Abstract: A stiffening system for the perimeter edges of a foam core mattress comprising a coil spring (or other spring-based) structure disposed along one or more perimeter edges (e.g., one or both side edges, the foot, the head, or a combinations thereof including the foot and both side edges) of a mattress having a foam sleeping area. The perimeter spring structure is rectangular or square in cross-section and provides sufficient stiffness for comfortable seating on the edges of the mattress and is joined to the foam core by planar fabric elements that span the joint between them and are attached to both. The sleep area provides the softness and other salutary effects of a foam sleeping surface while the stiffer spring perimeter element provides the rigidity need for comfortable seating and wear resistance.

Abstract: An improved spring construction for mattresses, box springs, furniture and other applications is provided. The application of such springs in mattresses, box springs, furniture and other applications is also provided. In one aspect of the invention, the spring construction is a spring including a series of spring segments, each having a flattened, irregular configuration where the spring varies in compression strength and deflection from a top portion thereof to a bottom portion thereof.

Abstract: A method for the manufacture of an innerspring assembly, suitable for a mattress, cushion, or the like, is disclosed. In one aspect, the method involves the steps of: positioning a first string of pocketed coil springs in juxtaposition with a plurality of adhesive applicators disposed in mutually fixed relation on an axis parallel to a longitudinal axis of the first string; applying adhesive from the adhesive applicators to the first string of pocketed coil springs; and bringing the first string of pocketed coil springs into adhesive contact with a second string of pocketed coil springs. An apparatus for carrying out the method, and innerspring assemblies produced by the method, are also disclosed.

Abstract: A mattress and a method of manufacturing a mattress are disclosed. The mattress includes a mattress core, a side rail joined to the mattress core by a one or more adhesive patches, optionally a deck applied over an area of the mattress core and joined to the mattress core by adhesive patches, and an upholstery layer defining a sleep surface applied over the deck or the mattress core and joined to the deck by adhesive patches. The adhesive patches have a bonding strength sufficient to maintain a relative position between the various mattress components at least during assembly of the mattress. The upholstery layer is permanently secured to the side rail by, for example, sewing or stapling.

Abstract: A mattress comprising coil springs arranged as spring units in covering pockets, a so-called pocket mattress, is provided. The spring units of the mattress are arranged in succession in elongate strings, the mattress comprising a plurality of such interconnected strings arranged side by side. A distinguishing feature of the mattress is that at least one spring unit within at least one string has a height that differs from the height of the other spring units within the same string. A method and a device for manufacturing such a mattress are also provided.

Abstract: An apparatus is configured to support at least a portion of a body thereon. The apparatus includes a base portion and a three dimensional engineered material, the three dimensional engineered material and the base cooperate to provide support for the body.

Abstract: This invention is directed to a mattress assembly for use in a sofa sleeper. The mattress assembly has an outer shell and an inner support received within the outer shell. The shell includes a lower panel, a sidewall, and a cover that fit together to form a cavity to receive the inner support. The inner support includes an air bladder and an innerspring portion. The air bladder has a valve that is adapted to allow air into and out of the bladder. The air bladder is deflated when the mattress is stored to provide a compact configuration.

Abstract: Asymmetric spring components for mattress and other flexible support structures, in the form of helical coil springs with turns in the coil body having varying pitch angles and radii, and a single support end for use in a one sided innersprings in one-sided mattresses. The coil springs are asymmetric about an axis of the coil or a horizontal reference plane, or both, and with ends of the coil springs shaped and sized differently to accommodate different mounting and support arrangements. Asymmetric coil springs can be contained in individual pockets or strings of pockets and arranged together to form an asymmetric pocketed coil innerspring for use in a one-sided mattress.

Abstract: A spring assembly including a helical coil formed from a multi-strand cord.

Abstract: A bed construction having a one-sided mattress assembly supported on a rigid foundation. The one-sided mattress assembly includes a core of pocketed coil springs having a layer of resiliently compressible material covering the upper surface thereof and having a bottom surface constructed of a substantially rigid material without a compressible layer. The core of coil springs is attached to the bottom surface around its periphery. The foundation has a rigid inner construction and a noncompressible top layer. The bed construction reduces the amount of compressible padding in the mattress by one-half and consequently the mattress is capable of exhibiting a substantial reduction in the amount of permanent deflection in use.

