Abstract: A spring assembly for mattresses, innersprings, and the like. The assembly comprises rows of coils, each row comprising a continuous length of wire formed into a plurality of coils interconnected by Z-shaped wire segments alternately disposed at the top and bottom of the coils. Adjacent rows of coils are connected by helical wire wound through overlapping sections of the Z-shaped wire segments. The overlapping connected sections are straight, flat offset sections located on opposite sides of each coil with the center of each overlapped section being located in a common diametral plane of the coil so that complete compression of the coil does not result in the coil being pulled laterally, twisted and distorted.

Abstract: A bedding mattress support foundation comprises a base frame, a plurality of formed wire springs mounted upon the base frame, and a wire grid mounted atop the formed wire springs. Each formed wire spring comprises a generally S-shaped horizontal load supporting portion and a pair of vertically extending yieldable end portions extending downwardly from opposite ends of the load supporting portion. Two parallel wires of the wire grid are secured to curvilinear portions of the S-shaped horizontal load supporting portion of each spring and three other parallel wires extending perpendicular to the first two parallel wires and rest atop but are unsecured to the S-shaped horizontal load supporting portion of each spring.

Abstract: A box spring for supporting a bedding mattress. The box spring includes a rectangular base frame, a plurality of modular spring elements mounted atop the base frame, and a wire grid mounted atop the modular spring elements. Each of the modular spring elements comprises a horizontal straight center section terminating in horizontal plane curved end sections, at least some of the curved end sections having single revolution coil springs extending vertically downwardly therefrom. The modular spring elements are arranged in parallel rows, said adjacent spring elements of each row having aligned straight center sections and overlapping curved sections. The overlapping curved center sections of adjacent modular spring elements are connected by transverse wires of the grip top, which transverse wires have generally U-shaped bights or hooks from therein received over the overlapping curved sections and crimped shut to secure adjacent modular spring elements of multiple rows of modular spring elements to one another.

Abstract: A bedding foundation box spring having novel double twist coil springs interconnecting a wooden base frame and a top wire grid. The coil springs each comprise a single length of wire having a middle section located in a diametral plane of one end convolution of the spring and a pair of spring arms coiled in the same rotational direction from opposite ends of the middle section. Each of the spring arms is formed into a helix of varying pitch which terminates in a free end of the spring arm. The free ends of the two spring arms of each coil are located on opposite sides of the end convolution of the coil and are secured to the wire grid. The novel coils are manufactured by inserting a straight length of wire through a stationary pair of forming dies and a mandrel located between the dies. With the middle of the straight length of wire located in the mandrel, the mandrel is then simultaneously rotated and moved axially while the ends of the length of wire are pulled through the stationary forming dies.

Abstract: A bedding foundation box spring having novel double twist coil springs interconnecting a wooden base frame and a top wire grid. The coil springs each comprise a single length of wire having a middle section located in a diametral plane of one end convolution of the spring and a pair of spring arms coiled in the same rotational direction from opposite ends of the middle section. Each of the spring arms is formed into a helix of varying pitch which terminates in a free end of the spring arm. The free ends of the two spring arms of each coil are located on opposite sides of the end convolution of the coil and are secured to the wire grid. The novel coils are manufactured by inserting a straight length of wire through a stationary pair of forming dies and a mandrel located between the dies. With the middle of the straight length of wire located in the mandrel, the mandrel is then simultaneously rotated and moved axially while the ends of the length of wire are pulled through the stationary forming dies.

Abstract: A spring assembly for mattresses, innersprings, and the like. The assembly comprises rows of coils, each row comprising a continuous length of wire formed into a plurality of coils interconnected by Z-shaped wire segments alternately disposed at the top and bottom of the coils. Adjacent rows of coils are connected by a helical wire wound through overlapping Z-shaped wire segments. The overlapping connected segments on opposite sides of each coil are located in a common diametrical plane of the coil so that complete compression of the coil does not result in the coil being pulled laterally, twisted and distorted.

Abstract: A coil spring assembly, and a method of forming that assembly, in which the assembly's edgemost coil springs are connected to a border wire by a single continuous spiral lacing wire. The method involves the steps of guiding a rotation spiral lacing wire completely around the periphery of a spring coil matrix and border wire through use of helical path defining dies until the leading and trailing ends of the lacing wire are overlapped. During the lacing operation, the helical path defining dies cooperate to deflect a peripheral segment of each corner and edge coil into juxtaposition with the border wire. The resulting final coil spring assembly includes corner coil springs in which the deflected peripheral segments of the corner coils are retained contiguous to the corner of the border wire by the lacing wire.