Abstract: A tubular border frame for inner spring assemblies is disclosed. The border frame includes an opening defined by a pair of inwardly directed lips adapted to receive and secure the coil springs. Straight and corner connectors are provided for joining the sections of the frame to form a complete border surrounding the springs.

Abstract: An internal support structure for a mattress which has a plurality of springs oriented in matrix fashion into a plurality of rows and columns, at least one outer border wire extending around the periphery of the matrix and secured to the springs located at the border or terminal rows and columns of the matrix, layers of padding or cushioning material and a fabric cover. The internal support unit comprises an inner border wire structure which is connected to the outer border wire of the mattress and to at least some of said springs. The inner border wire includes four separate wire band sections which overlap one another in a grid pattern and form a closed inner border loop. The ends of each band section are connected to the outer border wire. The inner border wire and outer border wire are concentric and located in the same horizontal plane.

Abstract: A spring foundation unit having one or more pairs of inner border members on the top and bottom surfaces of the unit. In a conventional fashion, the spring unit has a plurality of transverse rows and longitudinal columns of coil springs, and top and bottom perimeter border wires extending along the outer periphery of the unit and attached to outer coil springs of the transverse rows and longitudinal columns. The inner border members have side elements extending parallel to opposed sides of the unit, with one or more spring widths separating the side elements from the perimeter of the unit. Each side element has a free end which is attached to an end section of the perimeter border wire, and a cross-connecting element interconnecting the opposite ends of the opposed side elements of each inner border member. In one embodiment of the invention, the cross-connecting elements of each pair of inner border members are straight and have at least one spring width separating them.

Abstract: A mattress box spring comprising a plurality of substantially conical coil springs rigidly fastened at the spring ends of lesser diameter to a support frame such that the spring end coils of greater diameter lie in a substantially common plane, a wire mesh overlying the end coils in the common plane with the spring end coils being unattached or free-floating with respect to the mesh and with respect to each other, and a cloth cover or pad disposed over the mesh and having a periphery attached to the frame to hold the assembly together. Preferably, the diameter of each spring end coil lying in the common plane is greater than the corresponding spring height.

Abstract: A preformed grid of perpendicularly intersecting wires equally or unequally spaced apart and welded together or part of such grid such as a pair of parallel wires and a binding cross wire, are tightly joined together as well as to the top turn or ring of a coil spring by an inverted U-shaped wire clip detached and fed preferably automatically from a cemented group of such clips much like conventional staples. An upper grid wire is arranged to span the ring diametrically while a pair of lower wires parallel to each other are arranged as respective opposed chords of the ring each spaced inwardly at its weld from the adjacent perimeter of the ring just enough to permit the insertion of a clip leg or legs at an inward and downward slant into the space between the perimeter of the ring and the chord portion of the other wire while straddling the spanning wire.

Abstract: An improved single cone coil spring and an improved box spring assembly made from the improved single cone coil springs. The box spring assembly comprises a base frame, a series of the improved small diameter single cone coil springs and a welded wire grid, the coil springs being connected at their bottom ends to the base frame and connected at their top ends to the welded wire grid. The coil springs are established in a plurality of rows and columns throughout the box spring assembly, at least one transverse wire and at least one longitudinal wire of the wire grid span all coil springs within each row and column, respectively. Further, a supplemental transverse wire is positioned between adjacent coil spring rows, and is of a length equal to at least one of the coil springs' transverse wires adjacent thereto. All crossover points of all the grid's transverse and longitudinal wires are welded to establish the welded wire grid.

Abstract: A foam foundation unit for bedding in which a foam layer is supported on a wire grid that is fixed to the top side of the wooden base frame.

Abstract: An improved mattress innerspring unit is provided which includes a plurality of rows of coil springs and a plurality of cross helicals which extend transversely of the rows of coil springs, lacing together adjacent terminal convolutions of the coil springs, wherein a welding means is provided to eliminate the tendency of the cross helicals to spin-out of the unit. Also provided is a method of constructing an innerspring unit which includes welding an end revolution of a cross helical to another component of the unit or to an adjacent cross helical revolution.

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 coil spring assembly stable against torque twist deterioration, assembled of rows of coils of alternate right and left-hand, the coils having wound ends, the end turns of each coil having linear portions normal to the row and interconnected with linear portions of adjacent coils by cross helicals extending across the assembly normal to the rows.

Abstract: An improved mattress innerspring unit is provided including cross helicals which extend transversely of the rows of coil springs and lace together adjacent terminal convolutions of the springs in a row and a retention and support strip which overlies the terminal convolutions of the springs in a row of the unit, the retention and support strip and the helicals being crimped together and otherwise secured about the interlaced portions of the coil springs. The cross helicals are prevented from spinning out of the unit and the unit is firmed, particularly in the area close to the retention and support strip. Preferably, retention and support strips are provided along both the top and bottom terminal convolutions of the coil springs of at least one row near each of the two longitudinal edges of the innerspring unit.

