FIELD OF THE INVENTION

[0001] 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

[0002] 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.

[0003] 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.

[0004] U.S. Patent 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.

[0005] U.S. Patent 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.

[0006] 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

[0007] 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.

[0008] 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.

[0009] 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.

[0010] 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.

[0011] 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.

[0012] 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.

[0013] 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

[0014] 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:

[0015] Fig. 1 is a perspective view of one embodiment of the bedding foundation of the present invention in an erected condition without a cover;

[0016] Fig. 1 A is a bottom view of the bedding foundation of Fig. 1 ;

[0017] Fig. 2 is a side elevational view of the bedding foundation of Fig. 1 in an erected condition;

[0018] Fig. 3 is a side elevational view of the bedding foundation of Fig. 1 being collapsed;

[0019] Fig. 4 is a side elevational view of the bedding foundation of Fig. 1 in a collapsed condition;

[0020] 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;

[0021] 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;

[0022] 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;

[0023] Fig. 8 is a perspective view of one lower connector showing the foundation in a collapsed condition; [0024] 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

[0025] Fig. 10 is a perspective view of an upper connector which may be used in accordance with the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODI ENTS

[0026] 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.

[0027] 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.

[0028] Referring to Figs. 1 , 1A 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. [0029] 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.

[0030] 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.

[0031] 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.

[0032] 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.

[0033] 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.

[0034] 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 80 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.

[0035] 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.

[0036] 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.

[0037] 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. [0038] 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.

[0039] 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.

[0040] 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 Fig. 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.

[0041] 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.

[0042] 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.

[0043] What is claimed is: