U.S. patent number 3,725,965 [Application Number 05/233,491] was granted by the patent office on 1973-04-10 for box spring assembly.
This patent grant is currently assigned to Leggett & Platt, Inc.. Invention is credited to Larry Higgins, John King, Richard A. Smith.
United States Patent |
3,725,965 |
Smith , et al. |
April 10, 1973 |
BOX SPRING ASSEMBLY
Abstract
A box spring comprising a wooden bottom frame, a border wire, a
welded top grid located within and attached to the border wire, and
a plurality of modular spring units interconnecting the bottom
frame and the grid. Each modular spring unit comprises a single
strand of wire extending between the sides of the assembly and
interconnecting the top grid to the bottom frame through a
plurality of individual spring units formed in the single strand of
wire. Each spring of the modular spring unit comprises a loop
formed in the single strand of wire. An arcuate spring section is
formed in the loop to provide the resiliency of the spring. In the
preferred embodiment the modular spring units are attached to the
wooden frame by staples, and the welded grid is attached to the
border wire by welding the ends of the wires of the grid to the
border wire and by wrapping the ends of the grid wires around the
border wire.
Inventors: |
Smith; Richard A. (Carthage,
MO), Higgins; Larry (Carthage, MO), King; John
(Sarcoxie, MO) |
Assignee: |
Leggett & Platt, Inc.
(Carthage, MO)
|
Family
ID: |
22877463 |
Appl.
No.: |
05/233,491 |
Filed: |
March 10, 1972 |
Current U.S.
Class: |
5/260; 5/277;
5/719; 5/247 |
Current CPC
Class: |
A47C
23/00 (20130101) |
Current International
Class: |
A47C
23/00 (20060101); A47c 023/02 () |
Field of
Search: |
;5/247,255,260,261,267,276,277,351 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Nunberg; Casmir A.
Claims
Having described our invention, we claim:
1. A box spring assembly comprising
a rectangular bottom frame, said bottom frame having side boards
and end boards connected at their ends and a plurality of
transverse slats extending between said side boards,
a rectangularly configurated border wire having a pair of
oppositely disposed side sections and end sections overlying said
rectangular frame,
a top grid of transverse and longitudinal wires extending between
and connected to said side and end sections of said border wire,
and
a plurality of modular spring units interconnecting said border
wire and top grid to said bottom frame, each of said modular spring
units comprising a single wire extending between the sides of said
assembly and having a plurality of individual springs formed
throughout the length of said wire, each of said modular spring
units being connected at its ends to said bottom frame and
connected intermediate its ends to said bottom frame and to said
top grid.
2. The box spring assembly of claim 1 in which said modular spring
units extend transversely between the sides of said border wire,
each of said modular spring units having connecting sections
located between said individual springs, said connecting sections
being parallel to and in juxtaposition to said transverse wires of
said top grid.
3. The box spring of claim 2 in which said transverse wires of said
grid each have a plurality of channels formed therein, each of said
channels being open to the bottom of said grid, and said connecting
sections of said modular spring units being received in said
channels of said transverse grid wires.
4. The box spring assembly of claim 1 in which said modular spring
unit comprises
a single strand of wire having generally colinear straight sections
located in a horizontal plane and interconnected by a plurality of
springs formed throughout the length of the wire,
each of said springs having a first generally vertical portion
extending downwardly from one of said straight sections, a loop
portion connected to the lower end of said first vertical portion,
and a second generally vertical portion extending upwardly from
said loop portion to another of said straight sections,
said loop portion of each of springs being bent through an arc of
between 30.degree. and 90.degree. out of the common vertical plane
through both of said first and second portions of said spring so
that the deflection of said springs occurs in the arcuate loop
portion of said spring.
5. The box spring assembly of claim 4 in which said opposite ends
of each of said modular spring units terminate in an end spring,
each of said end springs having a vertical portion located beneath
said border wire and terminating in an arcuate spring section bent
through an arc of between 30.degree. and 90.degree., said arcuate
spring sections of said end springs being connected at their outer
ends to said bottom frame so that said end springs provide
substantial edge support for said box spring assembly.
