam welding device is also described.

Abstract: Three-dimensional unitized thermoplastic foam structures are made by thermoplastic welding of different foam components. The unitized foam structures may include a planar base to which other foam components are welded to project from the base and provide a flexible three-dimensional structure. The thermal bonding or welding of the thermoplastic foam components creates a unitized structure which is both flexible and load bearing. For mattress and seating applications, the welded foam structures may be combined with an innerspring, and certain of the foam components of the structure may mechanically engage parts of the innerspring. The preferred foam deck has first and second panels interconnected by one or more webs. One or more foam decks may be employed. Other foam components may be attached to the foam decks or other components. The unitized foam structures can be employed as single or double-sided mattresses, seating structures or other flexible support structures.

Abstract: A modular sleep system has a foundation unit, an support unit having an innerspring and a support surface covered with a friction material, and a comfort unit having compressible material encapsulated in a woven upholstery material which is engaged by the friction material on the support surface of the support unit to prevent lateral movement or sliding of the comfort unit relative to the support unit, without any fasteners between the support unit and the comfort unit. The comfort unit can be lifted vertically off of the support unit without release or use of any fasteners, to be turned over, fluffed or exchanged for a different comfort unit having different layers of internal materials, feature layers, and support characteristics.

Abstract: A high profile coil with an overall height in a range of 6¾ to 7½ inches maintains axially alignment under compression. A high profile innerspring constructed with the high profile coils can be baled with other high profile innersprings in a baling machine without spin-out or lateral distortion. On-axis of compression of the coils under various loading conditions avoids contact with adjacent coils in an innerspring.

Abstract: A selectively contoured single unibody foam piece for use as a layer in a cushioned load bearing structure has a first zone with a first surface topography having distinct support properties from a second zone with a second surface topography. The zones of differing topography are formed in the surface of a single, unibody piece of foam by applicable foam cutting techniques. Patterned removal of foam material from a single piece creates zones with different density, ILD or other load bearing properties with different support and feel characteristics. A single unibody component in a responsive flexible support structure has distinct zones with distinct support characteristics, the zones corresponding in location with the anticipated loads and loading patterns of a flexible support device in use.

Abstract: A selectively contoured single unibody foam piece for use as a layer in a cushioned load bearing structure has a first zone with a first surface topography having distinct support properties from a second zone with a second surface topography. The zones of differing topography are formed in the surface of a single, unibody piece of foam by applicable foam cutting techniques. Patterned removal of foam material from a single piece creates zones with different density, ILD or other load bearing properties with different support and feel characteristics. A single unibody component in a responsive flexible support structure has distinct zones with distinct support characteristics, the zones corresponding in location with the anticipated loads and loading patterns of a flexible support device in use.

Abstract: A modular sleep system has a foundation unit, an support unit having an innerspring and a support surface covered with a friction material, and a comfort unit having compressible material encapsulated in a woven upholstery material which is engaged by the friction material on the support surface of the support unit to prevent lateral movement or sliding of the comfort unit relative to the support unit, without any fasteners between the support unit and the comfort unit. The comfort unit can be lifted vertically off of the support unit without release or use of any fasteners, to be turned over, fluffed or exchanged for a different comfort unit having different layers of internal materials, feature layers, and support characteristics.

Abstract: Composite material spring modules have a fiber reinforced composite material spring body with attachment fittings integrally formed about the spring body. The attachment fittings are molded of a flexible material which dynamically responds to changes in the shape of the spring body upon deflection. Integral formation of the fittings with the spring body provides a unified single piece module which is readily attachable to any structure where spring support is desired. In one embodiment, a mounting foot is configured for mounting of the spring module directly to a planar surface of a supporting frame member by a fastener, or alternatively configured to engage with a frame member without use of a fastener. The composite material spring modules exhibit the properties of stiffness and return to uncompressed state from total depth deflection without set.

Abstract: A cavitated pad and innerspring assembly combination, for use in mattresses, furniture, or other cushioned flexible support structures, wherein coils of the innerspring assembly have terminal convolutions which extend beyond the coil body and are not connected to adjacent coils. A cavitated pad has openings in which the terminal convolutions fit, and the pad overlies the coil bodies. In one embodiment, the cavitations extend either partially or entirely through the pad. Upholstery is attached over the pad. The combination of coils with terminal convolutions positioned within the cavitations in the pad provides a dampened or attenuated dual spring rate support surface with controlled lateral deflection of the terminal convolutions.

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.