Abstract: Spring sets each include a pair of coil springs joined together by a connecting wire and are encased in individual fabric pockets such that the connecting wire joining the coil springs spans an otherwise empty fabric pocket. A spring unit, mattress or the like includes a number of such pocketed spring sets with the connecting wire being alternately positioned near a top face or a bottom face of the spring unit. The pocketed coil spring unit can be used to form a mattress or other spring assembly of pocketed coil springs wherein every third pocket is left empty. The connecting wire spreads the load across the empty pocket and distributes the load to the adjacent springs. The absence of one-third of the springs that are normally in a mattress drastically reduces material costs without diminishing performance.

Abstract: A wire spring module and wire grid for use in a furniture spring assembly for mounting an array of multiple spring modules to the wire grid and the resulting furniture spring assembly. The wire grid includes a plurality of straight, coplanar wires arranged in a first sub-plurality of parallel spring placement wires and a second sub-plurality of parallel spring seating wires extending in generally perpendicular relation to the spring placement wires, the spring seating wires being arranged in a plurality of seating wire pairs with the spring seating wires of each seating wire pair disposed at a first predetermined spacing from one another and with each seating wire pair disposed at a second greater predetermined spacing from each seating wire pair adjacent thereto. The unitarily-formed wire spring module comprises a generally coplanar top and a pair of legs extending from opposite ends of the top and in spaced relation to one another.

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: 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: 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 transversely extending bands of springs disposed side by side and connected together by longitudinally extending 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 coil springs interconnected by interconnecting segments of wire located alternately in the top and bottom faces of the bands. The spring interior is characterized by sections of differing firmness or height throughout the length of the spring interior, which differing firmness or height sections are created by either having the wire from which the bands of coil springs differ in physical characteristics or by having the coil springs of the differing bands differ in height when in the relaxed state.

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 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 coil springs interconnected by interconnecting segments of wire located alternately in the top and bottom faces of the bands. The coil springs of each row are interlaced with the adjacent coils of the same row. The spring interior is characterized by sections of differing firmness throughout the length of the spring interior. The sections of greatest firmness have such increased firmness imparted by a plurality of posture rods which extend through interlaced portions of a plurality of pairs of interlaced coils of the spring interior.

Abstract: A box spring assembly includes a base frame, a top wire grid and a plurality of sinuous wire spring strips interconnecting the top wire grid and the base frame. The sinuous wire spring strips each comprises six substantially vertical legs and three spaced, substantially flat, horizontal platform sections with the flat platform sections of each spring being attached to the top wire grid and the bottom ends of each leg being attached to the base frame.

Abstract: A bedding or seating spring product comprising a spring assembly having multiple rows of coil springs wherein each row of coil springs is made from a single continuous length of wire and wherein each row contains a plurality of coils interconnected by interconnecting segments, alternate ones of which are disposed in the top and bottom planes of the spring assembly. The interconnecting segments are generally planar and include U-shaped portions having parallel legs and a connecting web. Adjacent rows of coils are connected by securement of the web of a U-shaped portion of each interconnecting segment of one row of coils to a pair of spaced portions of interconnecting segments of an adjacent row.

Abstract: A box spring assembly in which the mattress support deck is formed by a plurality of components all of which are formed from spring wire to thereby achieve a support deck of increased strength and improved durability. In addition, the components are structurally interrelated and clipped together so as to restrain relative movement of the components to thereby achieve a box spring assembly of improved stability.

Abstract: A box spring comprises a rectangular base frame, a wire grid, and a plurality of parallel rows of coil springs supporting the grid atop the base frame. Each row of coil springs is made from a single continuous length of wire in which adjacent coils are interconnected by an interconnecting segment of the wire. Each interconnecting segment is in the form of a generally diagonally extending bar having substantially parallel end portions interconnected at the center by an offset section, which offset section is formed by rotating the offset section relative to the parallel end portions while the end portions are restrained against rotation.

Abstract: A bedding mattress, including a spring assembly having top and bottom parallel surfaces, padding over the top and bottom surfaces, and an upholstered covering completely encasing said spring assembly and padding. The spring assembly comprises multiple parallel rows of coil springs, each row of which is formed from a single continuous length of wire with each row containing a plurality of coils interconnected by connector segments. The rows of coils are interconnected by helical springs extending parallel to the rows and alternately wound around endmost turns of coils in a pair of adjacent rows of coils. The connector segment which interconnects the coils of each row comprises a generally diagonally extending connector bar having parallel end portions connected at the center by an offset section, which offset section is formed by rotation of the offset section relative to the end portions of the connector bar while the end portions of the connector bar are restrained against rotation.

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 assembly having modular spring elements distributed in an array beneath rectangular pockets of a wire grid top. The elements include a single piece of wire formed into a head configured to support and be contained within selected pockets of the wire grid top, a base formed of the two ends of the wire to attach to a lower base frame, and a pair of compressible arms formed into a pattern of bars and bends which give firm elastic support with economy of wire.

Abstract: A bedding unit spring has an upper portion attached to a grid, a lower portion attached to a frame, and a vertically collapsible midportion which connects the upper portion to the lower portion. The upper portion of a spring may have two transverse bars at its ends, a third transverse bar at its center, and a center bar formed of two sections which are on opposite sides of the third transverse bar. The center bar sections are directed toward the midportions of the end transverse bars. A deflection limiter member is attached to the spring to limit the collapsing movement of the spring and to increase the effective stiffness of the spring. It is formed of a wire which has an abutment portion and two connector bar portions. The connector bar portions extend at different inclination angles from the abutment portion to the spring.

Abstract: A coil spring unit having a series of coil springs connected together in column and row matrix configuration, the end loops of the coil springs being open loops that terminate in free ends, i.e., the end loops of the coil springs not being closed and knotted. The coil spring assembly method comprises forming a series of coil spring rows, each row being formed from a single continuous length of spring wire. Each intermediate spring within a row has an adjacent coil spring on one side directly connected at one end of that intermediate spring, and an adjacent coil spring on the other side directly connected at the other end of that coil spring, through use of connector sections that are part of the single continuous length of spring wire used to form that row. The pre-formed rows thereafter are connected in matrix form. After the rows have been connected in matrix configuration, the connector sections are selectively cut between adjacent springs on both sides of each intermediate spring.

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.