6. A box spring assembly comprising
a rectangular bottom frame, said bottom frame having side boards
and end boards connected at their ends and a plurality of
transverse slats extending between said side boards,
a rectangularly configurated border wire having a pair of
oppositely disposed side sections and end sections overlying said
rectangular frame,
a top grid of transverse and longitudinal wires extending between
and secured to said side and end sections of said border wire,
a plurality of modular spring units, each of said modular spring
units comprising a single wire extending between the sides of said
assembly and having a plurality of individual springs formed
throughout the length of said wire, each of said modular spring
units being connected intermediate its ends to said bottom frame
and to said top grid,
the opposite ends of each of said modular spring units terminating
in an end spring, each of said end springs having a portion located
immediately beneath said border wire and terminating at its lower
end in an arcuate spring section, said arcuate spring sections
being connected at their outer ends to said bottom frame so that
said end springs provide substantial edge support for said box
spring assembly.
7. The box spring assembly of claim 6 in which said modular spring
units extend transversely between the sides of said border wire,
each of said modular spring units having connecting sections
located between said individual springs, said connecting sections
being parallel to and in juxtaposition to said transverse wires of
said top grid.
8. The box spring of claim 7 in which said transverse wires of said
grid each have a plurality of channels formed therein, each of said
channels being open to the bottom of said grid, and said connecting
sections of said modular spring units being received in said
channels of said transverse grid wires.
9. A box spring assembly comprising
a rectangular bottom frame, said bottom frame having side boards
and end boards connected at their ends and a plurality of
transverse slats extending between said side boards,
a rectangularly configurated border wire having a pair of
oppositely disposed side sections and end sections overlying said
rectangular frame,
a top grid of transverse and longitudinal wires extending between
and connected to said side and end sections of said border wire,
and
a plurality of modular spring units interconnecting said border
wire and top grid to said bottom frame, each of said modular spring
units comprising a single strand of wire extending between the
sides of said assembly and having generally colinear straight
sections located in a horizontal plane and interconnected by a
plurality of springs formed throughout the length of the wire,
each of said springs having a first generally vertical straight
portion extending downwardly from one of said straight sections, a
loop portion connected to the lower end of said first vertical
portion, and a second generally vertical straight portion extending
upwardly from said loop portion to another of said straight
sections,
said loop portion of each of springs being bent through an arc of
between 30.degree. and 90.degree. out of the common vertical plane
through both of said first and second generally vertical portions
of said spring so that the deflection of said springs occurs in the
arcuate loop portion of said spring.
10. The box spring assembly of claim 9 in which said opposite ends
of each of said modular spring units terminate in an end spring,
each of said end springs having a vertical portion located beneath
said border wires and terminating in an arcuate spring section bent
through an arc of between 45.degree. and 90.degree., said arcuate
spring sections of said end springs being connected at their outer
ends to said bottom frame so that said end springs provide
substantial edge support for said box spring assembly.
11. A box spring assembly comprising
a rectangular bottom frame, said bottom frame having side boards
and end boards connected at their ends and a plurality of
transverse slats extending between said side boards,
a rectangularly configurated border wire having a pair of
oppositely disposed side sections and end sections overlying said
rectangular frame,
a top grid of transverse and longitudinal wires extending between
and connected to said side and end sections of said border wire,
and
a plurality of modular spring units interconnecting said border
wire and top grid to said bottom frame, each of said modular spring
units comprising a single strand of wire extending between the
sides of said assembly and having generally colinear straight
sections located in a horizontal plane and interconnected by a
plurality of springs formed throughout the length of the wire,
each of said springs having a first generally sinuous wave-shaped
portion extending downwardly from one of said straight sections, a
loop portion connected to the lower end of said generally sinuous
wave-shaped portion, and a second generally sinuous wave-shaped
portion extending upwardly from said loop portion to another of
said straight sections.
12. The box spring assembly of claim 11 in which said opposite ends
of each of said modular spring units terminate in an end spring,
each of said end springs having a sinuous wave-shaped portion
located beneath said border wires, and each of said end springs
being connected at its lower end to said bottom frame so that said
end springs provide substantial edge support for said box spring
assembly.
