Abstract: A hybrid pillow includes a first coil panel and a second coil panel which are joined along peripheral edges to form an inner shell defining a gap therebetween. The first coil panel is formed of a plurality of coil springs, an upper fabric layer, and a lower fabric layer, with the upper fabric layer and the lower fabric layer joined between the plurality of coil springs and along peripheral edges of the first coil panel. The second coil panel is formed of a second plurality of coil springs, a second upper fabric layer, and a second lower fabric layer, with the second upper fabric layer and the second lower fabric layer joined between the plurality of coil springs and along peripheral edges of the second coil panel. A support material disposed in the gap of the inner shell, and one or more additional layers disposed about the inner shell.

Abstract: A reverse coil head coil and innerspring has a generally cylindrical and helical wire form coil body and opposing coil ends which terminate on opposite sides of a reference plane that passes through the coil body. The reverse coil head coils are interconnected in a matrix to form an innerspring wherein only one terminal end of each coil is located at a perimeter of the innerspring. Variations in the number and pitch of helical turns of the coil body are also disclosed.

Abstract: A spring wire support for foundations and innerspring mattresses, and a variable spring surface deck for a foundation and variable spring surface for a mattress. The spring wire support comprises an elongated spring element enveloped in a pliant carrier, with the carrier including an attachment margin. The variable spring surface deck for a foundation comprises a plurality of the spring wire supports secured as desired to an upper surface of a foundation. The variable spring surface for a mattress comprises a plurality of the spring wire supports located between top and adjacent convolutions of rows or columns of springs of the mattress.

Abstract: A mattress core including an array of strings of pocket springs extending in parallel across the mattress core; and a fastener coupling the array of strings of pocket springs together, wherein said array of strings of pocket springs includes single strings of pocket springs and double strings of pocket springs, each double string of said double strings of pocket springs including a superior string of pocket springs and an inferior string of pocket springs.

Abstract: Disclosed herein is a bedding or seating product (10) having a spring core (12) comprising coil springs (26) having unknotted end turns (72, 74) made from high tensile strength wire. In each embodiment, the end turns (72, 74) of the coil springs (26) are generally U-shaped having one arcuate leg (76) longer than the other (78), the legs (76, 78) being joined by a connector (80) having an arcuate bump (81) therein. The springs (26) are oriented in the spring core (12) such that a long leg (76) of one end turn (72) abuts a short leg (78) of the adjacent end turn (72) prior to be wrapped in helical lacing wire (32). The high tensile wire enables the coil springs (26) to be manufactured using less wire than heretofore possible.

Abstract: A spring cushion assembly for a one-sided mattress includes a plurality of spring coils. Each spring coil has a length of spring wire formed at opposite upper and lower ends in respective upper and lower end turns and in an intervening coil extent therebetween. The spring coils are characterized in that the lower end turns of each coil is closed by a knot formed between the lower wire end and the coil extent. The spring coils are further characterized in that the upper end turn of a first selected number of the spring coils is open with the upper wire end unknotted to the coil extent and the upper end turn of a second selected number of the spring coils is closed by a knot formed between the upper wire end and the coil extent.

Abstract: Innerspring coils for innersprings for mattresses and other reflexive support structures, have generally helical coil bodies and at least one non-helical segment or step which extends between one or both axial ends of the coil body and one or both of the coil ends. The step or steps may be linear or non-linear, and parallel to or angularly disposed with respect to a longitudinal axis of the coil body. When located proximate to a coil end, the step extends out of the plane in which the coil end lies. One or more steps may alternatively be formed intermediate to helical turns of the helical coil body.

Abstract: Disclosed herein is a bedding or seating product having a spring core comprising coil springs having unknotted end turns made from high tensile strength wire. In each embodiment, the end turns of the coil springs are generally U-shaped having one leg longer than the other, the legs being joined by an arcuate connector. The springs are oriented in the spring core such that a long leg of one end turn abuts a short leg of the adjacent end turn prior to be wrapped in helical lacing wire. The high tensile wire enables the coil springs to be manufactured using less wire than heretofore possible.

Abstract: A spring mattress including a plurality of interconnected coil-spring elements, said coil-spring elements being interconnected by securing elements, preferably in the form of spirals, which, at least in one plane essentially in parallel with the plane of the mattress, extend between and are attached to pairs of neighboring spring elements, thus interconnecting these spring elements. A method of manufacturing a mattress, wherein at least some of the securing elements in the longitudinal direction are subdivided into independent segments.

Abstract: An innerspring assembly, such as for use in a mattress, comprises a plurality of coil springs defining upper and lower terminal convolutions and body portions therebetween. Adjacent coil springs are attached together at the body portions thereof with the terminal convolutions being unattached to one another, so that the terminal convolution can move independently of one another.

Abstract: A mattress spring core having a plurality of zones of differing firmnesses due to different characteristics of helical lacing connectors within the particular zones. The spring core has a plurality of identical coil springs arranged in side-by-side transversely extending rows and columns. The coil springs are connected together at the upper and lower ends of the springs with helical lacing connectors which encircle a portion of the upper and lower faces of the springs. The helical lacing connectors may be of a heavier gauge wire in one or more zones of the mattress spring core thus causing that particular zone to be of an increased firmness relative to the other zones of the mattress. Alternatively, the helical lacing connectors within a zone may comprise two or more co-axial lacing wires to impart greater strength or rigidity to one or more zones of the mattress.

