New Box Spring

Abstract

A box spring assembly including a wooden frame with a plurality of spring members arranged on the frame to define a load-supporting area having side and end marginal edges. Each of the spring members is defined by an integral wire having a straight section with a fishmouth section at each end thereof. The spring members are disposed with the straight sections thereof perpendicular to the side marginal edges, and each spring member is disposed in isolated non-contacting relationship with all of the remaining spring members. Various species are illustrated showing the individual spring members in various patterns; but in each pattern, each of the spring members is isolated and not contacting any other spring member. Connecting means such as wires or grids are utilized for interconnecting the spring member.

Description

This invention relates to a box spring assembly including spring members defined by wire bent into various forms.

Wire bent into various forms to define spring members of the type utilized in the instant invention for use in box spring assemblies are not new. The subject invention, however, is specifically related to the utilization of spring members which are known as formed wire elements. Such spring members utilized in a spring assembly are shown in U.S. Pat. No. 3,596,299. In that patent, the various spring members are disposed in overlapping and abutting or engaging pairs extending transversely across the box spring assembly.

It is an object and feature of this invention to provide an improved box spring assembly, including a plurality of such spring members but wherein the spring members are isolated and in nonengaging relationship with one another and in various patterns.

In correlation with the foregoing object and feature, it is another object and feature of this invention to provide a box spring assembly wherein the individual spring members are isolated and in nonengaging relationship with one another and in various patterns, some of which include spring members having the ends disposed along the marginal edges and others of which include individual spring members with the ends spaced inwardly from the marginal edges, and various combinations thereof.

Other objects and attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a fragmentary plan view of a first species of the instant invention;

FIG. 2 is a cross-sectional view taken substantially along line 2--2 of FIG. 1;

FIG. 3 is a fragmentary view taken substantially along line 3--3 of FIG. 1;

FIG. 4 is a prospective view of a fishmouth section incorporated in each of the spring members of the subject invention;

FIG. 5 is a fragmentary plan view of a second species of the instant invention;

FIG. 6 is a plan view partially broken away and in cross section of a third species of the instant invention; and

FIG. 7 is a fragmentary plan view of a fourth species of the instant invention.

Referring first to the species shown in FIGS. 1 through 3, a box spring assembly constructed in accordance with the instant invention is generally shown at 10. The assembly 10 includes a plurality of spring members, each of which is generally indicated at 20. Each spring member 20 is defined by an integral wire having a straight section 22 and a fishmouth section which is generally shown at 24 at each end thereof.

Each fishmouth section 24, as indicated in FIGS. 2 through 4, includes a generally U-shaped portion having upper and lower legs 26 and 28 respectively interconnected by a base 30 and extending downwardly from the straight section 22. The upper leg 26 defines a torsion bar which is shorter than the torsion bar defined by the lower leg 28. Each fishmouth section also includes a V-shaped portion having a torsion bar 32 and upper and lower spacer bars 34 and 36 respectively extending from opposite ends of the torsion bar 32. The upper spacer bar 34 is integrally connected to the lower leg 28. Integrally attached to the spacer bar 36 is a U-shaped portion including a torsion bar 38, a connecting length 40, and a terminal portion 42 which is utilized to support the fishmouth section 24. More specifically, the box spring assembly includes a wooden frame comprising the side members 44, the end members 46, and the longitudinally extending members 48. The fishmouth sections 24 are supported on the frame 44 as the torsion bar 38, connecting length 40 and terminal length 42 are all disposed on a member of the wooden frame with at least the torsion bar 38 stapled or otherwise secured to the wooden frame. As an alternative, the terminal length 42 may also be stapled or otherwise secured to the wooden frame.

Thus, each fishmouth section 24 includes a plurality of torsion bars 26, 28, 32, and 38 disposed transversely of the straight section 22 which is disposed generally centrally of the torsion bars 28, 32, and 38 because the fishmouth section 24 is connected to the straight section by the short torsion bar 26, which is approximately one-half of the length of the torsion bars 28, 32, and 38.

The side frame members 44 define first and second side marginal edges and the end frame members 46 define first and second end marginal edges of the assembly. Each of the spring members 20 is disposed with the straight section 22 thereof generally perpendicular to the side marginal edges of the assembly. Additionally, each spring member 20 is disposed in isolated noncontacting relationship with all of the remaining like spring members 20,

The assembly also includes connecting means comprising the longitudinally extending wires 50 for interconnecting the spring members 20 for stabilizing the spring members 20. The wires 50 interconnect the spring members by being clipped to the short torsion bars 26 by the clips 52. Additionally, the connecting means includes a border wire 54, which also defines the marginal edges of the assembly and which is clipped to the short torsion bars 26 by clips 56.