13. A modular spring unit adapted to be used to form the spring
section of an item of furtniture, said unit comprising
a single strand of wire having generally colinear straight sections
located in a horizontal plane and interconnected by a plurality of
springs formed throughout the length of the wire,
each of said springs having a first generally vertical portion
extending downwardly from one of said straight sections, a loop
portion connected to the lower end of said first vertical portion,
and a second vertical portion extending upwardly from said loop
portion to another of said straight sections,
said loop portion of each of springs being bent through an arc of
between 30.degree. and 90.degree. out of the common vertical plane
through both of said first and second portions of said spring so
that the deflection of said springs occurs in the arcuate loop
portion of said spring.
14. The modular spring unit of claim 13 in which the opposite ends
of said strand of wire terminate in an end spring, each of said end
springs having a vertical portion terminating in an arcuate spring
section bent through an arc of between 30.degree. and 90.degree.,
said arcuate spring section of said end springs terminating in
means for attaching said spring units to a frame.
15. A modular spring unit adapted to be used to form the spring
section of an item of furniture, said unit comprising
a single strand of wire having generally colinear straight sections
located in a horizontal plane and interconnected by a plurality of
springs formed throughout the length of the wire,
each of said springs having a first generally wave-shaped vertical
portion extending downwardly from one of said straight sections, a
loop portion connected to the lower end of said first vertical
portion, and a second generally vertical wave-shaped portion
extending upwardly from said loop portion to another of said
straight sections,
said loop portion of each of springs being bent through an arc of
between 30.degree. and 90.degree. out of a vertical plane which
passes through said colinear straight sections of said wire so that
at least a part of the deflection of said springs occurs in the
arcuate loop portion of said spring.
16. The modular spring unit of claim 15 in which the opposite ends
of said strand of wire terminate in an end spring, each of said end
springs having a generally wave-shaped vertical portion terminating
in an arcuate spring section bent through an arc of between
30.degree. and 90.degree., said arcuate spring section of said end
springs terminating in means for attaching said spring units to a
frame.
17. A spring assembly comprising
a bottom frame,
a border wire vertically spaced from said bottom frame,
a top grid of transverse and longitudinal grid wires extending
between and connected to said border wire, said grid wires being
welded to one another at the intersections therebetween, and
a plurality of modular spring units interconnecting said top grid
and said bottom frame, each of said modular spring units comprising
a single wire extending between the sides of said assembly and
having a plurality of individual springs formed throughout the
length of said wire, each of said modular spring units being
connected at its ends to one of said bottom frame and border wire
and connected intermediate its ends to said bottom frame and to
said top grid.
18. The box spring assembly of claim 17 in which said modular
spring units extend transversely between the sides of said border
wire, each of said modular spring units having connecting sections
located between said individual springs, said connecting sections
being parallel to and in juxtaposition to said transverse wires of
said top grid.
19. The box spring of claim 18 in which said transverse wires of
said grid each have a plurality of channels formed therein, each of
said channels being open to the bottom of said grid, and said
connecting sections of said modular spring units being received in
said channels of said transverse grid wires.
20. A spring assembly comprising
a bottom frame,
a border wire vertically spaced from said bottom frame,
a top grid of transverse and longitudinal grid wires extending
between and secured to said side and end sections of said border
wire, said grid wires being welded to one another at the
intersections therebetween, and
a plurality of modular spring units, each of said modular spring
units comprising a single wire extending between the sides of said
assembly and having a plurality of individual springs formed
throughout the length of said wire, each of said modular spring
units being connected intermediate its ends to said bottom frame
and to said top grid,
the opposite ends of each of said modular spring units terminating
in an end spring, each of said end springs having a portion located
immediately beneath said border wire and terminating at its lower
end in an arcuate spring section, said arcuate spring sections
being connected at their outer ends to said bottom frame so that
said end springs provide substantial edge support for said box
spring assembly.
21. The box spring assembly of claim 20 in which said modular
spring units extend transversely between the sides of said border
wire, each of said modular spring units having connecting sections
located between said individual springs, said connecting sections
being parallel to and in juxtaposition to said transverse wires of
said top grid.
22. The box spring of claim 21 in which said transverse wires of
said grid each have a plurality of channels formed therein, each of
said channels being open to the bottom of said grid, and said
connecting sections of said modular spring units being received in
said channels of said transverse grid wires.
