This invention relates generally to bedding foundations and, more particularly, to a bedding foundation which is collapsible for storage and shipment.
Conventional bedding foundations, such as box springs, typically include an array or matrix of springs, a wooden base and an upper grid including a generally rectangular border wire. The springs may be coil springs or modular springs. The components are commonly shipped from a spring manufacturer to a box spring manufacturer separately. Once the components arrive at the box spring manufacturer's facility, the box spring manufacturer attaches the lower ends of the springs which extend downwardly from an upper wire grid assembly to a base. Padding and a cover are applied by the box spring manufacturer as desired. Such conventional bedding foundations are large and cumbersome to handle in storage, transportation, or shipment which, of course, increases the ultimate cost.
Moreover, it is not uncommon for a coil spring manufacturer to compress or deform coil spring units layered one on top of the other into condensed or compacted multilayered packs for shipment to a box spring manufacturer. The aforementioned step is performed by means of a press machine enabling the foundation units to be compressed to reduce their height dimension. The coil spring units of each pack are held in their compacted state against return to their normal or unstressed condition by means of strapping applied about the unit. The spring units of each pack being compressed, the strapping is under a great amount of tension. When the packs arrive at the place of the manufacturer, it is, of course, necessary to sever the strapping around the packs in order to release the spring units for installation into box springs or mattresses. This, of course, is difficult because of the high degree of tension to which the strapping is subjected by the compression of the coil springs.
U.S. Pat. No. 4,377,279 discloses a wire foundation unit for a box spring which may be shipped to a box spring manufacturer in a collapsed condition. The manufacturer would erect the foundation wires and then fix by staples, rigid struts between the wire unit and base to permanently secure the wire unit in the erected position. The box spring manufacturing process is completed by providing the conventional layer of padding on the top of the wire foundation and a sheet covering or casing about the entire unit. However, once the manufacture is completed, the box spring is no longer collapsible and thus must be shipped in its expanded or full-size state to the point of retail or use whereby the same storage and shipment costs result at this point as with conventional box springs.
U.S. Pat. No. 4,654,905 discloses another collapsible bedding foundation for a box spring which can be shipped to a box spring manufacturer in a collapsed condition. The box spring manufacturer would erect the collapsed bedding foundation before applying padding on the top of the erected bedding foundation and covering or casing the entire unit. The collapsible bedding foundation disclosed in this patent utilizes a hinge to connect two sections of the bedding foundation so that when collapsed, one section may overlay the other section. One drawback to this bedding foundation is that the hinge is expensive, thereby adding substantial cost to the manufacturer of the collapsible bedding foundation, which is in turn passed on to the manufacturer of the box spring.
Therefore, there is a need for a collapsible box spring which is less expensive to manufacture than known collapsible box springs. There is further a need for an affordable box spring which may be collapsed after being upholstered.
The foldable bedding foundation of the present invention includes first and second sections which are hingedly secured together with upper and lower hinges or connectors. Each section includes a wooden base, the first and second bases of the first and second bases, respectively, being hingedly secured together with a pair of lower connectors, such as a hinge or hinges. Each section also includes an upper wire grid, the upper wire grids of the first and second sections, respectively, being connected to one another via a pair of upper connectors. The first and second wire grids are each independently movable relative to the upper connectors. In particular, the upper connectors may be pivotally connected to each of the first and second wire grids. Each of the first and second upper wire grids comprises a rectangular border wire and a plurality of intersecting grid wires. Each end of each of the intersecting grid wires is wrapped around one of the border wires of one of the upper grids of one of the sections.
Each section of the bedding foundation also includes a plurality of wire support modules pivotally secured to the section base and to the upper wire grid of the section. Each of the wire support modules is movable between a retracted position (wherein the bedding foundation is collapsed, such as by being folded, for example) and an extended position (wherein the bedding foundation is erected for use). In their retracted positions, the wire support modules are generally unstressed and lie between the first and second bases. Thus, the bedding foundation may be substantially reduced in its depth dimension, thereby facilitating storage handling and/or shipment at reduced unit cost. In their extended positions, the wire support modules are erect, and thus, the bedding foundation is ready for use. After use, the bedding foundation may be collapsed to its storage position and then later expanded to its use or erected position. This process may be repeated as often as desired.
In one aspect, the bedding foundation is foldable or collapsible upon itself into two overlying sections, thus reducing the length approximately in half for storage or shipment. Unfolding of the bedding foundation (to a usable position) places the first and second sections in a generally co-planar position, moving the wire support modules from their retracted position to their erect position. The subsequent folding actuates the wire support modules from their erected positions into their retracted positions.
The first and second sections of the bedding foundation may be joined at the first and second bases with at least one connector, such as a hinge, as mentioned above. In particular, one or more hinges may be secured to the first and second bases of the first and second sections and extend(s) therebetween. In one embodiment, each connector is generally rectangular and has a pair of living hinges built therein so that when the bedding foundation is collapsed, each lower connector assumes a generally U-shaped configuration, and when the bedding foundation is erected, each connector is generally planar. Such connectors are preferably made of plastic, but may be made of any desirable material. Other types or configurations of connectors comprising one or more components may be used in accordance with the present invention.
Each of the first and second wire grids includes (1) an outer border wire of a general rectangular shape, (2) a plurality of longitudinal wires parallel to and spaced from one another, and positioned within the border wire, and (3) a plurality of transverse wires parallel to and spaced from one another, and positioned within the border wire, each of the transverse wires being substantially perpendicular to and intersecting with the longitudinal wires.
