Abstract: A mattress has a main sleep area surrounded by a perimeter trim. Both the main sleep area and the perimeter trim are formed from wire springs contained within pockets of soft material. The wire springs in the sleep area are arranged in honeycomb nested rows. The wire springs of the perimeter trim, which are of different wire construction with different flex characteristic from the wire springs in the main sleep area, are arranged in side by side rows which are not honeycomb nested. In addition, the wire springs of the perimeter trim are pivotally linked directly to one another across the perimeter trim, both widthwise and lengthwise of the mattress which produces an essentially non-feelable flex transition between the perimeter trim and the main sleep area of the mattress.

Abstract: A pocketed coil spring assembly for use in the manufacture of mattresses or cushions or the like comprising a plurality of strips of integrally connected closed fabric pockets each containing one helically coiled wire compression spring having its axis disposed transversely of the strip, and wherein each of the strips contains a single band of interconnected springs formed from a single length of wire into a plurality of interconnected helical coil springs. The springs of the bands may contain inserts such as foam cylinders or pocketed coil springs to impart differing degrees of firmness to different strips. Adjacent coil springs may be separated by multiple transverse lines of attachment in order to posturize the product.

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: 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 bedding or seating product comprising a spring core made up of a plurality of parallel strings of springs joined to each other. Each of the strings of springs comprises a row of interconnected pocketed coil springs. The pocket of fabric surrounding each of these coil springs is divided into at least two subpockets by at least one line of attachment of opposite sides of the fabric to each other. Each of these subpockets contains one portion of the coil spring, thus resulting in a multilayered product.

Abstract: A 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 preferably attached to the bottom surface only around its periphery. By such a construction the amount of compressible padding is reduced by one-half and consequently the mattress is capable of exhibiting a substantial reduction in the amount of permanent deflection in use. Maintenance of the mattress such as by rotating or turning the mattress over is also avoided.

Abstract: A pocketed coil spring assembly for use in the manufacture of mattresses or cushions or the like comprising a plurality of strips of integrally connected closed fabric pockets each containing one helically coiled wire compression spring having its axis disposed transversely of the strip, and wherein each of the strips contains a single band of inter-connected springs formed from a single length of wire into a plurality of interconnected helical coil springs. The springs of the bands may contain inserts such as foam cylinders or pocketed coil springs to impart differing degrees of firmness to different strips. Adjacent coil springs may be separated by multiple transverse lines of attachment in order to posturize the product.

Abstract: An inner spring, for use in furniture and bedding, comprises coil springs which are encased in cylindrical casings having a predetermined number of spring casing portions, and which are continuously arranged in parallel. The axes of the coil springs are arranged in parallel, and at least a part of the coil springs encased in the spring casing portions are given different repulsions by varying their pitches and are set in place in the cylindrical spring casings to form a row of inner springs.

Abstract: A bedding or seating product comprising a centrally located spring core, edge support means located around the perimeter of the spring core, filling material located above and below the spring core and an upholstered covering. The edge support may be either a string of springs, a pair of spiral edge supports or plastic edge reinforcements. The edge support means extends above and below the upper and lower surfaces of the spring core thus creating a higher peripheral edge than the central portion of the spring core. Layers of filling material are inserted over the central portion of the spring core in order to create a uniform upper and lower surface.

Abstract: A method and apparatus for forming a mattress having a core formed from a plurality of elongated rows of interconnected coil spring containing fabric pockets, each row having a plurality of spaced apart pockets with a spring encased in each pocket, and having a reinforcing and/or adhesive material between adjacent rows. A first row of spring encased pockets is placed in a tray in a horizontal position and held in the tray by fingers which engage the fabric of the pockets at the ends of each spring, there being a finger at each end of each pocket. An adhesive, if necessary, may be placed on the upper surface of the row. The tray is mounted on a pivotable plate which is then rotated to a vertical position and moved linearly toward a table containing prior rows of the core to bond the row carried in the tray to the last row on the table.

Abstract: A bedding or seating product comprising a centrally located spring core, edge support means located around the perimeter of the spring core, filling material located above and below the spring core and an upholstered covering. The edge support may be either a string of springs, a pair of spiral edge supports or plastic edge reinforcements. The edge support means extends above and below the upper and lower surfaces of the spring core thus creating a higher peripheral edge than the central portion of the spring core. Layers of filling material are inserted over the central portion of the spring core in order to create a uniform upper and lower surface.

Abstract: A sectioned ergonomic bed mattress is disclosed. The mattress includes at least two sub-mattresses each with a top and a bottom cover. Each cover may have a color or pattern unlike any other of the covers such that a user can vary the appearance of the bed mattress by assembling the sub-mattresses in a number of permutations. A plurality of clamps is used to combine the sub-mattresses, and at least one clamp extends between two adjacent sub-mattresses.

