Abstract: A box spring (9) having a rigid perimeter wall (16) to provide a firm foundation to support an edge of a mattress (1) where individuals normally sit. A layer of coil springs (20) rests on a center portion (2) of the box spring and extends above the rigid perimeter wall to provide active support to a center portion of the mattress where individuals normally lie.

Abstract: By providing a unique product enhancing step which enables any desired section, portion, or element of a product being produced to be treated in a manner to provide desired enhanced physical, structural, and/or aesthetics characteristics, a new, fully integrated enhanced foam manufacturing system is attained which is capable of producing virtually any desired foam product, with each product incorporating any desired area or zone being formed with a particular physical, structural, and/or aesthetic property, characteristic, or enhancement. In addition, in accordance with the teaching of the present invention, any desired cross-sectional shape or configuration is capable of being manufactured in fully automated, high volume, rapid production conditions, with virtual ease and simplicity, with a specific physical, structural, or aesthetic property incorporated therein.

Abstract: A stackable wire core assembly for a bedding foundation which may be nestably stacked with numerous other such assemblies for transportation, thereby avoiding the need to compress and tie the assembly for shipping. The wire core assembly includes corrugated formed support wires having inverted U-shaped channels formed at the bottom of the corrugated formed support wires adapted to be wrapped over and secured to slats of a wooden base frame.

Abstract: A mattress comprises a support plate having a plurality of mounting holes, a plurality of independent spring assemblies individually mounted to the support plate, and a cover enclosing the support plate and the plurality of spring assemblies. Each of the spring assemblies includes a tubular mounting member fixed to the support plate preferably by snap-fit through a mounting hole in the support plate, a sliding cap axially movable relative to the mounting member, and a spring acting between the mounting member and the sliding cap, wherein the spring is axially compressible when the sliding cap is forced in an axial direction toward the support plate. A spacer of chosen length can be provided to set preload on the spring. In a “flippable” embodiment, the mounting member includes a mid-portion snap-fitted to the support plate and upper and lower portions each having a sliding cap associated therewith, wherein the spring acts between the two sliding caps.

Abstract: A support system has an array of telescoping columns that are each extended by a means such as a spring. The ends of the extended columns define a plane of support for a body resting on the array of columns. The columns move perpendicular to the plane of support, and independently, in response to the weight of a body resting upon them. The means for keeping the columns extended may be passive or active, and the columns may be moved independently by actuators connected to them. The columns may be assembled into modules, which can in turn be assembled into support systems of arbitrary size and shape.

Abstract: A spring-support lath for supporting upholstery of furniture includes a lath body defining a longitudinal direction and having a pair of longitudinally extending U-profiles. Each U-profile is of U-shaped cross-section open in a downward direction and spaced apart in a lateral direction. The U-profiles are interconnected at their longitudinally spaced ends by end pieces and by fixed links situated intermediate the end pieces. The fixed links are spaced apart longitudinally, and at least some of the fixed links include a fastener structure such as a T-shaped member or an oblong hole for connecting to spring elements.

Abstract: The invention relates to a bearing element having a base plate fitted on a support, for a seat or bed system, with a bearing plate to hold upholstery. The invention seeks to produce a bearing element whose range of spring is approximately equal to the total height, and which is easy to produce. To this end, at least two spring elements serving as bearing arms (12, 22) are fitted between the base plate (11, 21) and the bearing plate (15, 25). These spring elements, configured like leaf springs, are directed outwards from the base plate (11, 21). Their outer ends join the hearing plate (15, 25). In another version of the invention, a spring body (35, 35′) is fitted between the base and bearing plate. The spring body head (35.2) and foot (35.1), like the bearing plate and base plate, have corresponding locking parts, so that the bearing plate can also be removably placed on the spring body (15, 15′) and on the base plate (21).

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 unitary base member for supporting a wire spring assembly of a bed foundation. The base member includes a lattice formed of a plurality of lateral members and a plurality of longitudinal members. The lattice has a lower surface and an upper surface for mounting a wire spring assembly thereon. The lateral members are oriented substantially parallel to each other, and the longitudinal members are oriented substantially parallel to each other. The plurality of lateral members are positioned above said plurality of longitudinal members. Significantly, the lateral and longitudinal members of the lattice are integrally and inseparably formed together with each other as a single piece of substantially rigid plastic for preventing movement of the members with respect to each other.