23. A box spring assembly comprising
a rectangular bottom frame, said bottom frame having side boards
and end boards connected at their ends and a plurality of
transverse slats extending between said side boards,
a rectangularly configurated border wire having a pair of
oppositely disposed side sections and end sections overlying said
rectangular frame,
a top grid of transverse and longitudinal wires extending between
and connected to said side and end sections of said border wire,
said top grid defining the top of said box spring assembly, and
a plurality of modular spring units interconnecting said border
wire and top grid to said bottom frame, each of said modular spring
units comprising a single wire extending between the sides of said
assembly and having a pair of end springs and a plurality of
intermediate springs formed throughout the length of said wire,
each of said end springs being connected to said bottom frame
adjacent said border wire and said intermediate springs being
connected to said bottom frame and to said top grid.
24. A box spring assembly comprising
a rectangular bottom frame, said bottom frame having side boards
and end boards connected at their ends and a plurality of
transverse slats extending between said side boards,
a rectangularly configurated border wire having a pair of
oppositely disposed side sections and end sections overlying said
rectangular frame,
a top grid of transverse and longitudinal wires extending between
and connected to said side and end sections of said border wire,
said top grid defining the top of said box spring assembly, and
a plurality of modular spring units interconnecting said border
wire and top grid to said bottom frame, each of said modular spring
units comprising a single wire extending between the sides of said
assembly and having a pair of end springs and a plurality of
intermediate springs formed throughout the length of said wire,
each of said end springs being connected to said bottom frame
adjacent said border wire and said intermediate springs being
connected to said bottom frame and to said top grid,
said end springs of each of said modular spring units being spaced
differing distances from the adjacent intermediate spring,
said modular spring units being arranged in pairs, with each
modular spring unit of a pair reversed end for end from the other
modular spring unit of the pair, and
the intermediate springs of one of each pair of modular spring
units being interspaced between the intermediate springs of the
other modular spring unit of the pair.
Description
BACKGROUND OF THE INVENTION
This invention relates to items of furniture, as for example,
seats, chairs and mattresses; but particularly it relates to the
manufacture of box spring assemblies for supporting bed
mattresses.
The manufacture of box springs as it is commercially practiced
today involves a great deal of hand labor. Generally, box springs
are made from a multiplicity of individual coils or helical springs
sandwiched between a wooden frame and a top grid of wires. The
assembly is completed by placing a cushion or fabric pad over the
top grid of wires and, while the whole assembly is compressed,
upholstering the complete assembly. The majority of the manual
labor required for manufacturing this type of box spring is
required to position or situate and lock the helical springs to the
wooden frame and to the top grid.
As the price of labor has increased so have the efforts to
eliminate manual labor from the manufacturing process. Generally,
though, these efforts have met with limited success because the
construction of existing box spring assemblies is such that it is
not easily or inexpensively automated.
It has therefore been a primary objective of this invention to
provide a box spring assembly construction which lends itself to
automatic assembly and manufacture.
Another objective of this invention has been to provide a box
spring assembly which is superior in quality to existing box spring
assemblies yet which may be manufactured automatically. Two
principal features which determine the quality of a box spring
assembly are the firmness of the assembly and its useful life. This
latter quality is measured in terms of its ability to withstand a
great deal of abuse in use.
The quality of firmness is generally a function of the quantity of
metal utilized in the construction of the assembly. In other words,
the heavier gauge metal wire employed in the springs of the
assembly, the more firm will be the assembly and therefore the
higher price it will bring as a quality product. The ability to
stand up in use or withstand abusive use is generally a function of
the techniques employed to assemble the unit and the care or
attention paid to those techniques. Generally, the more points at
which each spring is connected to the wooden frame and to the top
grid, the longer lived it will be and the more punishment it will
withstand before breaking. In order to measure the anticipated life
or the ability of box spring assemblies to hold up in use, most
manufacturers have some technique for measuring the useful life of
a box spring, as for example, by rolling a heavy roller back and
forth over the completed assembly. Similarly, the American Hotel
and Motel Association has a testing procedure for measuring the
useful life of a box spring which involves multiple loading and
unloading of the springs of the unit.
Still another criteria of quality in a box spring assembly is the
ability of the unit to withstand edge loading. Generally, the
greater the edge support the better the box spring. Many of the
higher quality box spring assemblies include special edge supports
in addition to the springs of the unit to reinforce the border of
the unit.