Abstract: A conventional bedding mattress is constructed in a manner that permits light to permeate upwardly throughout the bedding components so as to illuminate the entire bed structure when a light source is placed below the mattress proper. The illuminating feature of the bed is accomplished by forming a bed mattress of a spring core section, a translucent netting layer disposed over the spring core, a unique foam padding that freely lays on top of the netting layer, and a material cover that envelopes the core and padding. The cover is provided with a clear plastic bottom portion sewn into the cover. The padding layer is translucent and this same padding is used as a padding layer within the cover. Light freely passes through the plastic of the cover, through the spring cores, then passing through the padding layer and into the cover, thereby illuminating the mattress upon provision of an underlying light source.

Abstract: The invention concerns a mattress spring structure that includes multiple spring assemblies. Each spring assembly comprises an array of open-ended spring coils. The spring assemblies are arranged in superimposed relationship with the individual spring coils of the respective assemblies registering in vertical alignment with one another. A membrane extends between each pair of superimposed assemblies and the assemblies are connected to one another to form a unitary structure.

Abstract: A mattress construction with a stranded wire spring is disclosed. The stranded wire spring can be designed with the same performance characteristic as a conventional single strand coil spring, but at a lower manufacturing and material cost.

Abstract: The invention concerns inner spring assemblies for mattresses, typically bed mattresses. The invention proposes an inner spring assembly having open-ended coil springs arranged in first rows and second rows transverse to the first rows and a connecting arrangement which connects the coil springs to form a unitary assembly. For ease of manufacture all the coil springs in the assembly are of the same hand, those in the first rows are oriented similarly to all other springs in the same first row and in at least some of the second rows there are springs which are oriented oppositely to other coil springs in the same second row.

Abstract: The support characteristics within a foam mattress body may be varied by inserting reinforcements into channels cut or otherwise formed within the foam.

Abstract: A body impression resistant mattress assembly comprised of an inner mattress unit, at least one raised sleep zone, a first cushion top, and an outer cover encasing the raised sleep zone and the first cushion top. The insert is sized and located within the mattress so that it inhibits the formation of body impressions.

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: There is provided an innerspring assembly used in a mattress for absorbing external loads. An outermost coil spring 115 of a spring array 110 is secured in a space between upper and lower border wires 120 and 120? by pins 140, and helical coils 130 are disposed in row directions R on upper and lower portions of the spring array 110 to knit an adjacent coil spring 115, such that each coil spring has a free terminal convolution 115a protruded from an upper portion of the upper border wire 120 and/or a lower portion of the lower border wire 120?. The spring assembly includes an enclosure 10 partially or fully provided on an upper end portion and/or an lower end portion of the coil spring for covering the terminal convolution 115a in the row direction R or column direction L, thereby interrupting interference between the terminal convolution 115a and the upper and/or lower border wire 120 and 120? and absorbing a lateral load applied to the terminal convolution.

Abstract: An innerspring assembly comprising at least two sets of coil springs. In one embodiment, a first set of coil springs has a first elevation, a second set of coil springs has a second elevation different from the first elevation, and wherein one of the first and second sets of coil springs is compressed upon initial loading of the innerspring assembly, and wherein each of the first and second sets of coil springs is compressed upon continued loading of the innerspring assembly. In another embodiment, a first set of coil springs is pre-loaded to a first compressed state and a second set of the coil springs is pre-loaded to a second compressed state that exhibits a different degree of firmness relative to the first compressed state. In yet another embodiment, a first set of the coil springs has a barrel-shaped outer profile while a second set of the coil springs has an hourglass-shaped outer profile.

Abstract: A mattress construction with a multi-strand coil spring is disclosed. The multi-strand coil spring can be designed with the same performance characteristic as a conventional solid wire coil spring, but at a lower manufacturing and material cost.

Abstract: A one-sided mattress construction includes a spring assembly with asymmetric spring coils. Only the bottom portion of each spring coil is attached, either to adjacent spring coils or to a bottom surface of the mattress. The top portion of each spring may have a narrowing taper that permits the top to move independent of other adjacent springs.

Abstract: A low-profile mattress comprises an inner spring core having a plurality of spring coils and having an upper and lower surface. The mattress further includes a padding layer disposed on the upper surface and a quilting layer disposed over the padding layer and having an exterior layer of a liquid resistant material, wherein the innerspring core padding layer and quilting layer are dimensionally adapted to be less than eight inches in height.

