Abstract: A shippable and foldable bed foundation for supporting a bed mattress. The bed foundation includes a base including a first frame having a bottom and a top, a second frame having a bottom and a top, and a connector pivotally connecting the second frame to the first frame. The first frame and the second frame are selectively pivotal with respect to one another about a pivot axis, such that the first frame and the second frame are selectively pivotal with respect to one another between an open unfolded position wherein the tops of the first frame and the second frame are generally coplanar and are adapted to support the bed mattress and a closed folded position wherein the base is folded and the top of the second frame overlies the top of the first frame.

Abstract: An insert adapted to be inserted between a foundation of a bed and a mattress of the bed. The insert includes a frame having a first side rail and a second side rail spaced apart from the first side rail. A plurality of elongate upper slats extend between the first side rail and the second side rail of the frame at a first level with respect to the frame and are spaced apart from one another. A plurality of elongate lower slats extend between the first side rail and the second side rail of the frame at a second level located below the first level of the upper slats. Each lower slat is located below a gap formed between a pair of adjacent upper slats. A mounting member resiliently supports the ends of two adjacent upper slats and rigidly supports the end of a lower slat that is located below the gap formed between the two adjacent upper slats, whereby the firmness of a mattress overlying the insert can be selectively adjusted.

Abstract: An all truss foundation unit, method of making the foundation unit, and a foundation unit kit. The foundation unit is formed of multiple cross trusses interconnected by bridging top and bottom side rails. This results in a flat surface on both the top and the bottom of the foundation unit. The kit is formed of a plurality of the trusses and four side rails, with the trusses and side rails being oriented together with their longitudinal dimensions aligned in a generally parallel orientation and with at least some of their flat sides in contact with one another. When the foundation unit is constructed, a truss locator guide is provided on at least two of the side rails, and the cross trusses are oriented in a parallel, spaced relationship in accordance with the truss locator guide.

Abstract: An insert adapted to be inserted between a foundation of a bed and a mattress of the bed. The insert includes a frame having a first side rail and a second side rail spaced apart from the first side rail. A plurality of elongate upper slats extend between the first side rail and the second side rail of the frame at a first level with respect to the frame and are spaced apart from one another. A plurality of elongate lower slats extend between the first side rail and the second side rail of the frame at a second level located below the first level of the upper slats. Each lower slat is located below a gap formed between a pair of adjacent upper slats. A mounting member resiliently supports the ends of two adjacent upper slats and rigidly supports the end of a lower slat that is located below the gap formed between the two adjacent upper slats, whereby the firmness of a mattress overlying the insert can be selectively adjusted.

Abstract: An all truss foundation unit, method of making the foundation unit, and a foundation unit kit. The foundation unit is formed of multiple cross trusses interconnected by bridging top and bottom side rails. This results in a flat surface on both the top and the bottom of the foundation unit. The kit is formed of a plurality of the trusses and four side rails, with the trusses and side rails being oriented together with their longitudinal dimensions aligned in a generally parallel orientation and with at least some of their flat sides in contact with one another. When the foundation unit is constructed, a truss locator guide is provided on at least two of the side rails, and the cross trusses are oriented in a parallel, spaced relationship in accordance with the truss locator guide.

Abstract: An all truss foundation unit, method of making the foundation unit, and a foundation unit kit. The foundation unit is formed of multiple cross trusses interconnected by bridging top and bottom side rails. This results in a flat surface on both the top and the bottom of the foundation unit. The kit is formed of a plurality of the trusses and four side rails, with the trusses and side rails being oriented together with their longitudinal dimensions aligned in a generally parallel orientation and with at least some of their flat sides in contact with one another. When the foundation unit is constructed, a truss locator guide is provided on at least two of the side rails, and the cross trusses are oriented in a parallel, spaced relationship in accordance with the truss locator guide.

Abstract: A spring wire support for foundations and innerspring mattresses, and a variable spring surface deck for a foundation and variable spring surface for a mattress. The spring wire support comprises an elongated spring element enveloped in a pliant carrier, with the carrier including an attachment margin. The variable spring surface deck for a foundation comprises a plurality of the spring wire supports secured as desired to an upper surface of a foundation. The variable spring surface for a mattress comprises a plurality of the spring wire supports located between top and adjacent convolutions of rows or columns of springs of the mattress.

Abstract: A spring wire support for foundations and innerspring mattresses, and a variable spring surface deck for a foundation and variable spring surface for a mattress. The spring wire support comprises an elongated spring element enveloped in a pliant carrier, with the carrier including an attachment margin. The variable spring surface deck for a foundation comprises a plurality of the spring wire supports secured as desired to an upper surface of a foundation. The variable spring surface for a mattress comprises a plurality of the spring wire supports located between top and adjacent convolutions of rows or columns of springs of the mattress.