It has been another objective of this invention to provide a box
spring assembly which meets the highest standards for firmness,
useful life and edge support required by manufacturers or consumer
associations for box spring assemblies while still providing an
assembly which may be manufactured and assembled with a minimum of
hand labor.
The box frame assembly of this invention which accomplishes these
objectives comprises a wooden bottom frame, a border wire located
above and spaced from the bottom frame, a welded grid located
within and attached to the border wire, and a plurality of modular
spring units interconnecting the welded grid and the wooden frame.
Each modular spring unit is formed from a single strand of wire and
includes a plurality of individual springs formed in the unit. Each
individual spring comprises a loop formed in the single strand of
wire which extends downwardly from the top grid to the bottom frame
and has an arcuate spring section formed in it. The modular unit
also has a spring formed at each end and located immediately
beneath the border wire of the assembly so that the endmost springs
of a unit provide increased edge support for the assembly.
The primary advantage of this box spring assembly resides not only
in the quality characteristics of the assembly, i.e., the firmness,
the prolonged useful life, and the superior edge support, but also
in the fact that the construction particularly lends itself to
automatic manufacture. Because the top mat comprises a welded grid
secured to the border wire, the whole top section including the top
welded grid and the border wire may be manufactured as a
subassembly. Similarly, the modular springs and frame are subject
to automatic manufacture and assembly.
Another advantage of this construction is that it enables a very
firm box spring to be manufactured with a minimum of relatively
light gauge wire. By reducing the quantity and thickness or gauge
of the wire required to manufacture a box spring of a particular
firmness, the total material cost of the unit is substantially
reduced.
These and other objects and advantages of this invention will be
more readily apparent from the following description of the
drawings in which:
FIG. 1 is a perspective view of a box spring assembly incorporating
the invention of this application;
FIG. 2 is a side elevational view of a portion of the box spring
assembly of FIG. 1;
FIG. 3 is an enlarged perspective view of a portion of the box
spring of FIG. 1;
FIG. 4 is a view similar to FIG. 2 but illustrating a modified form
of modular spring unit; and
FIG. 5 is a view similar to FIG. 3 but incorporating the modified
modular spring unit of FIG. 4.
Referring to FIG. 1 it will be seen that the box spring assembly 10
of this invention comprises a bottom frame 11, a top grid 12
surrounded by a border wire 13, and a series of modular spring
units 14.
The bottom frame comprises a pair of side boards 16, 17 nailed or
otherwise fixedly secured to a pair of end boards 18 and 19. In the
embodiment illustrated in the drawings, there are seven wooden
slats 20-26 which extend transversely between and are nailed or
fixedly secured to the side boards 16 and 17. A longitudinal center
slat 28 may be provided for the length of the wooden frame as added
reinforcement for the center of the slats 20-26.
The border wire 13 is located immediately above and is spaced from
the outer circumferential edge of the bottom frame 11 of the
assembly 10. It is connected to and supported by the wooden frame
through the modular spring units 14, as is explained more fully
hereinafter.
The top grid 12 comprises a series of parallel transverse wires 30
and a series of longitudinal wires 31. In the preferred embodiment
there are sixteen transverse wires 30 equidistantly spaced between
the opposite ends 32, 33 of the border wire and twelve longitudinal
wires 31 equidistantly spaced between the opposite sides 34, 35 of
the border wire. The ends of all these transverse and longitudinal
wires 30,31 of the top grid are secured to the border wire by being
welded to the border wire and wrapped around it, as illustrated at
36 (FIGS. 1 and 3). In the preferred embodiment the longitudinal
and transverse wires of the top grid are welded at all of their
intersections so as to provide a grid subassembly which may be
easily secured to the border wire and handled as an assembly unit.
The welding of the longitudinal transverse wires of the top grid
stabilizes the box spring assembly and increases its firmness as
well as its resistance to sidesway.
Transversely spaced along each of the transverse wires 30 there are
seven 3-pronged channels 40, each one of which is open to the
bottom of the top grid. Referring to FIG. 3 it will be seen that
each of these 3-pronged channels 40 comprises a pair of reversely
bent fingers or prongs 41, 42 located in a common vertical plane
and interconnected by transverse bends 43, 44 to a central
reversely bent prong or finger 45. The central finger is also
located in a vertical plane but is spaced from the vertical plane
of the fingers 41, 42 so that a channel is defined between them. In
the completed assembly of the box spring, the modular spring units
14 are received within these channels 40 and may be locked therein
by bending the central finger 45 beneath the wire of the modular
spring unit.
