Method for forming a foamed innerspring unit

A method for forming a foamed innerspring unit having a plurality of coils, comprising:

• releasably securing a plurality of independent coils to a first jig, each coil having a first end and second end, the coils being releasably secured to the first jig at their first ends and free at their second ends so that each coil is independently suspended from the first jig;
• delivering a first foamable reaction mixture that will provide a flexible foam into a tray to form a layer of foamable reaction mixture of the desired thickness in the tray;
• positioning the jig above the tray so that the second ends of the suspended coils are placed in spaced relation to the bottom of the tray;
• allowing the first foamable reaction mixture to rise to form a first foam layer which embeds the independently suspended coils at their second ends;
• separating the first jig from the first ends of the coils and removing the first jig;
• releasing the first foam layer from the tray;
• providing a second jig with a first foam layer supporting wall and means extending from the first foam layer supporting wall to define the spacing between the first end of the coil and the bottom of the tray and a horizontal surface and a plurality of needles extending downwardly from the horizontal surface;
• releasably securing said first foam layer having the second ends of the coils embedded therein to the second jig;
• delivering a second foamable reaction mixture that will provide a flexible foam into a tray to form a layer of foamable reaction mixture of the desired thickness in the tray;
• positioning the second jig above the tray so that the first ends of the suspended coils are placed in spaced relation to the bottom of the tray;
• allowing the foamable reaction mixture to rise to form a second foam layer which embeds the independently suspended coils at their first ends;
• and releasably receiving the first foam layer by said plurality of needles.

A method for forming a mattress comprising forming a plurality of foamed innerspring unit sections, each innerspring unit section comprising a plurality of independent coils, each coil having a first end and second end, each coil embedded at said first end in a first foam layer and at said second end in a second foamed layer by releasably securing said plurality of independent coils to a first jig, the coils being releasably secured to the first jig at their first ends and free at their second ends so that each coil is independently suspended from the first jig;

• delivering a foamable reaction mixture that will provide a flexible foam into a tray to form a first layer of foamable reaction mixture of the desired thickness in the tray;
• positioning the jig above the tray so that the second ends of the suspended coils are placed in spaced relation to the bottom of the tray and to the first layer of foamable reaction mixture;
• allowing the first layer of foamable reaction mixture to rise to form a first foam layer which embeds the independently suspended coils at their second ends;
• separating the first jig from the first ends of the coils;
• removing the first jig;
• releasing the first foam layer from the tray;
• releasably securing said first foam layer having the second ends of the coils embedded therein to a second jig;
• delivering a foamable reaction mixture that will provide a flexible foam into a tray to form a second layer of foamable reaction mixture of the desired thickness in the tray;
• positioning the second jig above the tray so that the first ends of the suspended coils are placed in spaced relation to the bottom of the tray and to the second layer of foamable reaction mixture;
• allowing the second layer of foamable reaction mixture to rise to form a second foam layer which embeds the independently suspended coils at their first ends;
• providing a cover dimensioned to hold a desired quantity of said foamed innerspring unit sections;
• and inserting the desired quantity of foamed innerspring unit sections in said cover.