Abstract: An inner spring core comprises a nestably stackable first spring unit and a second generally planar stackable grid unit. The nestably stackable first spring unit comprises a first generally planar platform and a plurality of generally conical spring elements extending in one direction from the first generally planar platform. Each of the generally conical spring elements is in a preferred embodiment a double twist coil spring which has a bottom planar portion in the plane of the first generally planar platform, and two spring arms extending upwardly from the bottom planar portion terminating in a distal end portion. The second generally planar stackable grid unit is secured to the distal end portions of the generally conical nestable spring elements by a plurality of connectors located generally in the plane of the second stackable grid unit.

Abstract: A spring interior of a mattress comprising a plurality of longitudinally extending bands of springs disposed side by side and connected together with helical lacing wires in the top and bottom faces of the bands. Each band of springs comprises a single length of wire formed into a plurality of coil springs interconnected by innerconnecting segments located alternatively in the top and bottom faces of the bands. The spring interior is characterized by longitudinally extending sections of differing firmnesses throughout the length of the spring interior. The different firmnesses in the different sections of the spring interior are attributable to different configurations of the innerconnecting segments. The innerconnecting segments within the firmer sections of the mattress have a deeper V-shaped indentation than the portions of the bands of springs in the less firm sections of the mattress.

Abstract: An inner spring core comprising a plurality of coil springs arranged in rows and columns having an improved border firmness adjuster around the periphery of the core. The improved border firmness adjuster comprises one of more inflatable pneumatic members positioned inwardly of the outer edges of the outermost coil springs in a space between two adjacent convolutions of each of the outermost coil springs. The pneumatic member or members is capable of variably adjusting the firmness of at least one edge of the mattress.

Abstract: An apparatus and method for securing a top panel cover of a mattress to an innerspring core include a plurality of clips attached to an upper border wire of the core. Each clip has one or more barbs that project inwardly with respect to the core. The cover is attached to the core by stretching and wrapping the edges of the cover over and around the border wire and pushing the edges against the barbs so that the barbs pierce the edges and hold the edges in a taut position at least partially wrapped around the border wire.

Abstract: A spring core for a mattress consisting of a plurality of side-by-side rows of identically configured helical coil springs each made of a single piece of wire having a central portion of a first radius defining a central spring axis and terminating at opposing ends with unknotted upper and lower end turns disposed in planes substantially perpendicular to the spring axis. The springs are connected with each other at their upper and lower turns by connecting lacing wires. The upper and lower turns are each substantially U-shaped, having a longer relatively straight leg and a shorter arcuate leg located at the free end of each end turn, the legs connected to each other by a base web. The radius of the shorter arcuate leg is substantially less than the first radius of the central portion of each coil spring. All the coil springs are oriented in the same direction, except along an edge region of the spring core.

Abstract: An innerspring structure for a mattress comprises a plurality of outer coils extending generally parallel with each other to collectively form top and bottom face surfaces of the innerspring structure. One or more of the outer coils has an inner coil of preferably similar shape wound within and generally coaxially with the respective outer coil. Helical lacing wire wraps adjacent end turns of the inner and outer coaxially aligned coils together to form reinforced coil units in an area of the innerspring structure to increase the firmness of an area of the mattress utilizing the invention. Helical lacing wire connects the coils of the structure together and connects the end turns of peripheral coils to a border wire surrounding the periphery of the structures at the top and bottom face surfaces.

Abstract: A box spring assembly for use as a foundation for a bedding mattress has a triple beam frame. The frame has three layers of which the bottom layer consists of longitudinal side rails equally spaced from a center rail and connected at each end to a double thickness end rail consisting of a lower and upper board. The middle layer of the frame includes a number of transverse slats equally spaced between the upper board end rails positioned at each lengthwise end of the box spring assembly. The lower board end rails underlie the upper board end rails and are in the bottom plane of the frame. The top layer of the frame consists of longitudinal slats spaced atop the transverse slats and upper board end rails. The triple beam frame is constructed of metal, wood, or a combination thereof. Coil springs are secured to the longitudinal slats in the box spring assembly.

Abstract: A nestably stackable bedding foundation assembly which replaces the traditional border wire and disposed coil spring foundation assembly in a so-called box spring. The nestably stackable foundation assembly may be nestably stacked with numerous other such assemblies for transportation, thereby avoiding the need to compress and tie the assembly for shipping. A bedding foundation comprises a rectangular base, a nestably stackable bedding foundation assembly fixedly attached atop the base, and spring means disposed between and connected to the base and the nestably stackable assembly.