Abstract: An innerspring assembly includes a first plurality of interconnected strings of pocketed first springs. A second plurality of strings of springs is provided and so incorporated in the innerspring assembly that at least one string of springs of the second plurality is placed between two neighboring strings of the first plurality of interconnected springs, wherein the second springs have a diameter which is smaller than a diameter of the first springs.

Abstract: In one embodiment, a mattress is constructed of a core having a first side and a second side. A first padding layer is positioned at the first side of the core and comprises a foam material having contoured surface facing away from the core. A second padding layer of a foam material is positioned adjacent the contoured surface of the first padding layer.

Abstract: A coil spring containing mattress comprises a coil spring encased in a sealed container or casing. One or more compressible pads may be included within the casing. Desirably, these pads are of an open-celled foam material which may be compressed in response to applied pressure. Air may be allowed to flow from the mattress to facilitate compression of the mattress and then blocked to assist in maintaining the mattress in a compressed state, for example for shipment.

Abstract: An innerspring assembly comprising a plurality of strips of pocketed coil springs, each including axially interconnected spring pockets having a pocket height. The strips of pocketed coil springs are comprised of overlapping plies of material adjoined together by axially offset cross seams extending generally along the pocket height to define the spring pockets, with each spring pocket containing a coil spring. In one embodiment, the overlapping plies of at least two strips are coupled together by connecting seams extending along the pocket height and axially offset from the cross seams. In another embodiment, the overlapping plies of at least three strips are interconnected. In another embodiment, overlapping edges of the plies of material are adjoined by a closing weld seam positioned adjacent an end surface of the pocketed coil springs, with the overlapping plies of material of at least two strips interconnected by connecting welds positioned along the pocket height.

Abstract: A mattress innercore support system in the form of a padded tray with a substantially rigid bottom panel. The tray has of a perimeter sidewall that is preferably made of foam and attached to the bottom panel. The system is compatible with (and sized for) all standard mattress cores, e.g., coil spring, pocketed spring, foam, foam/coil composite, and all known sizes. The mattress innercore is attached to the bottom panel by an adhesive, which simplifies assembly and reduces manufacturing cost of the mattress.

Abstract: An improved spring support system is disclosed for use in seating or bedding. The invention includes an outer frame having opposed top edges. A plurality of vertically resilient members having top ends and lower ends are fixedly disposed within the outer frame in a plurality of rows and columns. An elastic top sheet is stretched between the opposed top edges of the frame and over the top ends of the vertically resilient members. The resilient top sheet and vertically resilient members cooperate to provide a resilient support surface for supporting a person seated or reclined on the support surface.

Abstract: A bedding or seating product is provided comprising a pocketed spring assembly made up of a plurality of parallel strings of springs joined to each other. Each string of springs comprises a row of interconnected pocketed springs. The pockets of fabric are vertically shortened with seams to create pockets of the same height, each containing a spring. The springs are vertically offset from one another due to the location of the seams. Upon an initial load, only some of the pocketed springs are compressed.

Abstract: A mattress includes a chamber defined by upper and lower panels and a peripheral border all constructed from synthetic polymeric/copolymeric plastic material and housing therein a spring unit. The spring unit includes a plurality of springs having upper ends connected to a peripheral border rod. The spring unit is devoid of a peripheral border rod at lower ends of the springs. Upper edges of the spring unit can be deformably gripped by the upper panel, the peripheral border and/or both to prevent “swimming pool” effect.

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 bedding or seating product comprising a pocketed spring assembly made up of a plurality of parallel strings of springs joined to each other. Each of the strings of springs comprises a plurality of interconnected pocketed coil springs. The product has multiple sections of differing firmness attributable in part to differing heights of the pockets of the strings of springs. Filler is placed above the lower sections of the pocketed spring assembly.

Abstract: A pocketed spring core includes a plurality of springs which are arranged sequentially in rows to form parallel adjoining spring strands, wherein each of the springs is supported in a pocket made of flexible material. A first cover sheet is placed over and connected to the spring strands, and a second cover sheet is placed under the spring strands and connected thereto. At least one of the first and second cover sheets has predetermined regions which are opened in a direction transversely to a longitudinal extension of the spring strands by a plurality of slots to thereby form strips.

