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.

Abstract: Composite material springs with integrals spacers for located between a frame attachment fitting and a spring body provide springs with an increased vertical profile for support structures with greater height. Spring elements are formed with encapsulated fibers. Attachment fittings and other structural elements such as the spacers are integrally formed by molding about the spring elements, in any suitable form for integration and assembly with spring support structure assemblies, such as a support frame on which the composite material springs are mounted, and a support structure such as a grid or wire work to which the springs are attached by the various types of attachment fittings. Direct mounting of springs to surfaces of frame members is also disclosed.

Abstract: The invention relates to a modular spring for a mattress foundation unit having a wooden base a plurality of modular springs and a mattress supporting wire grid that is supported above the wooden base by the modular springs. The modular spring comprises a planar top portion which can be attached to the wire grid, four straight legs and each leg terminating in a transverse foot portion. The top portion includes four partially curved spaced apart members. The legs extend downwardly from the top portion in an obtuse angular relation to the top portion and each leg interlinks two adjacent partially curved members.

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 nestably stackable assembly for use in a bedding foundation. The assembly has a rectangular border wire with parallel sides and ends. Transversely spaced, parallel and longitudinally extending support wires are connected at their ends to the border wire ends. The support wires are formed so as to be generally corrugated along their lengths with peaks and valleys. The peaks are flattened at their tops, and the flattened tops are generally coplanar with a plane defined by the border wire. The valleys are vertically displaced beneath and intermediate of the flattened tops. Longitudinally spaced and transversely extending, upper connector wires are connected to the sides of border wires, and the upper connector wires are connected along their lengths to the flattened tops of the peaks of the support wires. The valleys have flattened bottoms, and adjacent pairs of the flattened bottoms of the valley are interconnected by resilient connectors.

Abstract: The seat assembly of the present invention comprises a generally rectangular frame, a center rail, a plurality of modular springs secured to the frame and a wire grid secured to the modular springs. Each of the modular springs has a front section secured to the front rail of the rectangular frame, a resilient center section secured to the center rail and a rear section spaced above the frame and unattached to any of the rails. The front section of each modular spring is preloaded to increase the resilient support of the seat.

Abstract: The invention relates to a spring core for mattresses and seat cushions with leaf springs. The spring core consists of a plurality of spring elements bent up out of passages punched in a plate, with each spring element having an upper and a lower spring clip, with the upper spring clip bent up out of a passage punched in the lower spring clip. The spring elements can also be coated with extruded foam.

Abstract: High and low profile mattress foundation frames have perimeter and transverse members, and upper members to which spring modules are attached to support a grid over the frame, to form a flexible support surface for a mattress. In a high profile version of the frame, transverse members are oriented with a major width perpendicular to a major width of the perimeter members, to provide structural rigidity and increased height to the frame. Low profile spring modules, such as the described composite material spring modules, supported by the high profile frame form a foundation which is comparable in overall height to conventional mattress foundations which use wire-form spring modules. In a low profile version of the frame, the major widths of the perimeter and transverse members are arranged parallel, and longitudinal members are supported by the transverse members.

Abstract: A bedding product comprising a collapsible spring assembly, a pad covering the spring assembly and a fabric covering encasing the padded spring assembly. The spring assembly comprises a plurality of collapsible spring modules connected to a plurality of spaced parallel helical lacing wires and locking means to hold the assembly in an expanded condition and prevent its collapse. Each of the spring modules comprises four individual wires joined together with helical lacing wire wrapped around a center section of each of the wires. Upon the collapse of the assembly, each of the spring modules collapses. The assembly is held in an expanded condition by a plurality of locking rods, pieces of plastic mesh or other locking means.