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: A spring core for a mattress consisting of a plurality of side-by-side rows of identically configured helical coil springs each made of a single piece of wire having a central portion of a first radius defining a central spring axis and terminating at opposing ends with unknotted upper and lower end turns disposed in planes substantially perpendicular to the spring axis. The springs are connected with each other at their upper and lower turns by connecting lacing wires. The upper and lower turns are each substantially U-shaped, having a longer relatively straight leg and a shorter arcuate leg located at the free end of each end turn, the legs connected to each other by a base web. The radius of the shorter arcuate leg is substantially less than the first radius of the central portion of each coil spring. All the coil springs are oriented in the same direction, except along an edge region of the spring core.

Abstract: A runner wire useful with collapsible springs includes a plurality of generally parallel and generally aligned runner sections and at least one offset portion. The offset portion merges with and extends from an adjacent pair of runner sections and includes a pair of parallel, rectilinear wire segments that extend generally perpendicularly from the runner sections and a loop connecting the pair of wire segments. The loop extends away from the wire segments within a plane defined by the runner sections and the wire segments in a direction that is nonparallel relative to the wire segments.

Abstract: A spring includes upper and lower runs of wire interconnected by an intermediate run of wire, all of the runs being integrally formed from spring wire. The opposite ends of the upper and lower runs respectively include hooks and coils while the intermediate run includes a coil. The hooks and coils of the upper and lower runs are used to connect the spring to an adjacent spring with the hook of one spring being received about the coil of an adjacent spring. The upper and lower runs are offset above and below the coils of the upper and lower runs respectively to accommodate a helical wire which is wrapped around the upper run for interconnecting runner wires which extend transversely of the upper run. The runner wires have offset portions which are secured to the upper runs by the helical wire. In one form the coils in the upper and lower runs are provided with a projecting recess or ear for receiving the hooks of an adjacent spring.

Abstract: A spring includes upper and lower runs of wire interconnected by an intermediate run of wire, all of the runs being integrally formed from spring wire. The opposite ends of the upper and lower runs respectively include hooks and coils while the intermediate run includes a coil. The hooks and coils of the upper and lower runs are used to connect the spring to an adjacent spring with the hook of one spring being received about the coil of an adjacent spring. The upper and lower runs are offset above and below the coils of the upper and lower runs respectively to accommodate a helical wire which is wrapped around the upper run for interconnecting runner wires which extend transversely of the upper run. The runner wires have offset portions which are secured to the upper runs by the helical wire. In one form the coils in the upper and lower runs are provided with a projecting recess or ear for receiving the hooks of an adjacent spring.

Abstract: A spring assembly has a plurality of rows of springs interconnected in chain-like fashion, each spring including upper and lower runs and an intermediate run interconnecting the upper and lower runs. The upper and lower runs each include a coil on one end and a hook on the opposite end hooked about a coil of an adjacent spring. A plurality of runner wires extend transversely of the upper runs where they are connected thereto by a plurality of helical wires respectively received about the upper runs. The upper runs are in planes above the coils of the upper runs providing recesses above the coils receiving the helical wires.

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 spring assembly wherein there is a rectangular border wire and there are coils disposed in spaced, parallel rows within the border wire. The coils in the rows of coils lap and are connected by helices of wire. The helices of wire connect the adjacent rows of coils, and the coils adjacent the border wire are connected thereto by a helix of wire.

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 spring core comprises a plurality of coil springs 10 each made of a single, continuous piece of wire having two open ended final windings 11 which are approximately U-shaped. The coil springs are held together by spiral shaped connecting elements 30 enclosing the straight lateral arms 12, 13 of the final windings.

Abstract: A spring assembly for an innerspring unit, particularly an innerspring mattress, is provided wherein at least a pair of springs are restricted about their adjacent offset portions of adjacent terminal convolutions in one surface of the assembly so that hinging action between the adjacent offset portions is allowed only to a maximum angle of deflection between the offset portions and thereafter, upon further loading, the pair of springs provide a greater resistance to loading than would be realized without restriction of their adjacent offset portions. Also provided is an improved coil spring for such a spring assembly.

Abstract: A box spring assembly has an array of vertical springs attached to a horizontal foundation and supporting a deck or platform for receiving a bedding load, i.e. a mattress and its occupant(s). The assembly has a plurality of deck elements each formed from a single length of wire with an elongate central section terminating in curved sections extending at least in some elements into spring legs. The deck elements are arranged in parallel lengthwise rows with adjacent elements of each row having aligned central sections. Adjacent curved sections are secured to each other and to adjacent rows by transverse helical connecting elements. The central sections of the spring elements and the transverse helical connecting elements together form the deck for receiving the bedding load. This deck is supported by the spring legs which are secured at their lower ends to the foundation.

Abstract: A spring assembly for mattresses, innersprings, and the like. The assembly comprises longitudinal 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 longitudinally extending helical lacing wires wound through overlapping Z-shaped wire segments. By lacing the rows of coils longitudinally, the spacing between adjacent coils may be varied in selected longitudinal sections of the unit so as to vary the coil count and thus the firmness of selected areas of the assembly, as for example the center section. Furthermore, by so lacing the rows of coils, a single set-up of forming and assembly machine may be used to manufacture various widths of mattresses, as for example, twin, double or queen and king size units.

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.

Abstract: The improved mattress innerspring unit is provided which includes a plurality of coil springs arranged in a plurality of substantially parallel rows, a plurality of cross helicals extending transversely of the rows of coil springs, lacing together adjacent springs along their terminal convolutions in both the upper and lower surfaces of the unit, at least one border wire extending about the perimeter of the unit and at least one cross helical cap mounted on the end revolutions of a cross helical which cap includes a means for restraining movement of the cross helical outward of the unit. The restraining means of the cross helical cap is positioned inward of the border wire and provides a positive abutment for the end revolution of the cross helical, preventing movement beyond the border wire. A cross helical cap is also provided which is adapted to be mounted on the end of a cross helical and restrain movement of the cross helical beyond a border wire of an innerspring unit.

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: 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.