Patent Publication Number: US-2012042449-A1

Title: Collapsible Bedding Foundation

Description:
FIELD OF THE INVENTION 
     This invention relates generally to bedding foundations and, more particularly, to a bedding foundation which is collapsible for storage and shipment. 
     BACKGROUND OF THE INVENTION 
     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&#39;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. 
     SUMMARY OF THE INVENTION 
     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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       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: 
         FIG. 1  is a perspective view of one embodiment of the bedding foundation of the present invention in an erected condition without a cover; 
         FIG. 1A  is a bottom view of the bedding foundation of  FIG. 1 ; 
         FIG. 2  is a side elevational view of the bedding foundation of  FIG. 1  in an erected condition; 
         FIG. 3  is a side elevational view of the bedding foundation of  FIG. 1  being collapsed; 
         FIG. 4  is a side elevational view of the bedding foundation of  FIG. 1  in a collapsed condition; 
         FIG. 5  is a perspective view of a wire support module engaged with an upper wire grid and a base with the foundation in an erected condition; 
         FIG. 6  is a perspective view of the wire support module of  FIG. 5  engaged with an upper wire grid and a base with the foundation in a collapsed condition; 
         FIG. 7  is a perspective view of another wire support module of the foundation of  FIG. 1  engaged with an upper wire grid and a base with the foundation in a collapsed condition; 
         FIG. 8  is a perspective view of one lower connector showing the foundation in a collapsed condition; 
         FIG. 9  is a perspective view of the lower connector of  FIG. 8  in a planar orientation showing the living hinges of this lower connector; and 
         FIG. 10  is a perspective view of an upper connector which may be used in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     Referring to the drawings, and particularly to  FIGS. 1 and 1A , there is illustrated a collapsible bedding foundation  10 . The bedding foundation  10  has a pair of end surfaces  12  defining a length or longitudinal dimension L of the foundation  10  and a pair of opposed side surfaces  14  defining a width W of the foundation  10 . The bedding foundation  10  has a first section  16  hinged to a second section  18  with a plurality of upper connectors  20  and a plurality of lower connectors  22  (see  FIG. 1 ). In particular, the spaced lower connectors or hinges  20  are joined to adjacent first and second bases  24 ,  26 . Although  FIG. 1A  shows three spaced apart lower connectors  22 , each extending between and being secured to a lower surface of the first and second bases  24 ,  26 , the foundation may have any number of lower connectors or hinges. The lower hinges or connectors  22  enable the bedding foundation  10  to move from an erected position shown in  FIGS. 1 and 2  to a collapsed position shown in  FIG. 4  (the transition from erected position to collapsed position is shown in  FIG. 3 ). The lower connectors  22  are shown and described in more detail in  FIGS. 8-9 . 
     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  FIGS. 1 ,  1 A and  2 , the first section  16  comprises a first base  24  having a generally rectangular frame  25  comprising a pair of opposed end rails  28  and a pair of opposed side rails  30 . A plurality of cross rails  32 , including outermost cross rails  33  which rest atop the end rails  28 , extend between the side rails  30 , as is conventional. As best shown in  FIG. 1A , a center rail  35  extends between the opposed end rails  28  and is generally parallel the side rails  30 . 
     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  FIGS. 5 and 6 . Each wire support module  34  is made of one piece of wire and includes a lower section or foot  38  and an upper section or top  40 . The upper and lower sections  38 ,  40  are joined with spaced, parallel legs  42 . The lower section  38  of each wire support module  34  is generally planar and stapled to one of the cross rails  32 ,  33  of the first base  24  with staples  36  so the wire support module  34  may pivot relative to the first base  24  as the module  34  moves between an erect position shown in  FIG. 5  and a collapsed position shown in  FIG. 6 . When the bedding foundation  10  is in its erected condition or position as shown in  FIGS. 1 and 2 , the legs  42  of the wire support modules  34  are substantially vertically oriented, and the upper and lower sections  40 ,  38  of the wire support modules  34  are substantially horizontally oriented as shown in  FIG. 5 . 
     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  FIGS. 5 and 6 , the upper section  40  of each wire support module  34  of the first section  16  is pivotally secured to the first wire grid  44  due to the configuration of the upper section  40 . More particularly, the upper section  40  of each wire support module  34  has a pair of generally U-shaped shoulders  54 , each shoulder  54  comprising a base  56  and a pair of arms  58 ,  60  extending outwardly from opposed ends of the base  56 . For purposes of this document, arm  58  will be considered an inner arm and arm  60  considered an outer arm. As shown in  FIGS. 5 and 6 , one of the transverse grid wires  48  of the first wire grid  44  passes underneath the inner arms  58  and over the outer arms  60  of each of the shoulders  54 . Each of the longitudinal grid wires  46  passes underneath the transverse grid wire  48  and over the base  56  of each of the shoulders  54 . The shoulders  54  and, more particularly, the inner arms  58  of the shoulders  54  are joined by a linear upper connector  62 . The unique configuration of the upper section  40  of the module  34  allows for a snap-fit of one of the transverse grid wires  48  relative to the upper section  40  of the module  34 , so the wire support module  34  may pivot relative to the first wire grid  44 . This configuration of the upper section  40  prevents lateral shifting between the first wire grid  44  and first base  24 . 