Abstract: A nestable box spring foundation includes support modules each formed of a single length of wire defining a top base, a bottom base, and four straight legs. The top base is welded to a wire grid assembly and includes two upper wire segments each having a straight wire portion and respective first and second curved end portions, each upper wire segment lying in a first plane with the straight wire portions lying in angularly converging mirror image relation to each other, each upper wire segment being spaced from one another with first end portions thereof lying closer together than second end portions thereof. The bottom base includes two straight lower wire segments lying in parallel relation to and in a second plane with one another and a straight cross wire segment fixedly intersecting orthogonally the lower wire segments proximate first ends thereof, with the first plane being parallel with the second plane.

Abstract: Improved spring elements have a unique energy absorbing element that responds to applied loads to produce counter-acting forces that act to absorb the energy of the applied loading. The greater the magnitude of the applied loads, the more the counter-acting forces equilibrate, which enables the spring elements of the invention to accommodate a range of loading force magnitudes. The improved spring elements of the invention may be integrally formed of plastic, and are suitable for use in a variety of different articles of manufacture. Exemplary single- and double-configuration mattress spring, box spring and edge stiffener embodiments are disclosed.

Abstract: A detachably-mountable washing device is disclosed. The washing device generally comprises a cloth support section and a mounting section attached to the cloth support section. The support section is preferably a foam pad having an attachment surface and a curved, cloth support surface. The mounting section includes a mounting surface and an attachment surface. The mounting surface comprises a plurality of suction cups and gripper ribs for retaining a wash cloth. The attachment surface is connected to the attachment surface of the pad, preferably by a hot-melt adhesive, to assemble the washing device. The assembled washing device is secured to a wall or other surface by the suction cups. A wash cloth is then placed on the support surface of the support pad and secured by pressing its edges between the gripper ribs and the surface to which the washing device is mounted.

Abstract: A cushioning support for a mattress comprises a plurality of elements forming a grid structure. Compression springs are mounted on respective ones of the elements. Bearing plates are disposed atop respective ones of the springs, and are disposed closely adjacent one another to form together a support surface for the mattress. The baseplates are removably interconnected so that the size and shape of the cushioning support can be varied to conform to the size and shape of a cushion to be supported. The springs can be detachably connected to the elements, or of one piece construction therewith.

Abstract: An improved box spring assembly is selectively reinforced to reduce sagging. The box spring assembly includes a bottom frame with end rails and side rails and a series of cross slats lying across the frame. The box spring assembly incorporates a combination of conventional flat cross slats and reinforcing cross slats, each supporting a number of spring modules of complementary height, giving the box spring uniform height throughout. The spring modules are attached to a grid top, and the grid top and spring modules are enclosed by a fabric cover. By using reinforced cross slats in locations where extra strength is needed and conventional cross slats elsewhere, the improved box spring assembly reduces sagging that could otherwise occur, without incurring the extra cost and weight of using reinforcing cross slats throughout.

Abstract: A bedding product comprising a collapsible spring assembly, a pad covering the spring assembly and a fabric covering encasing the padded spring assembly. The spring assembly comprises a plurality of collapsible spring modules connected to a plurality of spaced parallel connecting rods and locking means to hold the assembly in an expanded condition and prevent its collapse. The parallel connecting rods are located between border rods in the top and bottom planes of the assembly. Each of the spring modules comprises four individual wires joined together with helical lacing wire wrapped around a center section of each of the wires. The center sections of the wires define an axis about which each of the wires are capable of rotational movement. Upon the collapse of the assembly, each of the spring modules collapses rotating around the axis of the module. The assembly is held in an expanded condition by a plurality of locking rods, pieces of plastic mesh or other locking means.

Abstract: A spring assembly comprising a frame, a plurality of rails secured to the frame and a plurality of spaced springs secured to the rails. Each of the rails has a generally U-shaped cross-section and comprises a bottom and two sidewalls. Each sidewall has an inwardly projecting detent creating a receptacle underneath the detent adapted to receive and hold a spring. Each of the springs has a substantially planar lower portion which is generally S-shaped and adapted to be positioned in the receptacles of the sidewalls of the rail and rotated into a snap-fit locked position. In this locked position, the detents of the sidewalls hold the lower portion of the spring against the bottom of the rail and prevent lateral or vertical movement of the spring.

