A body support, such as a mattress or box spring for seats, chairs or beds

Abstract: A body support, such as a mattress, box spring or the like for seats, chairs or beds, is disclosed which is foldable between a use position wherein it extends in a generally horizontal plane and a storage position wherein one section overlies the other section. The body support includes a plurality of support members (16; 92) movable between erect and retracted positions in response to movement of the body support between the use and storage positions, thereby resulting in an article of reduced depth and length when in the storage position. One embodiment disclosed (Figures 1 to 10) relates to a box spring and a second embodiment (Figures 11 to 17) relates to a mattress. The support members (16; 92) are mounted for pivotal move­ ment between upper and lower frames (22, 24, 26 and 10, 12, 14, 70, 72) and are automatically urged to move from the erect to the retracted or collapsed position by relative movement between first and second sections (C, D; F, G) of the framework of the support from a coplanar attitude to a juxta-posed one.

Description: This invention concerns a body support, such as a mattress, or a box spring, for seats, chairs or beds. Conventional body supports, such as box springs or mattresses, typically include an array of coil springs for supporting the body. The upper ends of the coil springs are attached to a wire grid made from a low carbon wire of limited resilience. The perimeter of the grid is attached to a border wire. Although such coil spring arrangements have provided adequate body supports, they are relatively expensive to manufacture and assemble into box springs or mattresses. Additionally, conventional box springs and mattresses 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 or mattress manufacturer. The aforementioned step is performed by means of a press machine enabling the spring units to be compressed to reduce their dimension. The coil spring units of each pack are held in their compacted stage 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 a dangerous step because of the high degree of tension to which the strapping is subjected by the compression of the coil springs. As can be seen from United States Patent Specification No. 4,377,279, one proposal has been made for providing a wire foundation unit for a box spring which unit can be shipped to the box spring manufacturer in a compact state. The manufacturer would erect the foundation wires and then fix by staples, rigid struts between the wire unit and the base to permanently secure the wire unit in the erected position. The box spring manufacturing process would then be 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. The present invention seeks to provide a construction for a body support, such as a box spring, mattress or seat, which construction eliminates the need to rely on conventional coil springs for support. The present invention also seeks to provide a body support for a bed, seat or like article which will reduce the unit costs of manufacturing, handling, storage and shipment thereof. It is related to the inventions disclosed in our European Patent Application Nos. 84300783.2 (Publication No. 0151840) and 84308128.2. This is achieved by providing a body support that may be packaged, stored or transported prior to use in a depressed or collapsed state and later expanded or erected to a use position at the point of use. Such a body support, once erected for use, display or otherwise may be subsequently collapsed or depressed into a compact state for storage, handling or shipment and then be again erected for use or otherwise, the conversion being repeatable as often as desired. Thus the body support may be repeatedly adjusted between a position of use and a storage position, in which the depth and length dimensions of the body support have been substantially reduced, by folding it upon itself into two overlying sections to decrease the length thereof for storage, handling or shipment. According to the present invention then, a body support comprising interconnected upper and lower border frames having support means of wire-like material extending across the frames from side-to-side, and comprising a plurality of upper and lower runs, is characterised in that each run is formed from a series of spring members having a loop or coil portion on one end and a hook on the other end, the hook of one member being engaged in the loop of the adjacent member to link the members together in chain-like fashion, opposite ends of each run being connected to the side members of the frames. The support members may be formed by spring wire bent into non-spiral, generally two-dimensional, shapes including serpentine or sinusoidal portions extending generally in the same planes. Extending lengtwise across the top of the support members at spaced intervals a plurality of runners may be provided formed of spring wire with offset portions movably attached to the support members. The invention will now be further described by way of example with reference to the accompanying drawings, in which: Fig. 1 is a side, elevational view of a mattress according to the invention shown in the use position and with certain portions removed and others broken away for clarity; Fig. 2 is a transverse, cross-sectional view taken generally along lines 2-2 of Fig. 1; Fig. 3 is a fragmental, plan view of the mattress; Fig. 4 is a transverse cross-sectional view taken