Abstract: A spring assembly comprising a plurality of blocks joined together. Each block contains a string of springs. The string of springs comprises a row of springs, an upper fabric retainer and a lower fabric retainer. The row of springs may be a band of springs made from a single length of wire or a plurality of individual springs. The end turns of the springs are located in receptacles created in the fabric retainers.

Abstract: A suspension assembly for use in a chair or sofa seat having a top strap secured to a bottom strap forming a pocket into which a rigid frame is inserted. In a first preferred embodiment, the rigid frame biases the straps both together and longitudinally towards the pocket ends. In a second preferred embodiment, the rigid frame biases the straps both open and longitudinally towards the pocket ends. Springs are inserted into the pocket to continually bias the pocket open. The opposing biasing forces of the frame and the springs form a pretensioned suspension assembly that may be installed in seating applications without further stretching of the assembly during installation in a chair or sofa frame.

Abstract: A resilient structure such as a seat cushion, mattress, furniture back or the like has enhanced resiliency and support at strategic locations due to the use of coil springs interlocked and held within a densified heat bonded low melt fiber batt used as the core or cover of the resilient structure. The densified fiber batt core includes low melt fibers which, when heated to the melting point and then cooled, intersect and interlock with the coil springs. The coil springs function as an integral part of the fiber batt, eliminating the need for lattice wires and the like to interlock the springs in the structure. The invention also increases the capability of manufacturing resilient structures in a wide variety of shapes and sizes.

Abstract: A longitudinally extending string of springs comprising a row of springs and a pair of fabric retainers securing the springs together. The row of springs may be a band of coil springs made of a single length of wire shaped to form a plurality of coil springs or multiple individual springs. The upper and lower end turns of the springs are located within pockets or receptacles created in the fabric retainers.

Abstract: A unitary mattress assembly comprises a plurality of coil springs interarranged to define a single innerspring core having a generally rectangular shape in plan. The core has a first portion which is sized to accommodate a first sleeping person and comprises coil springs having a first preselected compressive strength. Adjacent to the first portion is a second core portion sized to accommodate another sleeping person and having coil springs of a different compressive strength than the springs of the first portion. By the foregoing construction, a mattress may be manufactured having a single innerspring core but having two regions of differing firmness to suit the particular preferences of two people.

Abstract: A longitudinally extending spring retainer comprising a band of coil springs and a continuous piece of fabric adapted to hold the band of coil springs. The band of coil springs is made of a single length of wire shaped to form a plurality of coil springs arranged in a row, each of the coil springs having an upper and lower end turn. The upper and lower end turns of the coil springs are held in receptacles created in top and bottom portions of a continuous piece of fabric. The fabric is folded upon itself and secured together with connections in order to hold the end turns in place.

Abstract: An automated method for the manufacture of a coil spring assembly including inserting coil springs having predetermined multiple spring rates into respective individual pockets of a continuous pocket strip in a predetermined order. The predetermined multiple spring rates of at least one coil spring may differ from that of the other coil springs, and each of the multi-rate coils has at least two different spring rates. One or more wires having a substantially uniform thickness are coiled to form the multiple rate coil springs before insertion into the continuous pocket strip. The wire is preferably coiled to produce a coil spring having at least two different diameters and at least two different pitches. The method also includes cutting the spring-filled strip into one or more desired lengths, placing at least two spring-filled lengths adjacent to each other; and attaching adjacent lengths together. A coil spring assembly may thus be provided with one or more firmness zones.

Abstract: A pocketed coil spring assembly comprising a plurality of transversely extending integrally connected fabric blocks. Each block is defined between two sheets of fabric by transversely extending lines of attachment of the sheets to each other. Successive lines of attachment are located alternatively in the upper and lower planar surfaces of the assembly. The blocks may be further connected with fasteners in one of the planar surfaces of the assembly. The blocks may contain either continuous bands of coil springs or individual coil springs, but in any event, the springs within adjacent blocks are oppositely oriented to create a balanced spring assembly in which there is no tendency for the springs to tilt upon compression of the assembly.

Abstract: An innerspring construction comprises a first elongate string of pocketed coil springs with each coil having a longitudinal axis lying in a first plane and a first elongate tube of fabric having first transverse seams spaced along the length of the tube to define individual coil spring pockets. The tube is alternately bent proximate the first seams such that every other first seam lies on the same side of the first plane. A second elongate string of pocketed coils in which each coil has a longitudinal axis lying in a second plane has a second elongate tube of fabric with second transverse seams spaced along the length of the tube to define individual coil pockets. The second elongate string is attached to the first elongate string by bonds formed between circumferentially abutting surfaces on the coil pockets of the first and second tubes of fabric. The resulting construction provides for reduced tendency for leaning coils and permits greater innerspring firmness for a given coil wire diameter.