Each modular spring unit 14 comprises a single strand of wire
within which there are formed several individual springs. In the
preferred embodiment of the invention illustrated in FIG. 1, there
are two end springs 46-46 formed in each modular unit as well as
three intermediate springs 47, 48 and 49. Each of these five
springs 46-46, 47, 48 and 49 are separated by a straight section
50, 51, 52 and 53 of the wire strand.
Referring now to FIG. 2 it will be seen that each of the end
springs 46-46 comprises a straight vertical leg 55 which extends
downwardly from the straight section 50 or 53 of the wire strand.
This section terminates at its lower end in an arcuate section 56,
the lower end of which is bent into a closed loop 57. As may be
seen most clearly in FIG. 2, the arcuate section 56 is bent out of
the vertical plane of the leg 55 through an angle .alpha. of
approximately 60.degree.. It is this arcuate section which provides
the resiliency of the end springs 46-46. The loop 57 at the end of
the spring is secured to the frame by a staple 58.
The intermediate springs 47, 48 and 49 in each of the modular
spring units each comprise a vertical leg 60 which extends
downwardly from one of the straight colinear sections 50, 51, 52 or
53, a loop section 61 located at the lower end of the vertical leg
60, and a vertical leg 62 which extends back upwardly from the loop
61 to one of the straight sections 50, 51, 52 and 53. As may be
seen most clearly in FIG. 3, the loop portion 61 of the individual
spring units 47, 48, 49 are bent out of the common vertical plane
of the legs 60, 62 through an angle .alpha. of approximately
60.degree.. It is the bent section 64, 65 of the loop portion of
the individual springs which provides the resiliency in each
spring.
The angle .alpha. defined by the bend in the individual springs is
not critical to the operation of this invention. In fact, an angle
which varies anywhere from approximately 30.degree. to and through
90.degree. has been found to be satisfactory so long as sufficient
radius is provided on that portion 64, 65 of the bend which
interconnects the loop 61 to the legs 60, 62. This angle and the
radius of the arc within which it is located, are determinative of
the resiliency of the spring.
As may be seen most clearly in FIG. 1, the outermost ones of the
intermediate springs 49 and 47 are spaced differing distances from
the ends of the modular spring units. Consequently, the modular
spring units may be used in pairs with one unit reversed end for
end from the other and with the arcuate bends 64, 65 of the
individual modules facing each other. When paired in this manner
the intermediate springs 47, 48 and 49 of one of the pairs are
equidistantly spaced from or interleaved with the intermediate
springs 47, 48, 49 of the other modular spring unit of the pair.
Consequently, there is a very even distribution of resiliency of
the total box spring assembly.
The modular spring units are secured to the wooden frame by having
the lower ends of each of the springs of the unit stapled to either
the end boards 18, 19 or the slats 20-26 of the frame. The straight
sections 50, 51, 52 and 53 of the modular spring units are received
in the channel 40 of the transverse wires 30 and, if desired, the
central finger 45 of each of the channels is clinched or bent
beneath the straight section of the modular springs so as to lock
the modular springs in the channels of the transverse wires. The
straight horizontal sections of the endmost ones of the modular
springs are secured to the ends 32, 33 of the border wire 13 by
conventional metal clips 67.
The principal advantage of the box spring unit described
hereinabove resides in the fact that it may be very easily
manufactured with a minimum of manual labor on an automatic
machine. This characteristic is principally attributable to the
fact that the individual springs of the assembly are formed and may
be assembled as portions of a modular unit.
This box spring assembly also has the advantage of a very firm edge
support. This characteristic is attributable to the location of an
end spring of each of the modular spring units immediately beneath
the border wire. These end springs 46--46 of the modules provide
greater support at the edge of the box spring than at any other
point with the result that there is no need for special edge
support units.
Still another advantage of this construction resides in the fact
that the modular springs may be easily converted from twin bed to
queen bed size by simply adding one spring to each module. The
preferred embodiment illustrated in FIG. 1 is representative of a
so-called full size bed. By adding a single spring to each module,
the modules may be utilized in a queen size bed. Similarly, by
subtracting a single spring from each module, it may be utilized in
the manufacture of twin bed size box springs. Consequently, a
single machine may be utilized to manufacture spring modules for
all three size box springs.