generally along lines 4-4 of Fig. 1; and Fig. 5 is a plan view of the structure shown in Fig. 4. Referring to the drawings, there is illustrated an embodiment of the present invention in the form of a mattress which basically includes two sections generally designated F and G interconnected by an intermediate or transition section H as shown in Fig. 1. Sections G and F each include upper and lower generally rectangular frames each of which is formed by a rectangular border wire and runner wires extending longitudinally thereof. The border wire of each section may be made from one piece and includes opposite side portions 70, inner end portions 72 as best shown in Fig. 5 and outer end portions 73. Extending between the opposite end portions of the border wire and movably attached thereto by clips are a plurality of runners 75 (see Fig. 3) having a plurality of laterally extending offset portions 76. The outermost positioned runners 75 are also attached to the side portion 70 of the border wires by clips 77 as best shown in Fig. 3. The upper and lower frames are formed by identical border wire arrangements with their inner end portions 72 serving to form pivots for folding the sections G and F relative to each other and transition section H. Referring to Figs. 1, 4 and 5, sections G and F are interconnected by the transition section H through means including straight wire connecting links 80 interconnecting the side portions 70 of the border wires of Sections G and F; and a plurality of flexible and resilient constraining means formed of spring wire and generally designated 82 in Fig. 5. In the specific embodiment shown, the latter each include a lower generally inverted U-shaped part 84 having opposite legs coiled about adjacent inner border wire portions 72 of the lower frames and an upper generally U-shaped part 85 having opposite legs coiled about the adjacent inner border wire portions 72 of the upper frames. The lower part 84 is formed with coils at its mid-section received about the mid-section of the upper part 85 as best shown in Fig. 1. As shown in Figs. 4 and 5, a plurality of the constraining means are employed throughout the transition section H across the mattress at uniformly spaced locations. The constraining means function to keep the pivot axes defined by the inner border wire portions 72 in the proper rectangular interrelationship with each other as shown in Fig. 1 to permit the sections F and G to be pivotable relative to the transition section H between the use and storage positions. The use position is shown in Fig. 1 wherein sections G, F and H extend in horizontal coplanar relationship. In the storage position, one section G or F is folded over the other section with the transition section H extending generally at right angles to the sections G and F. Referring to Figs. 1 and 2, the frame members in the illustrated embodiment include a plurality of interconnected springs each of which includes an upper generally rectilinear run 90, and a lower generally rectilinear run 91 whilst a generally V-shaped intermediate run 92 forms the support members, all of the aforementioned portions lying generally in the same plane. The upper and lower runs 90 and 91 are united to the intermediate runs 92 through means of coil portions 93 while the intermediate runs 92 converge at a coil portion 94. In the preferred embodiment, each of the wire portions including the coils are formed integral with each other from the same piece of spring wire. As shown in Figs. 2 and 3, the extremities of the upper and lower runs 90, 91 are formed with hook portions 95 through which the springs in each row are interconnected by placing the hook portions 95 in and about the coil portions 93 of the adjacent spring. The hook portions 95 in the illustrated embodiment are offset inwardly from the runs 90, 91 to permit their receipt in coils 93. It will thus be seen when the springs in each row are assembled, the upper rectilinear runs 90 will extend in generally a straight line across the mattress and the lower rectilinear runs 91 will extend in a generally straight line located below and in generally the same plane as the upper runs 90. Additionally, the intermediate coils 94 will be in general horizontal alignment. When the mattress is folded into the storage position, that is, with one section G or F located over the other section, the support springs will pivot from their erect position shown in Fig. 1 to a retracted position (not shown). To this end, the upper and lower runs 90, 91 of the springs are pivotally attached to the longitudinally extending runners 75 at the offset portions 76 by means of suitable clips 96 so that when pivoting between their erect and retracted positions, the springs will pivot relative to the upper and lower runners 75 and, or course, the upper and lower border wires 70, 72 which, together with the runners 75, form the upper and lower frames of the mattress. When the mattress is unfolded from its storage position to the use position shown in Fig. 1, the springs will, of course, pivot upwardly into their erect positions shown in Fig. 1. The erect position of the srings is determined by the constraining means 84, 85 described above which prevents the springs from pivoting beyond their 90 degree erect position when the mattress is unfolded. Additionally, once the mattress is in the use position of Fig. 1, the constraining means 84, 85 will prevent the springs from pivoting out of their erect positions as long as the