Abstract: A spring assembly comprising a frame, a plurality of metal rails secured to the frame and a plurality of spaced spring modules secured to the rails. Each of the rails comprises a top portion and two sidewalls extending downwardly from the top portion and terminating in outwardly extending flanges. The sidewalls define a throat proximate the flanges. The spring module has at least one mounting foot comprising two opposed leg portions joined together by a connecting portion, each of the leg portions having a notch therein for engagement with a slot in the planar upper portion of the rail. The connection portion of the mounting foot is engagable with the throat defined by the sidewalls of the rail so as to inhibit lateral movement of the mounting foot within the rail.

Abstract: A low profile composite material bedding foundation system and methods of manufacture and assembly uses spring modules made of molded composite materials and supported by inner frame members. The low-profile of the spring modules, and the composite material spring property of return to uncompressed state from total depth deflection without set, greatly decreases the height of the bedding foundation in which the spring modules are attached directly to foundation frame members. The small size and simple geometry of the spring modules is especially suited for flexible arrangement and automated assembly of low-profile foundations.

Abstract: A nestably stackable pre-assembly for a box spring foundation having a top support surface formed by a substantially rectangular border wire, lateral surface support wires and longitudinal surface support wires. The top support surface is supported by a series of longitudinal formed wire structural support members having V-shaped sections extending down from the top support surface. The structural support members are attached to the surface support wires by clips. The V-sections of adjacent structural support members are angled towards each other in pairs such that they form a series of four-sided open-apex pyramids. The pre-assemblies can be stored and shipped by attaching a first pre-assembly to a bottom wooden frame, and stacking additional pre-assemblies on top of the first.

Abstract: An elastic framework for a mattress, chair, upholstery, etc. is disclosed which includes elastic springs made of opposing upper and lower elastic elements, each elastic element having a base portion and a plurality of flexible arms which extend from the base portion and are joined to the flexible arms of the opposing upper or lower element so as to form a closed flexible ring. These flexible rings are joined to top support elements and bottom support elements at the base portion of the upper and lower elastic elements, respectively, and the top support elements as well as the bottom supported elements are respectively interconnected so as to form a spring support.

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 cushioning assembly comprises a foundation, a plurality of springs mounted on the foundation, and a pad resting on the springs. Each spring is formed of plastic and forms a through-chamber having an axis. The axes of the springs lie in a common plane oriented perpendicular to the loading applied thereto when a user rests on the assembly. Pad-supporting plates are removably attached to the spring bodies, e.g., by clamp members.

Abstract: A foundation spring module especially adapted for easy assembly in an interlocking spring and grid bedding foundation structure has a short generally vertical section which extends down from an interlockable wire grid-engaging horizontal top portion to position an upper end of each of two contiguous legs of the spring away from the area of intersection of the top portion and legs of the spring with the wire grid to greatly ease manipulation and assembly of the spring into the interlocked position in the wire grid of the foundation structure.

Abstract: A support device having a plurality of support units, each comprising a plurality of flexible, substantially vertical support columns, with the bottoms of the support columns attached at equidistant intervals to a base member and the tops of the support columns attached at equidistant intervals to a substantially perpendicular support platform. The support columns provide directional flexibility to the columns, upon compression, to provide a substantially uniform counter-force through a range of flexion of the support columns and corresponding downward deflection of said support device. Such uniform counter-force during compression simulates a fluid-like support system. The support columns may be comprised of a solid, synthetic foam such as high density polyurethane or springs made of metal or other material. The support units preferably are arranged in a matrix to provide collective support.