Abstract: An all truss foundation unit, method of making the foundation unit, and a foundation unit kit. The foundation unit is formed of multiple cross trusses interconnected by bridging top and bottom side rails. This results in a flat surface on both the top and the bottom of the foundation unit. The kit is formed of a plurality of the trusses and four side rails, with the trusses and side rails being oriented together with their longitudinal dimensions aligned in a generally parallel orientation and with at least some of their flat sides in contact with one another. When the foundation unit is constructed, a truss locator guide is provided on at least two of the side rails, and the cross trusses are oriented in a parallel, spaced relationship in accordance with the truss locator guide.

Abstract: A compact foundation unit kit and a method of making a foundation unit from the kit. The kit comprises at least three elongated, generally flat truss rails, four generally flat end caps and a plurality of generally flat cross slats, with the truss rails, end caps and cross slats oriented together with their longitudinal dimensions aligned in a generally parallel orientation and with their flat sides in contact. A binding maintains the truss rails, end caps and cross slats in that orientation. The method includes providing the kit, opening the kit and orienting the truss rails in a parallel, spaced position, then affixing one of the end caps to each end of the truss rails, inverting the partially formed foundation, and affixing the last two end caps to opposite ends of the truss rails, then finally affixing the cross slats to the truss rails in a spaced, parallel orientation. The foundation can then be finished in a conventional fashion.

Abstract: A variable spring surface deck and a foundation having a variable spring surface deck thereon. The deck comprises a plurality of longitudinal spring wire support rods which are maintained in a spaced orientation in a planar configuration. They are maintained as such in various structures, such as a mat having a series of parallel slots, or a carrier having spaced, open corrugations. The support rods are located in chosen slots or corrugations. A second, cross-wire layer of lateral spring wire support rods can be included in the variable spring surface deck. The variable spring surface foundation includes the variable spring surface deck located on a top bearing structure of a foundation unit.

Abstract: A compact foundation unit kit and a method of making a foundation unit from the kit. The kit comprises at least three elongated, generally flat truss rails, four generally flat end caps and a plurality of generally flat cross slats, with the truss rails, end caps and cross slats oriented together with their longitudinal dimensions aligned in a generally parallel orientation and with their flat sides in contact. A binding maintains the truss rails, end caps and cross slats in that orientation. The method includes providing the kit, opening the kit and orienting the truss rails in a parallel, spaced position, then affixing one of the end caps to each end of the truss rails, inverting the partially formed foundation, and affixing the last two end caps to opposite ends of the truss rails, then finally affixing the cross slats to the truss rails in a spaced, parallel orientation. The foundation can then be finished in a conventional fashion.

Abstract: A compact foundation unit kit and a method of making a foundation unit from the kit. The kit comprises at least three elongated, generally flat truss rails, four generally flat end caps and a plurality of generally flat cross slats, with the truss rails, end caps and cross slats oriented together with their longitudinal dimensions aligned in a generally parallel orientation and with their flat sides in contact. A binding maintains the truss rails, end caps and cross slats in that orientation. The method includes providing the kit, opening the kit and orienting the truss rails in a parallel, spaced position, then affixing one of the end caps to each end of the truss rails, inverting the partially formed foundation, and affixing the last two end caps to opposite ends of the truss rails, then finally affixing the cross slats to the truss rails in a spaced, parallel orientation. The foundation can then be finished in a conventional fashion.

Abstract: A compact foundation unit kit and a method of making a foundation unit from the kit. The kit comprises at least three elongated, generally flat truss rails, four generally flat end caps and a plurality of generally flat cross slats, with the truss rails, end caps and cross slats oriented together with their longitudinal dimensions aligned in a generally parallel orientation and with their flat sides in contact. A binding maintains the truss rails, end caps and cross slats in that orientation. The method includes providing the kit, opening the kit and orienting the truss rails in a parallel, spaced position, then affixing one of the end caps to each end of the truss rails, inverting the partially formed foundation, and affixing the last two end caps to opposite ends of the truss rails, then finally affixing the cross slats to the truss rails in a spaced, parallel orientation. The foundation can then be finished in a conventional fashion.

Abstract: A bedding or seating product comprising a spring assembly made of a plurality of strings of springs connected to each other. Each string of springs comprises a plurality of individually pocketed coil springs. Within each pocket is a coil spring and at least one cushioning pad secured to the coil spring. In one embodiment, one cushioning pad is secured to the upper end turn of the coil spring. In an alternative embodiment, cushioning pads are secured to the upper and lower end turns of the coil spring.

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: 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 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.