Abstract: Three-dimensional unitized thermoplastic foam structures are made by thermoplastic welding of different foam components. The unitized foam structures may include a planar base to which other foam components are welded to project from the base and provide a flexible three-dimensional structure. The thermal bonding or welding of the thermoplastic foam components creates a unitized structure which is both flexible and load bearing. For mattress and seating applications, the welded foam structures may be combined with an innerspring, and certain of the foam components of the structure may mechanically engage parts of the innerspring. The preferred foam deck has first and second panels interconnected by one or more webs. One or more foam decks may be employed. Other foam components may be attached to the foam decks or other components. The unitized foam structures can be employed as single or double-sided mattresses, seating structures or other flexible support structures.

Abstract: A crowned mattress having an inner spring unit with a plurality of spring members, a foam layer, and a cover. Peripheral edges of the inner spring unit are compressed together by compression members to provide a crowning or bowing of the inner spring unit that is translated into a crowning of the mattress. The foam layer can also be crowned to provide additional crowning. Spring members within inner spring unit can be reinforced by resilient members to increase an effective spring rate of a reinforced spring member. Reinforced spring members are dispersed throughout the inner spring unit in a desired pattern.

Abstract: A mattress construction with a stranded wire spring is disclosed. The stranded wire spring can be designed with the same performance characteristic as a conventional single strand coil spring, but at a lower manufacturing and material cost.

Abstract: A mattress construction with a multi-strand coil spring is disclosed. The multi-strand coil spring can be designed with the same performance characteristic as a conventional solid wire coil spring, but at a lower manufacturing and material cost.

Abstract: A stiffening system for the perimeter edges of a foam core mattress comprising a coil spring (or other spring-based) structure disposed along one or more perimeter edges (e.g., one or both side edges, the foot, the head, or a combinations thereof including the foot and both side edges) of a mattress having a foam sleeping area. The perimeter spring structure is rectangular or square in cross-section and provides sufficient stiffness for comfortable seating on the edges of the mattress and is joined to the foam core by planar fabric elements that span the joint between them and are attached to both. The sleep area provides the softness and other salutary effects of a foam sleeping surface while the stiffer spring perimeter element provides the rigidity need for comfortable seating and wear resistance.

Abstract: A mattress comprises a core, a first padding layer and a second padding layer positioned on top of the core. A bottom support layer is disposed below the core. The bottom support layer is relatively dense and firm to support the core.

Abstract: An innerspring assembly comprising a plurality of strips of pocketed coil springs, each including axially interconnected spring pockets having a pocket height. The strips of pocketed coil springs are comprised of overlapping plies of material adjoined together by axially offset cross seams extending generally along the pocket height to define the spring pockets, with each spring pocket containing a coil spring. In one embodiment, the overlapping plies of at least two strips are coupled together by connecting seams extending along the pocket height and axially offset from the cross seams. In another embodiment, the overlapping plies of at least three strips are interconnected. In another embodiment, overlapping edges of the plies of material are adjoined by a closing weld seam positioned adjacent an end surface of the pocketed coil springs, with the overlapping plies of material of at least two strips interconnected by connecting welds positioned along the pocket height.

Abstract: A bed construction having a one-sided mattress assembly supported on a rigid foundation. The one-sided mattress assembly includes a core of pocketed coil springs having a layer of resiliently compressible material covering the upper surface thereof and having a bottom surface constructed of a substantially rigid material without a compressible layer. The core of coil springs is attached to the bottom surface around its periphery. The foundation has a rigid inner construction and a noncompressible top layer. The bed construction reduces the amount of compressible padding in the mattress by one-half and consequently the mattress is capable of exhibiting a substantial reduction in the amount of permanent deflection in use.

Abstract: An innerspring assembly comprising at least two sets of coil springs. In one embodiment, a first set of coil springs has a first elevation, a second set of coil springs has a second elevation different from the first elevation, and wherein one of the first and second sets of coil springs is compressed upon initial loading of the innerspring assembly, and wherein each of the first and second sets of coil springs is compressed upon continued loading of the innerspring assembly. In another embodiment, a first set of coil springs is pre-loaded to a first compressed state and a second set of the coil springs is pre-loaded to a second compressed state that exhibits a different degree of firmness relative to the first compressed state. In yet another embodiment, a first set of the coil springs has a barrel-shaped outer profile while a second set of the coil springs has an hourglass-shaped outer profile.