As will become more clear hereinafter, various connecting means may be utilized other than the longitudinally extending wires 50.

A first group of the spring members 20 are spaced from one another along a first side marginal edge of the assembly as defined by the border wire 54 above the frame members 44 with the fishmouth sections 24 at the outward ends of the spring members being aligned along the marginal edge and clipped to the border wire 54 by the clips 56. In a similar fashion, a second group of spring members are spaced from one another along the second marginal edge or opposite marginal edge with the fishmouth sections at the outward ends thereof aligned along the second or other marginal edge of the assembly. Each spring member 20 in the first group along one marginal edge is longitudinally aligned with a spring member 20 of the second group along the other marginal edge to define aligned pairs as generally indicated at 60. That is, the straight sections 22 of the aligned pairs 60 are generally axially aligned with one another. Furthermore, the inward ends or the fishmouths at the inward ends of the spring members 20 of aligned pairs 60 are spaced and in nonengaging relationship with one another in a direction transversely of the assembly.

There is also included a third group of spring members 20 which are spaced among the first and second groups of spring members 20 so that the straight sections 22 of the spring members of the third group extend across the space between the inward ends of the spring members of aligned pairs 60. These spring members of the third group are indicated generally by the number 20'. The straight section 22 of each of the spring members 20' of the third group is offset and generally parallel to the straight portions 22 of the spring members of aligned pairs 60 so that each spring member 20' of the third group is disposed between and spaced from two aligned pairs 60. Additionally, the straight section 22 of each spring member 20' of the third group longitudinally overlaps the straight sections of the aligned pairs 60 so that the fishmouth sections 24 of the spring members 20' of the third group are disposed outwardly toward the side marginal edges of the assembly from the inward ends or inward fishmouths 24 of the spring members of the aligned pairs 60. More specifically, the fishmouth sections or ends of the spring members 20' of the third group are supported on longitudinally extending members 48 which are disposed between the side marginal frame members 44 and the inwardly disposed longitudinally extending members 48 upon which the inward ends or fishmouths 34 of the spring members 20 of the first and second groups are disposed.

Thus, the fishmouth sections 24 of the spring members of each group are aligned with the fishmouth sections of the remaining spring members of the same group in a direction parallel to the side marginal edges of the assembly.

The short torsion bars 26 extend from the respective straight sections 22 of the spring members 20 in opposite directions among the spring members 20 so that various of the spring members 20 are oppositely disposed. More specifically, the short torsion bars 26 of the spring members 20 of aligned pairs 60 extend from the respective straight sections 22 thereof in opposite directions so that the spring members 20 of aligned pairs 60 are oppositely disposed.

The assembly 10 also includes auxiliary spring members 62 connected to the border wire 54. These auxiliary spring members include a pair of spaced apart fishmouth portions 24' interconnected by a support portion 64 with the support portion 64 clipped to the border wire 54. The fishmouth sections 24' are identical in configuration to the previously described fishmouth sections 24.

The spring assembly 10 also includes the corner spring members 66.

Turning now to the species of FIG. 5, there is generally shown at 110 a box spring assembly constructed in accordance with the instant invention. The assembly 110 includes the same basic components as the previously described assembly; however, the spring members 120', 120", and 120'" are identical to one another and include the same fishmouth sections 24 as previously described at each end thereof but are shorter in length than the spring members 20. A first group of the spring members is indicated at 120' and are spaced from one another along a first side marginal edge with the fishmouth sections at the outward ends thereof aligned along the side marginal edge and are clipped to the border wire 54. A second group of spring members 120" are spaced from one another along the second or other marginal side edge with the fishmouth sections at the outward ends thereof aligned along the second marginal edge and clipped to the border wire 54. Also included is a third group of spring members 120'", which are spaced among the spring members 120' and 120" of the first and second group. The straight sections of the spring members 120"' of the third group extend across the space between the inward ends of the spring members 120' and 120" of the first and second groups, which are disposed in aligned pairs. More specifically, the straight section of each member 120"' of the third group is generally longitudinally aligned with the straight sections of the spring members 120' and 120" of the aligned pairs of the first and second groups. The short torsion bars 26 of the various spring members extend from respective straight sections thereof in opposite directions so that various of the spring members are oppositely disposed. As illustrated, the short torsion bars 26 of the spring members 120' extend in an opposite direction from the straight sections thereof than the short torsion bars 26 of the spring members 120"' of the middle or third group. The fishmouth portions 24 at the ends of the spring members 120"' of the third group are spaced inwardly from and in nonengaging relationship with the inward fishmouth portions or ends of the spring members 120' and 120" of the first and second groups.

