Bedding coil spring unit and assembly method

Abstract

A coil spring unit having a series of coil springs connected together in column and row matrix configuration, the end loops of the coil springs being open loops that terminate in free ends, i.e., the end loops of the coil springs not being closed and knotted. The coil spring assembly method comprises forming a series of coil spring rows, each row being formed from a single continuous length of spring wire. Each intermediate spring within a row has an adjacent coil spring on one side directly connected at one end of that intermediate spring, and an adjacent coil spring on the other side directly connected at the other end of that coil spring, through use of connector sections that are part of the single continuous length of spring wire used to form that row. The pre-formed rows thereafter are connected in matrix form. After the rows have been connected in matrix configuration, the connector sections are selectively cut between adjacent springs on both sides of each intermediate spring. This results in a coil spring product having individual or separate coil springs not directly connected one with the other in which each such coil spring's end loops terminate in free ends, i.e., in which each such coil spring's end loops are not knotted in those sections where the connector sections are cut, and having adjacent coil springs directly connected one with the other in those sections where the connector sections are not cut, thereby providing a coil spring unit in which the hardness/softness deflection characteristics are selectively variable across the surface area of the unit.