A first plurality of the wire support modules contacts and connects the first wire grid and the first base. And a second plurality of wire support modules contacts and connects the second wire grid and the second base. Further, each wire support module includes a pair of legs joined by a foot or lower section and a top or upper section. The foot comprises a pair of aligned extensions stapled to the base, the extensions being joined together by a generally U-shaped stop. The top or upper section of each module comprises a pair of U-shaped shoulders joined by a linear or straight upper connector. One of the longitudinal wires of the upper wire grid passes over a base of each of the U-shaped shoulders while one of the transverse wires of the upper wire grid passes under one of the sides (the inner side) of each of the U-shaped shoulders and passes over the other of the sides (the outer side) of each of the U-shaped shoulders. Thus, with this configuration, each wire support module secures and holds at least one transverse wire and at least one longitudinal wire of an upper wire grid, such that the first and second upper wire grids cannot shift laterally relative to the first and second bases, respectively. Due to the unique configuration of each of the wire support modules, the upper wire grid of each section may be snapped into engagement or secured in a snap-fit manner to the wire support modules of the foundation section.
Finally, the bedding foundation is configured such that when in a folded position, the upper wire grids of the first and second sections are adjacent one another and the wooden bases outside the collapsed wire interior of the foundation. In this collapsed or folded position, the first and second bases lie in separate but generally spaced parallel planes with the modules therebetween. When the bedding foundation is unfolded to an extended or erect user position, the weight of an individual on top of the bedding foundation does not cause the bedding foundation to fold due to the unique configuration of the foundation and, in particular, the wire support modules of the foundation.
Various features, aspects and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying figures in which like characters represent like parts throughout the figures, wherein:
Referring to the drawings, and particularly to
Although the drawings illustrate the bedding foundation 10 with no cover, the bedding foundation 10 may be collapsed with a surrounding cover (not shown). If desired, padding (not shown) may be placed on the upper surface of the bedding foundation 10 before the surrounding cover is attached.
Referring to
A plurality of wire support modules 34 are pivotally secured to the cross rails 32, 33 of the first base 24 with staples 36, as best shown in
The first section 16 of the bedding foundation 10 further comprises a first wire grid 44 comprising a plurality of spaced, parallel longitudinal grid wires 46 and a plurality of spaced, parallel transverse grid wires 48 intersecting with the longitudinal grid wires 46 at intersections 50. Further, the transverse grid wires 48 may be secured, with welds, for example, to the longitudinal grid wires 46 at intersections 50. An outer border wire 52 of a generally rectangular shape surrounds the longitudinal grid wires 46 and transverse grid wires 48, and forms a part of the first wire grid 44. The ends of the longitudinal grid wires 46 and transverse grid wires 48 are wrapped around, welded or otherwise secured to the border wire 52, as is conventional.
As best seen in
As best seen in
Referring to
A plurality of wire support modules 34, identical to wire support modules of the first section 16, are pivotally secured to the cross rails 74, 76 of the second base 26 with staples 36. Each wire support module 34 of the second section 18 is rotated 180 degrees relative to the support modules 34 of the first section 16. Consequently, the generally U-shaped stop 66 of the lower section 38 of each of the support modules 34 is directed inwardly towards the space between the foundation sections 16, 18. Like the wire support modules 34 pivotally secured to the base 24 of the first section 16, the wire support modules 34 of the second section 18 are pivotally secured to the cross rails 74, 76 of the second base 18, as shown in
The second section 18 of the bedding foundation 10 further comprises a second wire grid 82 comprising a plurality of spaced, parallel longitudinal grid wires 84 and a plurality of spaced, parallel transverse grid wires 86 intersecting with the longitudinal grid wires 84 at intersections 88. Further, the transverse grid wires 86 may be secured with weld, for example, to the longitudinal grid wires 84 at intersections 88. An outer border wire 90 of a generally rectangular shape surrounds the longitudinal grid wires 84 and transverse grid wires 86, and forms a part of the second wire grid 82. The ends of the longitudinal grid wires 84 and transverse grid wires 86 are wrapped around, welded, or otherwise secured to the border wire 90, as is conventional.
The upper sections 40 of each wire support module 34 of the second section 18 are pivotally secured to the second wire grid 82 in the same manner they are secured to the first wire grid 44. The configuration of the wire support module 34 allows for a snap-fit of the transverse grid wires 86 of the second wire grid 82 relative to the upper section 40 of the module 34, so the wire support module 34 may pivot relative to the second upper grid 82.
Referring now to
The bedding foundation 10 is configured such that when in a folded or collapsed condition or position (seen in
Referring to the drawings, each wire support module 34 has a shape that prevents lateral shifting of the wire grid engaged with the module 34 relative to the base stapled to the module 34.
As best seen in
The embodiments of the invention shown and described are for illustrative purposes only. The drawings and the description shall not limit in any way the scope of the invention as defined in the claims. While those skilled in the art may make various changes to, or additional embodiments of, the invention, none of those changes/embodiments shall be deemed to depart from the spirit of the invention. Thus, all such changes/embodiments shall be embraced by the scope of the invention as defined in the claims. Accordingly, the invention is to be limited only by the scope of the following claims and their equivalents.