The assembly 110 includes auxiliary spring members 62' disposed along the end marginal edges of the assembly. The auxiliary spring member 62' differ from the previously described auxiliary spring member 62 in that the support portion 64' thereof includes a length which is spaced inwardly from the border wire or strand 54 to provide additional support adjacent the border wire 54.

Turning now to the species FIG. 6, there is generally shown at 210 a third species constructed in accordance with the instant invention. The assembly 210 includes the same basic components indicated with the same numerals as the previously described assemblies.

The assembly 210 includes a first group of spring members 220' spaced from one another along a first side marginal edge with the fishmouth sections at the outward ends thereof aligned along the first marginal edge and connected to the border wire 54. There is also included a second group of spring members 220" spaced from one another along the second or other side marginal edge with the fishmouth sections at the outward ends thereof aligned along the second or other side marginal edge and clipped to the border wire 54. The spring members 220' and 220" are identical to one another and differ from the previously described spring members only in the length of the straight sections 22 thereof. The inward ends or the fishmouths disposed inwardly of the spring members 220' and 220" are spaced and in nonengaging relationship to one another. However, the straight sections of the spring members 220' and 220" are generally longitudinally aligned with one another to define aligned pairs of spring members 60'. Although not illustrated, the short torsion bars 26 of the various spring members 220' and 220" may extend from the straight sections thereof in opposite directions so that various of the spring members are oppositely disposed to one another.

The spring members 220' and 220" are interconnected by connecting means defined by a pad assembly comprising the wire strands 70 and paper covered strands 72, which are attached to the border wire 54 and to the various spring members 220' and 220". A pad assembly of this type is well known and is described in U.S. Pat. application Ser. No. 76,722 filed Sept. 30, 1970. Disposed over the pad assembly is a cloth covering 74.

Turning now to the species of FIG. 7, there is disclosed generally at 310 another box spring assembly constructed in accordance with the instant invention. The assembly 310 includes the same basic components of the previously described assembly, which are indicated with the same numerals. The assembly 310 includes a first group of spring members 320' and a second group of spring members 320". The spring members 320' and 320" are identical to the previously described spring members except for the length of the straight sections thereof. Each of the spring members 320' of the first group is longitudinally aligned with a spring member 320" of the second group and the inward ends of the spring member 320' and 320" of the aligned pairs 60" are spaced and in nonengaging relationship with one another. Furthermore, the fishmouth sections or ends of all the spring members 320' and 320" are spaced inwardly from the marginal edges of the assembly. In other words, none of the fishmouth sections of the spring members 320' or 320" of the first and second groups engage or are connected to the border wire 54. Additionally, the auxiliary spring members 62' are disposed completely about the periphery of the assembly so as to be disposed along the side and end marginal edges to support the border wire 54.

Like the previously described assemblies, the fishmouth sections of the spring member of each group are aligned longitudinally of the assembly in a direction parallel to the side marginal edges.

The short torsion bars 26 of spring members in aligned pairs 60" extend from the respective straight sections thereof in opposite directions so that the aligned spring members 320' and 320" are oppositely disposed in aligned pairs 60".

Although not illustrated, any one of various connecting means, including the wires 50 or the pad assembly illustrated in FIG. 6, may be utilized to interconnect the spring members 320" and the border wire 54.

It should be understood that the straight sections of the various spring members may extend transversely or longitudinally of a rectangular assembly having side and end marginal edges. Accordingly, the frame may take various configurations.

The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.

Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.

Claims

The embodiments of the invention in which an exclsuive property or privilege is claimed are defined as follows:

1. A box spring assembly comprising: a plurality of spring members arranged to define a load-supporting area having first and second side and first and second end marginal edges, each of said spring members being defined by an integral wire having a straight section and a fishmouth section at least at one end thereof, each spring member being disposed in isolated non-contacting relationship with all of the remaining spring members.

2. An assembly as set forth in claim 1 wherein each spring member includes a fishmouth section at each end thereof.

3. An assembly as set forth in claim 2 including connecting means interconnecting said spring members.

4. An assembly as set forth in claim 2 wherein a first group of said spring members are spaced from one another along one of said marginal edges with the fishmouth sections at the outward ends thereof aligned along said one-marginal edge.

5. An assembly as set forth in claim 4 wherein a second group of said spring members are spaced from one another along the opposite marginal edge to said one-marginal edge with the fishmouth sections at the outward ends thereof aligned along said opposite marginal edge.

6. An assembly as set forth in claim 5 wherein each spring member in said first group is longitudinally aligned with a spring member of said second group to define aligned pairs.

