Bed foundation having a structural foam perimeter utilizing mechanical interlocking

Abstract

A bed foundation includes, in an advantageous form, a sidewall frame, a box-spring array, at least one spring interconnect, and at least a first structural foam layer. The sidewall frame includes a plurality of interlocking frame members. The sidewall frame has a frame interior, a frame top, and a frame bottom. The box-spring array is received within the frame interior and includes a plurality of springs. The at least one spring interconnect extends from the sidewall frame and into the frame interior. At least one spring interconnect interacts with at least one spring to thereby aid in retaining that at least one spring in place relative to the sidewall frame. The first structural foam layer is attached to one of the frame top and the frame bottom and extends thereacross. Advantageously, this first structural foam layer forms a mechanical interlock with the sidewall frame at the given one of frame top and the frame bottom to which it is attached.

Description

BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to a bed support or foundation having a perimeter formed of structural foam, and more particularly to a structural foam perimeter which utilizes mechanical interlocking to attach the various structural foam portions to each other and / or to a box spring set carried therewithin. [0003] 2. Description of the Related Art [0004] Most beds available today employ a form of a bed support. With the use of a standard mattress, this bed support typically comes in the form of a set of box springs. In the case of a waterbed, this bed support is generally designed to enclose a waterbed bladder carried therewithin. Other bed supports may incorporate another type of interior support member such as an air bladder or a foam insert. [0005] When the bed support is a standard set of box springs, there are certain associated drawbacks therewith. Such drawbacks include, but are not limited to, the “edge roll”...

AI Technical Summary

Benefits of technology

[0014] An advantage of the present invention is that the cost of manufacturing such a bed foundation, utilizing the mechanically interconnecting members of the present invention, is reduced over the cost associated with supports using standard box springs and with those using structural foam members attached via a resin, glue, or other adhesive, due to cost savings related to both assembly and parts.

[0015] Another advantage of the present invention is that the ability of the foam perimeter to interlock at least with a portion of the perimeter springs within the box-spring array helps to reduce the occurrence of “edge roll”.

[0016] Yet another advantage of the present invention is that it permits the creation of a tub / box that is capable of supporting / containing any one of a foam support insert, a box-spring array, an air bladder, a water bed bladder, or other interior support mechanism / system.

[0017] A series of advantages are associated with the use of a foam tub / box is that such a tub or box has an inherently cushiony feeling and is reasonably durable, sufficiently supportive, and inexpensive to produce.

[0018] An even further advantage of the present invention is that structural foam pieces can be cut to shape using computer controlled machinery (e.g., die cutting machines), thereby increasing the efficiency and accuracy possible with their production.

[0019] An additional advantage of the present invention is that the foam members will aid in dampening spring noise associated with a standard set of box springs.

Problems solved by technology

Such drawbacks include, but are not limited to, the “edge roll” that occurs as consumers sit or lay on or very near the edge of the bed.

While there have been some attempts in the art to correct this “edge roll” the results have been less than ideal and have been generally labor intensive (as an example, the use of twist ties to attempt to attach the perimeter springs with adjacent interior springs within the box-spring array).

One drawback is the spring noise which can be associated therewith.

Additionally, the standard set of box springs generally requires the employment of a significant amount of wood and carpentry expertise, thereby contributing to the expense thereof.

However, such polyurethane perimeters have generally required a gluing step for their attachment to one another.

There are several problems associated with such gluing.

Gluing is a labor intensive process; gluing creates emissions of gas that may potentially be noxious to those working with and around them; and such glue requires a certain period in which to set, thereby necessitating a large number of premade supports taking up a large area of factory space and thereby decreasing the potential throughput of bed supports created during a production cycle.

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