Abstract: An improved steel span for use in mattress foundations has increased strength and rigidity characteristics achieved by a longitudinal ridge formed in a center section of the span between vertical legs of the span. The central location of the ridge in the cross-section of the span centers and thereby improves precise formation of symmetrical halves of the span which in turn insures accurate alignment of opposing spring-receiving slots formed in the vertical legs. Widened horizontally disposed base sections at the bottom of the vertical legs further increase rigidity and provide a greater surface area for attachment of the spans to a foundation frame.

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: A box spring assembly having a support deck, a frame and support springs. The deck includes a border wire, long wires extending longitudinally and cross wires extending transversely. Support springs are mounted between the frame and the deck to yieldably support the deck above the frame. The support springs each include a pair of yieldable portions extending between the frame and deck and a deck attaching portion extending between upper ends of said yieldable portions. The deck attaching portion has end bars longitudinally extending from each of the yieldable portions and a cross bar transversely extending between the end bars. The deck attaching portion is configured to engage a cross wire of the deck in an interwoven fashion in response to axial movement of the entire support spring relative to the deck thereby clamping the spring module to the deck.

Abstract: The invention relates to a generic mattress system which is easily adjustable to differing and space varying stresses with limiting spring paths. It has a top mattress and a bottom mattress with supporting elements connected to a frame and located in the plane of a frame. The elements are in U-shape and bear elastic support elements fastened to crosspieces. The upper mattress can also have spring elements between the upper and lower support, with each spring element having a section of elastic material.

Abstract: Disclosed is an improved innerspring unit for a mattress using a plurality of formed wire elements for support. Enhanced lateral and longitudinal stability of the improved innerspring is provided by one or more stabilizing features including dual formed wire elements, complimentary recesses to secure the intersection of longitudinal and lateral wires and formed wire elements disposed on the edges of the unit which are formed of the same wires which extend longitudinally and laterally across the unit. A variety of different formed wire elements is disclosed, each of which provide different support characteristics. By varying the type, number and location of the different formed wire elements, a particular support profile may be provided which may correspond, for example, to the weight contour of a prone human body.

Abstract: Wire spring assemblies for use in furniture items such as mattresses and seat cushions are made of two half units. The half units include spring elements extending from a generally planar deck with the spring elements containing complementary connecting structures at their distal ends which enable the half units to be assembled together by inverting one half unit relative to the other, aligning the two half units and snap-fitting the connecting structures of the spring elements together to form a double sided mattress or seat core. The assemblies are then upholstered in a normal fashion.

Abstract: A bent wire spring unit having a spaced pair of foot portions and a spring member extending upwardly from each foot portion. Each spring member is formed of a series of torsion bars and connector bars interconnected by bends in the spring wire. The spring members are connected at their upper ends by a locking member or portion having first and second pairs of bends in the spring wire and two locking bars extending from the second pair of bends. The locking bars are linear segments of wire angled downwardly such that they converge into a connecting bend. The locking bars and the connecting bend lie in a single plane and the distal ends of the locking bars and the connecting bend extend significantly below an uppermost torsion member of each spring member. A spring assembly is disclosed which includes the bent wire spring unit attached to a wire grid at its upper end and a base frame at its lower end.

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: A box spring assembly which having a frame, a plurality of upwardly extending wire springs mounted on the frame and a wire deck supported by the springs so that the deck and springs cooperate to yieldably resists downwardly directed bedding loads. Each of the springs has a body comprised of a pair of side-by-side yieldable portions connected at their upper ends by a mounting bar. The yieldable portions include an upper column section and a lower column section connected by a middle section. The middle section is configured to bend in a substantially vertical plane in response to the downwardly directed load. Mounting feet extend from the lower ends of the yieldable portions and enable securement of the spring to the frame. The use of bending stresses in the springs to resist the bedding load produces a spring which stimulates a non-spring system in effective firmness while improving deformation resistance under normal abuse conditions.

