Dreamwell, Ltd.

Sealy Technology, LLC

Simmons Company

Bernhard W Kuchel

Michael Stephen DeFranks

Eugen Constantinescu

Michael W Mauldin

Richard F Gladney

Michael DiMarco

Michael S Notheis

Michael S Defranks

Michael S De Franks

A suspended matrix support structure has a perimeter frame which supports a flexible matrix formed with intersecting flexible members, the ends of which are supported by the perimeter frame. Edges of the flexible members are held within channels which form a frame about the flexible matrix. In one embodiment, the perimeter frame is constructed of foam with contoured features which support the frame of the flexible matrix. The flexible members of the flexible matrix extend across the expanse within the perimeter frame to provide a flexible support structure which can be used as a mattress, mattress foundation or both in combination.

Suspended flexible matrix support system

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.

One-sided mattress

A mattress foundation with a perimeter structure has a frame, springs mounted upon the frame, and a grid supported by the springs, and perimeter structure at a perimeter of the frame which extends from the frame to the grid, forming an exterior wall which extends from the frame to a border wire of the grid. When the perimeter structure is made of structural and reflexive material such as closed-cell foam, it co-acts with the grid and springs and provides additional support to the perimeter region of the grid and foundation. The exterior wall of the perimeter structure forms a solid surface over which padding or upholstery is placed.

Mattress foundation with perimeter structure

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

Multi-stranded coil spring

An apparatus and method for winding strings of pocketed coils onto a spool. The coil spooling apparatus includes a feed mechanism and a spooler. The feed mechanism includes buffer rollers and an adjustable hollow feed arm. The feed arm terminates adjacent to the spooler. The spooler includes a spool with a horizontally or vertically oriented spool core, a drive mechanism, and a turntable base with a pallet. The drive mechanism powers the rotation of the spool core. The rotation of the spooler winds the string of pocketed coils received from the feed mechanism. The feed mechanism buffers the tension and directs the string of pocketed coils along the horizontal and vertical axis. After the desired size of wound package is reached, the rotation of the spooler ceases. The completed wound package can then be lifted while attached to the spool through the use of a fork lift. The vertical spools can be stored and transported in a vertical position since the core base is flat. The spools can be unwound and the springs uncompressed when needed to manufacture mattress constructions.

Method and apparatus for storing and transporting strings of pocketed coils

Methods and apparatus are provided for forming strings of springs enclosed within pockets having flat overlapping side seams avoiding problems with false loft in mattress construction.

Method and apparatus for forming strings of pocketed springs

An apparatus for assembling innerspring constructions from rows or strings of pocketed coil springs comprises a generally planar support surface with a pressure plate mounted parallel to and above the support surface. The apparatus includes a bonding material applicator for applying bonding material to a first row of pocketed coil springs retained by the pressure plate. A pusher bar assembly is provided for pushing a second row of coil springs into intimate contact with the first row whereupon the two rows become bonded. The pusher bar assembly includes a pusher fixture having two opposed sides, each with differently spaced dividers for receiving rows of springs having differing diameters. The pusher fixture is manually rotatable to employ a desired set of dividers depending on the size of the coils being assembled. The bonding material applicator includes a trigger bar having alternatively readable indicia for synchronizing the application of bonding material depending on the preselected sizes of coils being assembled.

Growing community of inventors

King, NC, United States of America

Bernhard W Kuchel