Abstract: A rigid spring unit is constructed of coil springs and a top grid comprising a plurality of wires, including a first group or pair of parallel wires spaced apart a distance less than the diameter of the top coil of each spring. A second group of three wires, at right angles to the first pair, includes a pair of outside wires spaced apart a distance less than the diameter of the top coil of the spring and a locking wire intermediate the outside wires. The top coil of each spring includes indentations that permit the top coil to be seated from below, in a pre-stressed, woven fashion into the wires of the top grid.

Abstract: A box spring grid which includes coil spring engaging ears and a plurality of support wires secured to the grid and each including an ear. The ends of each support wire may be reversely bent around one end coil of a coil spring. Also disclosed is a method of manufacturing a box spring support grid wherein ears are formed in all longitudinal wires, between each pair of transverse wires, and, subsequently, selected portions of certain longitudinal wires are removed.

Abstract: An improved spring assembly in which the springs are connected together by a novel thermoplastic connector strip structure. The connector strip structure is used to interconnect the spring rows one with another, and also functions as a border strip, to establish a connector grid for the springs in each of the top and bottom planes of the spring assembly.

Abstract: A mattress or cushion spring assembly includes aligned rows of coil springs connected together within each row and between rows and additional reinforcing springs which are interspersed around the periphery of the spring assembly and are held in place by border helicals or other means.

Abstract: A spring assembly comprising, spaced pairs of crossing wires welded at their intersections such as to form a dimensionally stable structure wherein the pairs of crossing wires define seats for attachment thereto of the end loops of coiled springs, characterized in that at least two of the wires of the seats are spaced apart a distance less than the distance of the diameter of the end loops and contain deviations perpendicular to the plane of the structure providing longitudinal downwardly facing openings and an upwardly facing opening between the downwardly facing openings and wherein the end loops have arcuate portions which pass through the downwardly facing openings from the inner side outwardly and deviating portions which pass through the upwardly facing openings from the outer side inwardly and wherein the distance between the deviating portions and the end loops is less than the distance between the wires.

Abstract: A rectangular box spring assembly of the disclosure includes a grid of crossing wires whose lateral edges have an improved construction in combination with formed wire springs that support the edges of the grid on lateral side members of a lower frame. Each lateral edge of the grid includes a pair of inboard and outboard longitudinally extending wires that are of a heavier gauge than the other wires of the grid. Each formed wire spring on the side frame members includes a pair of fishmouth sections extending upwardly from the frame and a connecting section that interconnects the fishmouth sections and supports the adjacent grid edge. The connecting section of each spring includes an inboard main portion and outboard end portions connected to the main portion. The outboard heavier gauge wire at each lateral grid edge is secured to the outboard end portions of the spring connecting sections to locate the grid.

Abstract: A generally rectangular box spring assembly of the disclosure includes a wire grid supported on a lower frame by center coil springs and by formed wire springs at the edge of the assembly. The formed wire springs provide relatively firm edge support while the coil springs provide softer center support. Each of the formed wire springs includes at least one fishmouth section extending upwardly from an associated frame member for connection to the grid. The formed wire springs preferably include a pair of the fishmouth sections which are interconnected by a connecting portion. The grid may be secured to the connecting portion of the formed wire springs or to a border wire that is itself secured to the fishmouth sections of these springs. The center coil springs are preferably of a conical shape with their smaller ends secured to laterally extending frame slats and with their larger ends clipped to the wire grid.

Abstract: A box spring grid which includes coil spring engaging ears and a plurality of support wires secured to the grid and each including an ear. The ends of each support wire may be reversely bent around one end coil of a coil spring. Also disclosed is a method of manufacturing a box spring support grid wherein ears are formed in all longitudinal wires, between each pair of transverse wires, and, subsequently, selected portions of certain longitudinal wires are removed.

Abstract: A box spring assembly having a generally rectangular frame consisting of side and end rails and a plurality of spaced cross rails extending between the side rails, a border wire conforming generally to the shape and boundaries defined by the side and end rails, a plurality of longitudinal and transverse main springs parallel to the side and end rails and perpendicular to each other, and a plurality of internal support springs extending diagonally between pairs of main springs, all of the springs being of the formed wire type. Each main spring is attached to the border wire by a clip, and either the border wire or the spring or both are coated with a plastic material to preclude slippage of the clip. Furthermore, each internal support spring is attached to a pair of main springs by a clip, and either the support spring or the main spring or both are coated with plastic. All the wires may be coated with a different color plastic to facilitate assembly of the product.

Abstract: A coil spring supporting grid structure of the type used to reinforce the top surface of a box spring foundation unit is provided with formations on the longitudinal and transverse wires thereof, enabling a snap-in interconnection with a plurality of coil springs to form a spring unit assembly. Each coil spring convolute engaged by the grid structure is supported on a pair of upwardly extending formations from a pair of spaced parallel first wires and is locked in place by means of two downwardly depending formations from a pair of spaced parallel second wires which extend transversely with respect to the first wires to form the grid.