Abstract: A foundation assembly is disclosed in which a wire grid is supported above a support frame by a plurality of wire form members extending parallel to one another and arranged in pairs. The wire form members have leg portions extending therefrom and are rotatably mounted to the wire grid to enable a wire subassembly to be shipped with the wire form members rotated to folded positions in which the leg portions lie against the wire grid. After shipping, the wire form members are rotated to extend the leg portions away from the wire grid at an angle less than ninety degrees where the paired wire support members cooperate together forming a rigid structure to prevent collapse of the foundation assembly.

Abstract: A spring and grid sub-assembly for use in furniture and box spring assemblies in which spring modules are attached to the wire grid through an attachment system in which the springs are in both an over-under relationship and a side-to-side interwoven relationship with the cross wires through plastic deformation of the cross wires whereby the springs can not be removed from the wire grid without plastic deformation of either the grid or spring modules. The resultant sub-assembly can be easily transported from a sub-assembler to a final assembler without risk of the springs being displaced or removed from the wire grid. Furthermore, spring clips are not needed for attaching the spring modules to the grid.

Abstract: A bedding spring is formed of a single piece of sinuous wire with a plurality of bars connected together by bends. A top portion of the spring includes two inboard bars and two outboard bars which connect the spring to a wire grid. The outboard bars lie below a grid wire, the inboard bars lie above the grid wire, and the inboard bars have localized bends which form downwardly facing notches for receiving the grid wire. The spring has a bottom portion formed of two spaced apart feet which are connectable to a horizontal platform, and a midportion formed of two downwardly diverging sinuous wire sections which connect the top portion to the feet. A bedding unit is made from a horizontal platform, a wire grid, and plurality of such springs which have their bottom portions connected to the platform and their top portions connected to the grid.

Abstract: A bedding foundation unit having a top planar portion defined by two pluralities of spaced parallel grid wires, and a rigid frame spaced apart from the top planar portion by a plurality of modular springs. Each modular spring is formed from one piece of wire and has a top section, two vertical legs and two foot sections, with each of the vertical legs having at least one arcuate portion. The top section of most, if not all, of the modular springs extend longitudinally of the foundation and are connected to the top planar portion in a snap-fit manner, each top section of each modular spring being held in place by three grid wires and one grid wire below the top section.

Abstract: A spring assembly for bedding and furniture which includes a rectangular support frame and a grid unit disposed above and in general vertical alignment with the frame, the grid unit including a border wire and cross wires arranged in a criss-cross pattern on said border wire. A plurality of upright formed wire springs modules are arranged in a predetermined pattern on the grid unit and supported on said frame. Some of the modules constitute main springs which are attached in a clipless manner at the upper ends thereof to the grid unit so as to be connected to the grid unit in a manner such that loads on the grid unit are yieldably resisted by the main springs. Others of the spring modules are corner springs located at the corners of the frame. The corner springs are similar to the main springs but are secured by conventional clips to the corners of the border wire in the grid unit.

Abstract: An improved spring is provided which may be used in cushions, mattresses, or box springs which includes a limiting internal member. This limiting member assist in limiting the longitudinal deflection of the springs. Also provided are snapped-fitting connections between the spring and a grid for use within a box spring. Also provided is a "floating" portion of a peripheral border wire, particularly suitable for use in a pair of box springs beneath a king-size mattress unit. Also provided is a corner guard which provided support for upholstered fabric on a box spring. Finally, an improved borderwireless mattress using a peripheral band is provided, which allows the mattress to bend more easily, without disadvantageous setting of its border wires.

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: A bedding foundation unit having a top planar portion defined by two pluralities of spaced parallel grid wires, and a rigid frame spaced apart from the top planar portion by a plurality of modular springs. Most, if not all, of the modular springs extend longitudinally of the foundation and are connected to the top planar portion in a snap-fit manner, each snap-fit end of each modular spring being held in place by three grid wires above and one grid wire below the snap-fit end.

Abstract: A bedding foundation unit having a top planar portion defined by two pluralities of spaced parallel grid wires, and a rigid frame spaced apart from the top planar portion by a plurality of modular springs. The modular springs are connected to the top planar portion in a snap-fit manner, each snap-fit end of each modular spring being held in place by three grid wires above and one grid wire below the snap-fit end.

