Abstract: A roll (54) of compressed materials (14) is provided which has a sleeve (50) formed around a rotatable mandrel (12). The sleeve (50) about which the materials (14) are rolled prevents the roll (54) from radially collapsing. The roll (54) may be removed from the mandrel (12) without tearing or telescoping of the material. In one embodiment the sleeve (50) is corrugated material (38). The corrugated material (38) is around the rotatable mandrel (12) prior to the compressible material (14) being wrapped around the sleeve (50). In another embodiment, the sleeve (58) comprises roll-packing material (32) laminated prior to being wound upon the mandrel (12).

Abstract: A bedding or seating product comprises a pocketed spring assembly having a plurality of parallel strings of springs joined to each other. Each of said strings of springs comprises a row of interconnected pockets, each of the pockets containing at least one spring encased in a fabric pocket. An inflatable member is sandwiched between a lower scrim sheet and some strings of springs. When inflated, the inflatable member preloads select areas of the product.

Abstract: A bedding or seating product comprising a spring assembly made up of a plurality of parallel strings of springs joined to each other. Each of the strings of springs comprises a row of interconnected pocketed coil springs. Selected pockets of fabric are shorter than adjacent pockets, so coil springs in the selected pockets are under a greater load than adjacent coil springs. In one preferred embodiment, every other pocket is under a greater load than the adjacent pockets, resulting in a checkerboard arrangement in at least one area of the product.

Abstract: A string (12) of pocketed coil springs (14) is formed by inserting compressed springs between upper and lower plies of a folded, preferably thermally weldable fabric (16). The springs are maintaned in a compressed configuration while a longitudinal seam (54) joins the free edges of the thermally welded fabric (16) together. Subsequently, the compressed springs (14) are allowed to relax into an expanded configuration after which a transverse seam (80) is formed in the fabric (16) between the adjacent springs (14) thereby encapsulating each spring (14) within a fabric pocket (86). The string (12) of pocketed coil springs (14) is advantageously formed without the need for reorienting the springs (14) after being inserted between the plies (24,26) of the fabric (16) and thereby avoiding the disadvantages and complications associated with turning or reorienting the pocketed coil spring (14).

Abstract: A bedding or seating product is provided comprising a pocketed spring assembly made up of a plurality of parallel strings of springs joined to each other. Each string of springs comprises a row of interconnected pocketed springs. The pockets of fabric are vertically shortened with seams to create pockets of the same height, each containing a spring. The springs are vertically offset from one another due to the location of the seams. Upon an initial load, only some of the pocketed springs are compressed.

Abstract: A bedding or seating product comprising a pocketed spring assembly made up of a plurality of parallel strings of springs joined to each other. Each of the strings of springs comprises a plurality of interconnected pocketed coil springs. The product has multiple sections of differing firmness attributable in part to differing heights of the pockets of the strings of springs. Filler is placed above the lower sections of the pocketed spring assembly.

Abstract: A method of roll packing a variety of compressible materials is provided which prevents the rotatable mandrel about which the materials are rolled from radially collapsing. The method further provides for easy removal of the roll packed material without tearing or telescoping of the material. One embodiment of the present invention provides for wrapping a corrugated material around the rotatable mandrel prior to the compressible material being wrapped around the mandrel. In another embodiment, roll-packing material is laminated prior to being wound upon the mandrel before the compressible material is wrapped around the mandrel.

Abstract: A method of roll packing a variety of compressible materials is provided which prevents the rotatable mandrel about which the materials are rolled from radially collapsing. The method further provides for easy removal of the roll packed material without tearing or-telescoping of the material. One embodiment of the present invention provides for wrapping a corrugated material around the rotatable mandrel prior to the compressible material being wrapped around the mandrel. In another embodiment, roll-packing material is laminated prior to being wound upon,the mandrel before the compressible material is wrapped around the mandrel.

Abstract: A roll (54) of compressed materials (14) is provided which has a sleeve (50) formed around a rotatable mandrel (12). The sleeve (50) about which the materials (14) are rolled prevents the roll (54) from radially collapsing. The roll (54) may be removed from the mandrel (12) without tearing or telescoping of the material. In one embodiment the sleeve (50) is corrugated material (38). The corrugated material (38) is around the rotatable mandrel (12) prior to the compressible material (14) being wrapped around the sleeve (50). In another embodiment, the sleeve (58) comprises roll-packing material (32) laminated prior to being wound upon the mandrel (12).

Abstract: A bedding or seating product comprising a pocketed spring assembly made up of a plurality of parallel strings of springs joined to each other. Each of the strings of springs comprises a plurality of interconnected pocketed coil springs. The product has multiple sections of differing firmness attributable in part to differing heights of the pockets of the strings of springs. Filler is placed above the lower sections of the pocketed spring assembly.