mattress sections G, F and H are in the coplanar horizontal position shown in Fig. 1. Upon reflection of the springs when a load is placed on the mattress in the use position, the intermediate portions 92 of the springs will remain generally in the same plane as the upper and lower runs 90, 91 of the springs and will not deflect laterally to either side even though deflection of the springs will occur about the axes passing through coils 94 of the intermediate portions 92 of the springs. It will also be noted that due to the upper and lower rectilinear runs 90, 91 of the springs, restraining cross-wires are not required. In order to provide added support at the sides of the mattress, a double spring arrangement may be provided along the sides of the mattress shown, for example, on the right-hand side of Fig. 2. In this double spring arrangement, a pair of springs are placed in opposed and partially overlapping relationship as best shown in Fig. 2 and with their free extremities clipped together by clips 98 which, in the illustrated embodiment, also serve to attach both springs to the runner 75 in the region of its offset portion 76. Although not shown, this arrangement can be employed throughout the mattress if it is desired to increase the support of the mattress. In one preferred embodiment, the runners 75 are made from fifteen (15) gauge spring wire while the support springs are made from thirteen (13) gauge spring wire. Of course, other spring configurations and gauges may be employed in keeping with the present invention. The use of the runners 75 and the support springs of the present invention replaces conventional grids and coil springs heretofore used in mattress construction, while providing greater resilient support at a cost believed to be significantly less than conventional spring mattress constructions. In use of the mattress, the sections G and F amy be placed into generally coplanar positions as best shown in Fig. 1 where the springs will provide a comfortable resilient support surface. If it is desired to fold the mattress for storage of handling one section G or F may be swung about the pivotal axes passing through the inner border wire portions 72 to place it into overlying relationship with the other section. By virtue of the fact that the support springs are constrained they will pivot relative to the upper and lower frames into the retracted position. During such pivotal movement, the constraining means will function to keep the pivot axes defined by the inner border wire portions 72 in the proper rectangularly spaced relationship relative to each other to achieve the desired movement of the sections. If later it is desired to convert the mattress back to the use position, one section merely has to be unfolded into the horizontal position which will actuate the springs to their erect position shown in Fig. 1 to provide the desired resilient support in use. It should also be noted that the erect position of the support springs is maintained against unwanted or undesirable collapsing movement when the mattress sections are in the coplanar horizontal use positions by virtue of the constraining means which will prevent the springs from pivoting out of their erect positions. Although, not shown, any suitable cover and padding may be employed on or about the mattress frames and springs; it being understood that such elements having been excluded from the drawings for the sake of clarity. The space provided between the folded mattress sections F and G by the transition section will accommodate the padding and cover of the mattress when folded.

Claims: A body support for use in bedding or seating structures comprising interconnected upper and lower border frames (70, 72, 73) having support means of wire-like material extending across the frames from side-to-side, and comprising a plurality of upper and lowers runs (90, 91), characterised in that each run is formed from a series of spring members having a loop or coil portion (93) on one end and a hook (95) on the other end, the hook (95) of one member being engaged in the loop (93) of the adjacent member to link the members together in chain-like fashion, opposite ends of each run being connected to the side members (70) of the frames. A body support as claimed in claim 1, characterised in that the runs of the or each of the support means are generally straight and extend in generally the same plane. A body support as claimed in claim 1 or 2, characterised in that the each of the support means includes intermediate runs (92) interconnecting the upper and lower runs (90, 91). A body support as claimed in claim 3 characterised in that the interconnecting intermediate runs (92) have coiled, sinusoidal or serpentine portions. A body support as claimed in claim 3 or 4, characterised in that the intermediate runs (92) are formed from spring wire and are integral with the upper and lower runs (90, 91). A body support as claimed in any one of claims 1 to 5, characterised in that the support means comprise a plurality of runners (75) of spring wire material extending in spaced rows over and across the runs (90) of the spring members. A body support as claimed in claim 6, characterised in that the runners (75) include offset portions (76) connected to the upper runs (90) of the support means at their points of intersection.

Inventors: MILLER JOHN E, MILLER, JOHN E.
Applicants: PARMA CORP, PARMA CORPORATION
Application year: 1985
Main classification: A47C23
IPC codes: A47C27