Abstract: An improved sheet metal clip is interconnected in a collated stack of clips with a plastic rope inserted within slots on each side edge of each clip. Each clip is generally U-shaped having a crown portion with a pair of parallel spaced leg portions depending from the crown portion. The rope is inserted within slots formed in the side edges of each clip. The preferred embodiments of the improved clip include slots which are obliquely angled relative to the side edge of the clip, slots which are in a keyhole configuration having a narrowed throat portion and an enlarged opening, and slots which are both obliquely angled and in the keyhole configuration. The rope can be retained within the slots by deflecting a tab section of the crown portion to enclose the rope within the slot or by sizing the rope to be larger in diameter than the width of the narrowed throat portion of the keyhole slot and to be retained within the enlarged circular opening portion of the keyhole slot.

Abstract: An improved sheet metal clip is interconnected in a collated stack of clips with a plastic rope inserted within side slots on each side edge of each clip. Each clip is generally U-shaped having a crown portion with a pair of parallel spaced leg portions depending from the crown portion. The rope is inserted within the side slots formed in the side edges of each clip. The preferred embodiment of the improved clip includes crown slots which are inwardly extending from each side edge of the crown portion. The rope can be retained within the slots by deflecting tabs on each lateral side edge of the crown portion to enclose the rope within the side slots. The collated stack of clips interconnected with the plastic rope of the present invention provides the needed flexibility and tensile strength for use in manufacturing applications and does not detrimentally affect the operation of the clip in clamping wires and springs together.

Abstract: A box spring assembly includes a base frame, a top wire grid and a plurality of modular wire springs interconnecting the top wire grid and the base frame. The modular wire springs each comprises a unitary wire formed into an inverted U-shaped configuration with the closed end of each U-shaped spring having two edge connector bars and a diagonally extending central connector bar interconnected at its opposite ends to the edge connector bars by attachment segments. The closed end of the modular spring is snap-fit to the top wire grid so each of the edge connector bars supports separate portions of the top wire grid at intersections within the wire grid. The vertical legs of the modular spring include at least three torsion bars and two edge loops of differing radii. The edge loops, because of their differing radii impart differing softness or deflection characteristics to the modular springs.

Abstract: An apparatus for forming and assembling spring interiors is provided in which, in the preferred embodiment, adjustable reforming dies adjacent a cutting station lengthen the supporting structure of a bridging portion of the coil band that interconnects coils near the end of the band to compensate for the change of length caused by the cutting of the endmost bridging portion separating spring assemblies. Adjustable dies are also provided to vary the length of the bridging portions when they are initially formed. The coils are interlaced at a lacing station from continuous lacing coil bands.

Abstract: A pocketed coil spring assembly for use in the manufacture of mattresses or cushions or the like comprising a plurality of longitudinally extending strips of integrally connected closed fabric pockets each containing at least one helically coiled wire compression spring having its axis disposed transversely of the strip, and wherein each of the strips contains a single band of interconnected springs formed from a single length of wire into a plurality of interconnected helical coil springs. In the preferred embodiment of the invention, each strip of spring containing pockets is spaced from each adjacent strip by a ply of resilient foam material, and each of the plies of resilient foam material are secured to the sidewalls of adjacent strips.

Abstract: A nestably stackable bedding foundation assembly which replaces the traditional border wire and disposed coil spring foundation assembly in a so-called box spring. The nestably stackable foundation assembly may be nestably stacked with numerous other such assemblies for transportation, thereby avoiding the need to compress and tie the assembly for shipping.

Abstract: A box spring assembly includes a base frame, a top wire grid and a plurality of sinous wire springs interconnecting the top wire grid and the base frame. The sinuous wire springs each comprises a sinuous wire strip formed into an inverted U-shaped configuration with the closed end of each U-shaped spring attached to the top wire grid by a snap-fit connection and the free ends at the bottom of the U-shaped spring being attached to the base frame.

Abstract: A box spring assembly includes a base frame, a top wire grid and a plurality of formed wire springs interconnecting the top wire grid and the base frame. The formed wire springs each comprises a wire strip formed into an inverted U-shaped configuration with the closed end of each U-shaped spring attached to the top wire grid by a snap-fit connection and the free ends at the bottom of the U-shaped spring being attached to the base frame.

Abstract: A collapsible bedding foundation comprises a rectangular base frame and a rectangular wire grid. The wire grid is hingedly supported upon the frame for movement between a collapsed position and an erect position. The hinged connection between the wire grid and the base frame is achieved by a plurality of transverse spaced, parallel planar support elements pivotally connected to the base frame and the wire grid. The foundation is supported in an erect position solely by a pair of longitudinally extending, parallel planar support elements pivotally connected to the longitudinal edge of the wire grid and, when the foundation is erect, fixedly secured to the base frame.