Abstract: A bedding or seating product comprising a spring assembly made up of a plurality of parallel strings of springs joined to each other. Each of the strings of springs comprises a row of interconnected pocketed coil springs. Selected pockets of fabric are shorter than adjacent pockets, so coil springs in the selected pockets are under a greater load than adjacent coil springs. In one preferred embodiment, every other pocket is under a greater load than the adjacent pockets, resulting in a checkerboard arrangement in at least one area of the product.

Abstract: A string (12) of pocketed coil springs (14) is formed by inserting compressed springs between upper and lower plies of a folded, preferably thermally weldable fabric (16). The springs are maintaned in a compressed configuration while a longitudinal seam (54) joins the free edges of the thermally welded fabric (16) together. Subsequently, the compressed springs (14) are allowed to relax into an expanded configuration after which a transverse seam (80) is formed in the fabric (16) between the adjacent springs (14) thereby encapsulating each spring (14) within a fabric pocket (86). The string (12) of pocketed coil springs (14) is advantageously formed without the need for reorienting the springs (14) after being inserted between the plies (24,26) of the fabric (16) and thereby avoiding the disadvantages and complications associated with turning or reorienting the pocketed coil spring (14).

Abstract: A non-woven fiber pad having a convoluted surface formed by cutting a non-woven fiber batt having a plurality of low melt synthetic fibers. The non-woven batt is compressed generally toward a cutting device by a pair of counter-rotating drums having convoluted surfaces.

Abstract: A multilayered bedding or seating product comprising a spring core made up of an upper layer and a lower layer of pocketed coil springs. Each layer comprises a plurality of parallel strings of springs joined to each other. Each of the strings of springs comprises a row of interconnected pocketed coil springs. The strings of springs of the upper and lower layers may be secured to at least one scrim sheet therebetween.

Abstract: A string (12) of pocketed coil springs (14) is formed by inserting compressed springs between upper and lower plies of a folded, preferably thermally weldable fabric (16). The springs are maintained in a compressed configuration while a longitudinal seam (54) joins the free edges of the thermally welded fabric (16) together. Subsequently, the compressed springs (14) are allowed to relax into an expanded configuration after which a transverse seam (80) is formed in the fabric (16) between the adjacent springs (14) thereby encapsulating each spring (14) within a fabric pocket (86). The string (12) of pocketed coil springs (14) is advantageously formed without the need for reorienting the springs (14) after being inserted between the plies (24, 26) of the fabric (16) and thereby avoiding the disadvantages and complications associated with turning or reorienting the pocketed coil spring (14).

Abstract: A method of assembling strings of pocketed coil springs into an innerspring assembly which may be used as the core of a mattress, cushion or similar body support foundation uses a fabric material, preferably having an adhesive component, between rows of pocketed coil springs. The adhesive material serves to bond the rows of springs to each other and to position them relative to one another to prevent expansion and/or contraction of the spring assembly.

Abstract: A method for roll packing foam mattress cores includes the step of providing a radially collapsible mandrel for winding up the foam material. Compression of the foam material is accomplished during the roll operation via a compression roller associated with the mandrel. After a sufficient amount of foam material has been rolled, the mandrel is collapsed to facilitate easy removal of the roll. In one embodiment of the invention, packing material is applied to a surface of the foam as it is rolled to prevent adhesion of successive layers in the roll.

Abstract: A non-woven fiber pad having a convoluted surface formed by cutting a non-woven fiber batt having a plurality of low melt synthetic fibers. The non-woven batt is compressed generally toward a cutting device by a pair of counter-rotating drums having convoluted surfaces.

Abstract: A string (12) of pocketed coil springs (14) is formed by inserting compressed springs between upper and lower plies of a folded, preferably thermally weldable fabric (16). The springs are maintained in a compressed configuration while a longitudinal seam (54) joins the free edges of the thermally welded fabric (16) together. Subsequently, the compressed springs (14) are allowed to relax into an expanded configuration after which a transverse seam (80) is formed in the fabric (16) between the adjacent springs (14) thereby encapsulating each spring (14) within a fabric pocket (86). The string (12) of pocketed coil springs (14) is advantageously formed without the need for reorienting the springs (14) after being inserted between the plies (24, 26) of the fabric (16) and thereby avoiding the disadvantages and complications associated with turning or reorienting the pocketed coil spring (14).

Abstract: A bedding or seating product comprising a base having a generally rectangular frame and a plurality of internal rails, a wire grid spaced above the base and a plurality of plastic modules connecting the wire frame and the base. Each of the plastic modules has four arms extending upwardly from a bottom portion and terminating in end portions. Each end portion has a pair of perpendicular grooves adapted to receive intersecting wires of the wire grid. The modules are nestably stackable to save space during shipping.