Abstract: A structural frame having laterally extending L-shaped braces for reinforcing resilient and non-resilient bedding foundations.

Abstract: A box spring includes a border frame with an opening therethrough and spaced and parallel slats extending thereacross, a wire grid spaced from and parallel with the border frame and slats, and a plurality of springs extending between the wire grid and the border frame/slats, wherein the internally located springs have ends which are secured to plastic clips, and each of these clips is removably secured to one of the slats via a snap-on connection. Each of the clips also has a hook for removably retaining a spring portion. The snap-on connections of these spring holding clips, and additionally, the hooks for removable spring retention, facilitate interconnection of the wire grid to the border frame/slats. The snap-on clips of this invention reduce the costs associated with construction and assembly of a box spring, while providing secure interconnection of the internal springs.

Abstract: A bedding foundation frame for use in manufacturing a bedding foundation. The foundation frame includes side rails and end rails formed into a rectangular configuration and a plurality of slats extending between the side rails and parallel to the end rails. Selected ones or all of the slats are reinforced by sheet metal strips positioned in juxtaposition to the bottom of the reinforced slats with a longitudinally extending flange in the central portion of the strip extending upwardly into a longitudinally extending slot in the center of the bottom face of the reinforced slat. These sheet metal strips, because of the presence of the flange in the sheet metal strip, function to provide additional resistance to bending of the slats under normal loads while simultaneously preventing breakage of those slats under abnormal loads.

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 foot member is disclosed for use in attaching a spring device to a rail for cushions, seats, or foundations for a bedding product. The foot member can straddle and snap into a frame rail, or be stapled or otherwise affixed to a frame rail.

Abstract: An improved, longitudinally extending, centrally disposed support member for a box spring frame of increased strength and reinforcing support is disclosed. The support member includes an elongate slat that has at least one metal reinforcing member affixed thereto. The metal reinforcing member has a plurality of longitudinally spaced openings therein, each of the openings having penetrating means projecting therefrom and penetrating into the elongate slat to affix the reinforcing members to the slat.

Abstract: Anchoring means for securing the lower end of a coil to a frame embodying spaced, parallel supports structured to be slidably engaged with upwardly and downwardly-facing shoulders on the supports for longitudinal adjustment of the lower ends of the springs on the supports.

Abstract: A mattress spring assembly is disclosed having increased firmness in a preselected center area of the mattress. This increased firmness is achieved through use of a grid structure attached to the opposite sides of the mattress. This grid structure comprises plastic straps extending diametrically across the mattress in the center third area and overlaid by a preformed wire grid. The plastic straps and wire grid are attached to the preassembled spring core by conventional connectors such as metal clips and/or hog rings.

Abstract: A coil seat spring assembly wherein spring coils are mounted on a plurality of sinuous spring bands extending between the front and back rails of a furniture seat frame. The axes of the coils are substantially vertical. The coils on each band are clamped to each other and to adjacent coils and adjacent bands at their uppermost coil turns and at their lowermost coil turns. The coils are approximately two-thirds the axial length of conventional coil springs.

Abstract: A mattress having increased firmness in a preselected area on both sides of the mattress through use of a welded wire grid structure attached to the opposite sides of the mattress. In one preferred form, the increased firmness is provided only in a preselected area, e.g., the center one-third area of the mattress, by a welded wire grid while in another preferred embodiment, the grid wires extend over the complete area of the mattress. The wire grids are preformed and assembled as a separate subassembly and are attached to the preassembled spring core by conventional connectors, as for example, conventional hog rings.

Abstract: A box spring assembly is disclosed in which a plurality of main wire springs and intermediate wire springs are mounted on a generally rectangular frame. Each wire spring has a generally straight body portion and relatively short depending end portions, each of which is formed to a generally fish-mouth configuration. The end portions are secured to the frame and provide a substantial resistance to downwardly directed loads.