This box spring construction also has the advantage of
accommodating differing heights without having to vary the height
of the wooden frame of the assembly. Currently it is the practice
when the box spring is to be used with a thin mattress (as for
example, a foam rubber mattress) to employ a box spring of
increased height. This is currently accomplished by increasing the
height of the wooden frame upon which the box spring is assembled.
With the construction of the box spring assembly of this invention,
because it has little or no sidesway, the height may be increased
by simply increasing the length of the vertical legs 55, 60, and 62
of the assembly. In this way differing height box spring assemblies
may be mounted on a single size wooden frame.
Still another advantage of this box spring assembly construction is
that it eliminates the need to compress the springs when the
assembly is upholstered. Current practice is to utilize helical or
coil springs and to compress those springs while the upholstery is
placed on the assembly. This box spring assembly may be upholstered
while in the uncompressed state of the springs.
Another advantage of this box spring assembly resides in its
dimensional stability. Because the intersections of the individual
wires of the wire grid are welded and the ends of the individual
wires of the grid are welded to the border wire and because of the
firmness and dimensional accuracy curacy of the modular spring
units, the assembly maintains its squareness and is always
accurately sized from one unit to the next. Current practice in the
box spring industry is to accept a tolerance of plus or minus
one-half inch in the over-all length and width of the box spring
assembly. Consequently, following this commercial practice, there
may be as much as one inch variance in length from one assembly to
the next. The practice of this invention, though, eliminates that
one inch tolerance so that the assembly is more easily upholstered
and the upholstering has a neater appearance from one box spring to
another.
Referring now to FIGS. 4 and 5, there is illustrated a second
embodiment of a modular spring unit incorporated into a box spring
assembly. The box spring of this second modification, except for
the configuration of the modular spring unit, is identical to the
box spring assembly of FIGS. 1-3. Specifically, the top wire grid
12, the frame 11, and the border wire 13 of this second
modification are identical to the corresponding components of the
modification of FIGS. 1-3.
The modular spring units 70 of this second embodiment of the
invention differ from the modular spring units of FIG. 1 in two
respects: (a) in that the straight portions of the wire strand
which interconnect the spring portions have an offset section 72
formed therein and (b) the vertical legs of the spring portions are
configurated slightly differently from the straight vertical legs
55, 60, and 62 of the modular springs of the modification of FIG.
1.
The offset 72 in the horizontal connecting sections 73 of the
modular spring units are offset in the top plane of the wire grid
12. As a result of this offset, the transverse wires 30 of the grid
rest upon the top of the offset section 72 of the modular spring
unit, illustrated at 76 in FIG. 5. As a consequence of the wire
grid resting upon the top of this offset portion 72 of the modular
spring, there is less metal fatigue of the welds 77 at the
intersection of the transverse and longitudinal wires 30, 31 of the
wire grid resulting from deflection of the springs. Consequently,
the grid is longer lived than it would be in the absence of the
offset 72 of the modular units.
The other feature which distinguishes these modular spring units 70
from the modular spring units 14 of the modification of FIGS. 1-3
is the configuration of the spring portion 79 of the unit. The
vertical legs 80 and 81 of the spring unit rather than being
straight as in the modification of FIGS. 1-3 each have a
wave-shaped bend 82, 83 formed therein so as to increase the
resiliency of the unit. Except for the presence of the wave-shaped
bends 82, 83, the springs 79 are identical to the springs of the
modular unit of FIGS. 1-3.
The box spring assembly of this second modification has all the
advantages and manufacturing characteristics of the first
modification described hereinabove. Additionally, though, because
of the increased resiliency of this second modification, it is more
readily usable in car seats, couches, or furniture where a less
firm surface is desirable.
While we have described only two preferred embodiments of a box
spring assembly incorporating the invention of this application,
persons skilled in the art to which this invention pertains will
readily appreciate that the invention of this application is
applicable to other items of furniture, as for example, chairs,
couches, car seats, etc. Additionally, persons skilled in this art
will appreciate that differing modular spring constructions will
result in different resiliency and firmness characteristics in the
resulting box spring or mattress assembly; but such modifications
are within the scope of the invention of this application.
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