7. An assembly as set forth in claim 6 wherein each fishmouth section includes a plurality of torsion bars disposed transversely of said straight section thereof and said straight section is disposed generally centrally of said torsion bars, each fishmouth section being connected to the associated straight section by a short torsion bar.

8. An assembly as set forth in claim 7 wherein said short torsion bars of said aligned pairs extend from the respective straight sections thereof in opposite directions so that said spring members of aligned pairs are oppositely disposed.

9. An assembly as set forth in claim 6 wherein the inward ends of said spring members of said aligned pairs are spaced in nonengaging relationship to one another.

10. An assembly as set forth in claim 9 wherein a third group of said spring members are spaced among said first and second groups.

11. An assembly as set forth in claim 10 wherein said straight sections of said spring members of said third group extend across the space between said inward ends of said spring members of said aligned pairs.

12. An assembly as set forth in claim 11 wherein said straight section of each spring member of said third group is generally longitudinally aligned with said straight sections of spring members of one of said aligned pairs.

13. An assembly as set forth in claim 11 wherein said straight section of each spring member of said third group is offset from and generally parallel to said straight sections of said aligned pairs so that each spring member of said third group is disposed between and spaced from two of said aligned pairs.

14. An assembly as set forth in claim 13 wherein said straight section of each spring member of said third group longitudinally overlaps the straight sections of said aligned pairs.

15. An assembly as set forth in claim 2 wherein a first group of said spring members are disposed with said fishmouth sections thereof aligned in a direction parallel to one of said side marginal edges.

16. An assembly as set forth in claim 15 wherein said fishmouth sections of said first group are spaced inwardly of said marginal edges.

17. An assembly as set forth in claim 16 wherein a second group of said spring members are disposed with said fishmouth sections thereof aligned in a direction parallel to said side marginal edges.

18. An assembly as set forth in claim 17 wherein each spring member in said first group is longitudinally aligned with a spring member of said second group to define aligned pairs.

19. An assembly as set forth in claim 18 wherein the inward ends of said spring members of said aligned pairs are spaced in nonengaging relationship to one another.

20. An assembly as set forth in claim 18 wherein said fishmouth sections of said first and second groups are spaced inwardly of said marginal edges.

21. An assembly as set forth in claim 19 wherein the inward ends of said spring members of said aligned pairs are spaced in nonengaging relationship to one another.

22. An assembly as set forth in claim 21 wherein each fishmouth section includes a plurality of torsion bars disposed transversely of said straight section thereof and said straight section is disposed generally centrally of said torsion bars, each fishmouth section being connected to the associated straight section by a short torsion bar.

23. An assembly as set forth in claim 22 wherein said short torsion bars of said aligned pairs extend from the respective straight sections thereof in opposite directions so that said spring members of aligned pairs are oppositely disposed.

24. An assembly as set forth in claim 20 including a plurality of auxiliary spring members disposed along said marginal edges.

25. An assembly as set forth in claim 2 wherein said straight section of each spring member is longitudinally aligned with said straight section of another of said spring members.

26. An assembly as set forth in claim 25 wherein the inward ends of said aligned spring members are spaced in non-engaging relationship to one another.

27. An assembly as set forth in claim 26 wherein each fishmouth section includes a plurality of torsion bars disposed transversely of said straight section thereof and said straight section is disposed generally centrally of said torsion bars, each fishmouth section being connected to the associated straight section by a short torsion bar.

28. An assembly as set forth in claim 27 wherein said short torsion bars of said aligned spring members extend from the respective straight sections thereof in opposite directions so that said aligned spring members are oppositely disposed.

29. An assembly as set forth in claim 2 wherein said fishmouth sections of said spring members are spaced inwardly of said marginal edges.

30. An assembly as set forth in claim 2 including a frame supporting said fishmouth sections of said spring members.

31. An assembly as set forth in claim 30 including a plurality of auxiliary spring members disposed along said marginal edges.

32. An assembly as set forth in claim 31 including connecting means interconnecting said spring members.

33. An assembly as set forth in claim 2 wherein each of said fishmouth sections includes; a generally U-shaped portion having upper and lower legs and extending downwardly from said straight section, and a V-shaped portion having a torsion bar and upper and lower spacer bars extending from opposite ends thereof, said upper spacer bar being integrally connected to said lower leg.

34. An assembly as set forth in claim 33 wherein said upper leg defines a shorter torsion bar than said lower leg.

35. An assembly as set forth in claim 34 wherein said short torsion bars of said aligned pairs extend from the respective straight sections thereof in opposite directions so that said spring members of aligned pairs are oppositely disposed.