Abstract: Conventional beds have a spring mattress and a sprung base for the comfort of the user, but on profiling beds, a sprung base cannot be used and, ordinarily, a mattress is laid on lifting and lowering mechanism, with a result that when pivoted or folded, folding or rucking of the surface of the mattress occurs to the discomfort of the user. A first object of the invention is to avoid the above disadvantage, and a second object is to provide a body support arrangement of greater comfort than conventional mattresses and separate bases. The first objective is met by a body support arrangement comprising at least two sectors connected in such a manner as to permit a relative pivoting of the sectors with respect to each other, each sector being formed by an upper sprung or filled mattress part and lower sprung base part.

Abstract: A mattress having an inverted top panel/border seam, with an optional appended decorative rope welting on the border is described. An inverted seam secures the top panel to the border portion of a mattress cover to eliminate bumps and creases found in conventional welted top seam. Manufacturing costs may be reduced by eliminating the need for an expensive table-mounted tape edge closure machine and/or skilled operators, since the inverted seam may be flay sewn with a conventional sewing machine or even hand-stitched. Alternatively, a conventional tape edge machine can be used with less-skilled labor and or reduced tape/welting material, as all of the stitches and welting are hidden inside the mattress by the inverted seam.

Abstract: A body support apparatus, for example, a bed, includes a support surface defined by support members. Each support member is mounted for movement in a direction substantially normal to the support surface. Support members are so arranged that movement of any one of the support members in a direction substantially normal to the support surface and beyond a threshold distance relative to an adjacent support member causes movement in substantially the same direction of said adjacent support member. No movement of a support member is caused by the movement of an adjacent support member when the distance of relative movement is below the threshold distance. The support members are resiliently urged towards an unloaded position, by tension springs.

Abstract: A mattress has a quilted internal pillow wherein one or more internal layers of material are quilt-stitched prior to encapsulation in mattress upholstery. The quilted internal pillow is positioned relative to a support surface of an innerspring or spring core of a mattress to provide support characteristics determined by the quilt stitch pattern. In a related method of manufacture of a mattress with an internal quilt stitched pillow, the layer or layers of the pillow are processed through a quilter stitching machine and then assembled in combination with a mattress spring core and upholstery. The quilted internal pillow may be located adjacent to the spring core, spaced from the spring core by other internal layers of material, or located adjacent to or within a mattress pillowtop, and in each embodiment on one or both sides of the mattress.

Abstract: A support device (10) includes a plurality of interconnected support units (12) arranged in a matrix. Each support unit (12) includes a plurality of support elements (16) configured to deform laterally outwardly when the support unit (12) is subjected to a compressive load in a load direction (54). A pre-compression is induced in the support units (12) by laterally pre-tensioning the support units (12) by means of springs (25) connected to a peripheral frame. Hence, when a support unit (12) is subjected to a compressive load in the load direction (54) it expands laterally which serves to relieve, at least partially, the pre-tension in the support units (12) connected thereto which then extend in the load direction under the influence of the springs (24).

Abstract: A resilient structure having a fiber batt with coil springs disposed therein and respective coil spring paths. Each of the coil spring paths extending from a respective coil spring and having a profile similar to a cross-sectional profile of the respective coil spring taken in a plane parallel to a length of the coil spring. A method is also provided for heating the coil springs and inserting the coil springs into a side wall of the fiber batt to produce the coil spring paths that have a profile similar to a cross-sectional profile of the respective coil spring taken in a plane parallel to a length of the coil spring.

Abstract: A folding mattress structure including a first mattress section having an end formed between first and second sides. Likewise, a second section is constructed with first and second sides and an end between the same. The connecting member is linked to the first and second sections by connection between spring members that lie adjacent one another in the separate first and second sections. The connecting member permits pivoting of the first and second section relative to one another by this expedient.

Abstract: A low-profile mattress comprises an inner spring core having a plurality of spring coils and having an upper and lower surface. The mattress further includes a padding layer disposed on the upper surface and a quilting layer disposed over the padding layer and having an exterior layer of a liquid resistant material, wherein the innerspring core padding layer and quilting layer are dimensionally adapted to be less than eight inches in height.