Abstract: The entire assembly includes an upper supporting panel, a base, and spring body means between the panel and base. The panel comprises a rectangular border frame and a grid made up of a series of grid wires extending longitudinally and another series extending laterally to define rows of rectangular openings serving as spring seats. The spring body means comprise coil spring bodies and attachment heads made up of single lengths of wire. The heads are bent to U-shape with a rectangular pattern similar in size and shape to the spring seats, and portions are offset to resiliently grip the grid wires defining a selected spring seat above and below the grid and lock the head in place. The rectangular engagement of the spring components with the spring seats prevents rotation in their mountings.

Abstract: A bed assembly comprising a metal frame of generally rectangular configuration including a pair of opposed side rails and a pair of opposed end rails and a plurality of metal slats extending transversely between the side rails in spaced parallel relationship to one another and to the end rails. Both of the end and side rails have a hollow cross section along their respective lengths. The hollow cross section in each of the rails is defined at least by two metal members welded together. The end rails of a first embodiment and all of the rails of a second embodiment are defined by a pair of U-shaped members having their legs overlapping with the bases of the U shapes spaced from one another to define the hollow cross section. The side rails of the first embodiment are defined by channeled members having a channel extending therealong and a plate-like strip covering the channel to define the hollow cross section.

Abstract: The invention pertains to a wooden frame structure for a box spring. Two spaced, parallel, upright members form elongated side rails which are initially held together by a base slat extending between the side rails at either end thereof, the base slats being affixed to the bottom of the side rails in recesses therein. Above each base slat, an end slat is installed extending between the side rails, each end slat having a formation such as a tenon formed on either end thereof which engages a corresponding formation such as a mortise formed in each side rail. Normally, at least one center slat, depending on the ultimate frame dimension, lies on its side between the end slats with each end of the center slat lying on a portion of the top of one of the base slats. A plurality of upright cross slats extends between the side rails, and similar to the end slats, each cross slat has a tenon formed in either end thereof which interlockingly engages a corresponding mortise formed in each side rail.

Abstract: A box spring assembly having a rectangular frame mounting a plurality of lateral support slats, formed wire torsion springs affixed to said slats and a metal grid interconnecting said springs. To minimize sag resulting from body weight, the support slats adjacent the lateral center line of the frame are first reinforced with U-shaped metallic bars which rest the wooden slats. In addition, the number or density of lateral slats adjacent this center line are increased leaving a lower density of slats adjacent the head and foot ends of the assembly. This arrangement of lateral slats permits reorientation of the formed wire spring units which further results in greater lateral stability of the box spring unit. The assembly is then completed by adding one or more insullating pads for cushioning and a fabric cover.

Abstract: A spring assembly formed of multiple coil springs arranged in lengthwise and crosswise rows and a sub-assembly for use in the manufacture of such spring assemblies in which the sub-assembly is formed of elongate slats having longitudinally spaced nodules extending from the upper surfaces thereof for mounting coil springs thereon in corresponding longitudinally spaced relation with the coil springs extending upwardly from the top surface of the slats.

Abstract: A spring assembly in which use is made of a grid of crisscrossing wires which extend through a plastic button at their cross-over points to intertie the wires in a manner to prevent relative movements without metal to metal contact and in which the buttons embody grooves dimensioned to receive terminal portions of spring members for suspending the spring members therefrom in the assembled relation.

Abstract: This invention relates to a spring mat, more particularly intended for the manufacture of resilient surfaces, which comprises substantially a series of known spring elements connected with each other into a cloth or a mesh work, each of said elements consisting of a single wire of spring steel which is bent to present a series of mutually parallel spiral pairs, each pair consisting of two substantially coaxial spirals, namely a raising spiral and a descending spiral, a metal strip being additionally inserted through all the spiral pairs of each spring element.

Abstract: A novel box spring construction is disclosed wherein sway is eliminated. The construction includes wooden framing members efficiently connected together at corners and frustoconical springs extending between transverse lower frame members and upper wire retainers. The wire retainers, connected at their ends to side and end frame members, serve to locate and prevent sway of the individual springs, while sway of the entire upper box spring surface is prevented by the wooden frame members and the corner construction. The springs are retained to the transverse lower frame members by passage of the lower spring ends through the members.

Abstract: A frame for a box spring unit utilizing torsion bar springs comprises a generally rectangular wood frame member and a plurality of parallel transverse metal slats secured to the frame member, the metal slats being adapted to precisely position and firmly secure the base of the torsion bar spring to the metal slat.