Sealy, Inc.

Robert F Wagner

Jack L Lewis

Keith A Flesher

A spring coil has an open-ended terminal convolution which is connected to the body of the coil through a gradient arm. The gradient arm can be readily varied in length in manufacture to alter the compression and thereby the firmness of the spring coil. Offset portions are advantageously formed on terminal convolutions with a major straight part which is outwardly spaced from minor straight parts. This provides a three point engagement for the offset portion when connected to a border wire with a border wire helical spring. The offset portions of the spring coils have inside and outside shoulders adjacent their ends. The pitch of cross-helicals which join overlapped offset portions is chosen so that a cross-helical simultaneously engages the outside shoulders of one of a pair of overlapped offset portions to firmly hold the spring coil against rotation. The cross-helical preferably also catches the inside shoulders of the other overlapped portion to additionally hold that spring coil against rotation.

Spring coil and spring assembly

An apparatus particularly suited for measuring the shape or contour of a surface under load, such as a mattress, is comprised of a humanoid having body limb extremities which are movable in a manner similar to the movement of comparable human extremities. Sensors are placed at joints, such as the knees and hips, to measure the amount of relative movement, i.e. deflection, that occurs at these joints when the humanoid is placed upon a mattress surface. The sensors provide an indication of the shape or contour of the mattress surface by correlation of the relative movement that occurs at these joints caused by the underlying mattress shape. In its preferred form, a movable frame is provided to raise and lower the humanoid in relation to the mattress surface to be tested. A 'spine' is also advantageously provided with associated sensors to measure deflection, and thus surface contour, in the lower torso/abdominal region.

Deflection and topography assessment mechanism anthropomorphically

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.

Coil spring and spring assembly

A mattress cover is provided which includes facing panel and a heat panel overlying at least a portion of the facing panel. The heat panel has an upper section, a backing section, and means for generating heat, the heat generating means being disposed between the upper and backing sections. Also provided is means for fastening the facing panel to the heat panel comprising at least one complementary pair of interlocking members comprising a first and a second locking member, the first locking member being secured to the facing panel, the second locking member being secured to the heat panel, and the first and second locking members being adjustable between an interlocked position, bridging the facing and heat panels, to an open position. The mattress cover is also provided with means for securing the facing panel to a mattress core. Also provided is a mattress construction having a mattress core and a facing panel and having said mattress cover secured to the facing panel.

Mattress construction and mattress cover therein

An improved foundation unit for a mattress or the like is provided which is firmer in the center than conventional torsion spring-type foundation units while having sufficient flexibility under normal loads and weight distribution to comfortably support a body upon an overlying mattress. The foundation unit includes a resilient border which protects the edge of an overlying mattress from damage when subject to extraordinary weight concentration and a center region formed of a plurality of cross rails cushioned at least about their upper surfaces which immediately underlie the upper surface of the unit. The cushioning elements may be thick foam housings that cover at least the upper surface of the cross rails or sinuous wire springs that extend along the length of the cross rails. The cross rails themselves preferably have a limited degree of flexibility so as to better withstand high impact loads.

Growing community of inventors

Lombard, IL, United States of America

Robert F Wagner