     As best seen in  FIGS. 5 and 6 , the lower section  38  of each wire support module  34  of first section  16  is pivotally secured to one of the cross bars  32 ,  33  of the first base  24 . More particularly, the lower section  38  of each wire support module  34  comprises a pair of aligned extensions  64 , each extension  64  extending inwardly from one of the legs  42  of the module  34 . The extensions  64  of each module  34  are joined together by a generally U-shaped stop  66 . As shown in the drawings, the extensions  64  of each module  34  are stapled to one of the cross bars  32 ,  33  of the first base  24 . Due to the configuration of the lower section  38  when the module  34  is in an erected position, the stop  66  engages and contacts one of the cross bars  32 ,  33  of the first base  24 . See  FIG. 5 . As shown in  FIG. 6 , when the module  34  is in a collapsed position, the stop  66  is generally perpendicular to the cross bars  32 ,  33  of the first base  24  in a generally vertical plane and does not contact one of the cross bars  32 ,  33  of the first base  24 . Thus, the extensions  64  of each module  34  define a pivot axis about which the module  34  pivots. 
     Referring to  FIGS. 1 and 2 , the second section  18  of the bedding foundation  10  comprises a second base  26  having a generally rectangular frame  68  comprising a pair of opposed end rails  70  and a pair of opposed side rails  72 . A plurality of cross rails  74 , including outermost cross rails  76  which rest atop the end rails  70 , extend between the side rails  72 , as is conventional. As best shown in  FIG. 1A , a center rail  78  extends between the opposed end rails  70  and is generally parallel the side rails  72 . 
     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  FIG. 7 , using staples  36  in the same manner describe above and illustrated herein. 
     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  FIGS. 4-8 , the bedding foundation  10  is constructed to be collapsible upon itself into two overlying sections, thus reducing the length approximately in half for storage or shipment. This action is also used to actuate the wire support modules  34  from their erected positions into their retracted or collapsed positions. Unfolding of the bedding foundation  10  places the first and second sections  16 ,  18  in a generally co-planar position, and moves the wire support modules  34  from their retracted position to their erect position. 
     The bedding foundation  10  is configured such that when in a folded or collapsed condition or position (seen in  FIGS. 4 and 8 ), the first and second wire grids  44 ,  82  are directly adjacent and confront one another. However, contact between the first and second wire grids  44 ,  82  is not necessary. Thus in the folded position, the first and second bases  24 ,  26  are positioned outside of the first and second wire grids  44 ,  82 . Due, at least in part, to the configuration of the wire support modules  34 , when the bedding foundation  10  is unfolded to an extended position, the weight of an individual on top of the bedding foundation  10  does not cause the foundation  10  to fold inwardly upon itself. 
     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  FIG. 8 , the lower connectors  22  connect the first base  24  to the second base  26  and, more particularly, connect one of the end rails  28  of the first base  24  to one of the end rails  70  of the second base  26 . As illustrated in  FIGS. 8 and 9 , each lower connector  22  comprises a generally rectangular piece of plastic or any other suitable material. The lower hinge or connector  22  has a middle portion  92  and a pair of end portions  94 , each joined to the middle portion  92  with a living hinge  96  which facilitates bending the lower connector  22  from a generally planar orientation shown in  FIGS. 1A ,  2  and  9  to a generally U-shaped configuration shown in  FIGS. 3 ,  4  and  8 . As seen in  FIG. 8 , the end portions  94  of each lower connector  22  are secured to the end rails  28 ,  70  of the first and second bases  24 ,  26 , respectively, with fasteners  98 . Other means of securing the lower hinge to the bases may be used if desired. In accordance with the present invention, the lower connectors  22  may assume other configurations and be made of any suitable material. Any number of lower connectors, as shown in  FIG. 9 , may be used in accordance with the present invention to secure the bases  24 ,  26 , together, yet still enable the bedding foundation  10  to collapse. 
       FIG. 10  illustrates one of the upper connectors  20  having a pair of grooves  100  each being formed or sized to receive and retain portions of the border wires  52 ,  90  of the first and second sections  14 ,  16 . See  FIG. 1 . Each groove  100  is created by a pair of C-shaped retainers  102  inverted relative to each other. Each upper connector  20  is preferably a unitary plastic part, but may be made of multiple components and/or be made of any desired material. In accordance with the present invention, the upper connector may assume other configurations and be made of any suitable material. Although three upper connectors  20  are illustrated in  FIG. 1 , any number of upper connectors may be used to secure and space the grids of the sections of the bedding foundation, thereby easing the collapsibility of the product. 
     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.