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 spring element for a foundation unit and a foundation unit employing the spring element. The foundation unit is of the type having a top wire grid structure and a wooden bottom structure, with a plurality of the spring elements being disposed in space relationship between the grid structure and the bottom substructure. The spring elements include spaced support legs extending from a top portion, with the legs converging toward one another. Each leg has a series of spaced support segments, with the support segments lying generally in a single plane and extending oppositely from one another in a zig-zag fashion between the top portion and an attachment segment. Torsion segments are located between adjacent support segments, with the torsion segments extending generally perpendicular to the plane of the support legs. Suitable links are used to interconnect each torsion segment with its adjacent support segments of each support leg.

Abstract: A box spring for supporting a bedding matress. 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 leat some of the curved end sections having single revolution coil springs extending vertically downwrad therefrom. The modular spring elements are arranged in parallel rows with adjacent spring elements of each row having alternatingly aligned straight center sections and adjacent modular elements within each row having a space between the curved end sections of the elements. The curved end sections of the modular spring elements are snap-fitted into upwardly open offset hooks in transverse wires of the wire grid.

Abstract: A spring interior comprising a plurality of longitudinally extending bands of springs disposed side by side and connected together by 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 substantially vertical coils of springs interconnected by interconnecting segments of wire located alternately in the top and bottom faces of the bands. Each interconnecting segment comprises a longitudinally extending bridging portion, a pair of transversely extending end portions, and a transversely extending support structure. The corners defined by the intersections between the bridging portions and the end portions of the interconnecting segments are radiused by radii of differing dimension so as to colinearly align the bridging portions of each band of springs.

Abstract: A limited deflection spring for use in a box spring assembly has a unitary wire body having a foot portion, an upright yieldable portion on the foot portion and a loading bearing portion at the upper end of the upright portion. The upright yieldable portion includes a pair of horizontally spaced upright columns which diverge relative to each other. Each of the upright columns is suspended between the load bearing portion and the foot portion by separate upper and lower torsion bar systems. Each of the torsion bar system includes a pair of generally horizontal torsion bars connected together by a central connecting bar. Suspension of the upright columns between separate torsion bar systems enhances lateral stability and impact load withstand capability of the spring elements. Spring elements having upwardly diverging upright columns may be mixed with elements having downwardly diverging upright columns in a box spring assembly so as to produce an optimum desired loading response in the assembly.

Abstract: A box spring assembly comprises a horizontal rectangular frame, a generally horizontal mattress support deck disposed a predetermined distance above the frame, and a plurality of deck support springs arranged between the deck and the frame to yieldably support the deck. The deck includes a plurality of long and cross deck wires each having notches. The long and cross deck wires are oriented in a criss-cross fashion engaging each other at the notches, and a plurality of deck support springs having notched deck attaching portions engaged with the notched intersections of the wire members. At least one of the deck attaching portions includes a pair of end straight wire sections arranged in a side-by-side relation with a spaced pair of the deck wire members and arranged in a supporting relation with spaced portion of another one of the deck wire members that intersects the spaced pair interlocking the deck wire members and the straight wire section together.

Abstract: A spring for a box assembly that is constructed to limit deflection of the spring to a position in which the spring is not overstressed. The limited deflection spring includes a wire body which has a load bearing portion, an upright yieldable portion, and a foot portion. The upright yieldable portion includes a pair of downwardly extending converging connecting bars integral at their upper ends with torsion bars at opposite ends of the load bearing portion. A pair of lower torsion bars are connected to the lower ends of the connecting bars and are spaced inward from a pair of downwardly extending converging wire columns which are connected at their upper ends to the lower torsion bars. As a downward load is applied to the load bearing portion, the wire columns move toward vertical positions in which they limit further deflection of the spring.

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 generally Z-shaped and 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.