BOX SPRING ASSEMBLIES EMPLOYING FOAM CUSHIONING GRIDS, AND RELATED COMPONENTS, MATTRESS ASSEMBLIES, AND METHODS
Box spring assemblies employing foam cushioning grids, and related components, mattress assemblies, and methods are disclosed. Foam cushioning grids are comprised of a plurality of foam grid members that are interconnected to form the foam cushioning grid. By interconnecting the foam grid members, a plurality of voids may be disposed between the interconnecting foam grid members as part of the foam cushioning grid. In this manner, as a non-limiting example, the foam cushioning grid can be disposed on a wire grid, such as in box springs, to provide cushioning support for the wire grid, as one non-limiting example. A load placed on the wire grid will be cushioned by the foam cushioning grid disposed therebetween. Further, as a non-limiting example, voids in the foam cushioning grid allow air to easily flow between the interconnected foam grid members.
The present application claims priority to U.S. Provisional Patent Application Ser. No. 61/608,810 filed on Mar. 9, 2012 entitled “Foam Grid Foundation Cushion,” which is incorporated herein by reference in its entirety.
FIELD OF DISCLOSUREThe technology of the disclosure relates generally to mattress cushions, assemblies, mattresses, and related methods for providing support.
BACKGROUNDInnerspring assemblies are a type of mattress core utilized for mattresses or seating structures and may be composed of spring coils attached together in a matrix or array. An example of such an innerspring assembly (“innerspring”) is illustrated by an innerspring 12 depicted in
With reference to the mattress 10 in
Mattresses, such as the mattress 10 in
Embodiments disclosed herein include box spring assemblies employing foam cushioning grids, and related components, mattress assemblies, and methods. Foam cushioning grids are comprised of a plurality of foam grid members that are interconnected to form the foam cushioning grid. By interconnecting the foam grid members, a plurality of voids may be disposed between the interconnecting foam grid members as part of the foam cushioning grid. In this manner, as a non-limiting example, the foam cushioning grid can be disposed on a wire grid, such as in a box springs, to provide cushioning support for the wire grid, as one non-limiting example. A load placed on the wire grid will be cushioned by the foam cushioning grid disposed therebetween. Further, as a non-limiting example, voids in the foam cushioning grid allow air to easily flow between the interconnected foam grid members between the box springs and a mattress disposed on the box springs. This is opposed to a solid sheet of foam that does not contain voids in this example. Further, the foam grid members may be tenably formed from closed cell foam, because the voids allow air flow without requiring air to flow through the foam grid members themselves. Closed cell foam cushioning members, such as those comprised of Polyethylene closed foam material, will not absorb moisture or odor, and will not contribute to mold and/or mildew growth.
In this regard, in one embodiment, a box spring assembly for supporting a mattress is provided. The box spring assembly comprises a frame having a first elongated end and a second elongated end opposite the first elongated end. The box spring assembly also comprises a plurality of elongated support members extending from the first elongated end of the frame to the second elongated end of the frame. The box spring assembly also comprises a wire support structure. The wire support structure comprises a plurality of wire springs each having a first end supported by the plurality of elongated support members. The plurality of wire springs is configured to support a mattress. The wire support structure also comprises a planar-shaped wire grid interconnecting the plurality of wire springs on a second end of the plurality of wire springs opposite the first end of the plurality of wire springs. A foam cushioning grid is disposed on the planar-shaped wire grid to provide cushioning between the planar-shaped wire grid and a mattress disposed on top of the planar-shaped wire grid.
In another embodiment, a method of assembling a box spring assembly for supporting a mattress is provided. The method comprises providing a frame having a first elongated end and a second elongated end opposite the first elongated end. The method also comprises providing a plurality of elongated support members extending from the first end of the frame to the second end of the frame. The method also comprises providing a wire support structure on the frame, which comprises providing a plurality of wire springs each having a first end supported by the plurality of elongated support members. The plurality of wire springs is configured to support a mattress, and interconnects the plurality of wire springs on a second end of the plurality of wire springs opposite the first end of the plurality of wire springs to provide a planar-shaped wire grid. The method also comprises disposing a foam cushioning grid on the planar-shaped wire grid to provide cushioning between the planar-shaped wire grid and a mattress disposed on top of the planar-shaped wire grid.
With reference now to the drawing figures, several exemplary embodiments of the present disclosure are described. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.
Embodiments disclosed herein include box spring assemblies employing foam cushioning grids, and related components, mattress assemblies, and methods. Foam cushioning grids are comprised of a plurality of foam grid members that are interconnected to form the foam cushioning grid. By interconnecting the foam grid members, a plurality of voids may be disposed between the interconnecting foam grid members as part of the foam cushioning grid. In this manner, as a non-limiting example, the foam cushioning grid can be disposed on a wire grid, such as in a box springs, to provide cushioning support for the wire grid, as one non-limiting example. A load placed on the wire grid will be cushioned by the foam cushioning grid disposed therebetween. Further, as a non-limiting example, voids in the foam cushioning grid allow air to easily flow between the interconnected foam grid members between the box springs and a mattress disposed on the box springs. This is opposed to a solid sheet of foam that does not contain voids in this example. Further, the foam grid members may be formed from closed cell foam as one example, because the voids allow air flow without requiring air to flow through the foam grid members themselves. Closed cell foam cushioning members, such as those comprised of Polyethylene closed foam material, will not absorb moisture or odor, and will not contribute to mold and/or mildew growth.
In this regard,
A top view of foam cushioning grid 62 apart from the box springs 40 is shown in
Further, as a non-limiting example with continuing reference to
The interconnected foam grid members 64 may be of any thickness desired. The thickness of the foam grid members 64 as well as the type of foamed material of the foam grid member 64 will determine the foam cushioning grids' 62 cushioning characteristics. The cushioning characteristics will determine the internal load deflection (ILD) of the foam cushioning grid 62. For example, the foam grid members 64 may be between 0.1 and 0.5 inches thick, as a non-limiting example. The foam grid members 64 may also be of any width desired (e.g, up to six (6) inches in width). The width of the foam grid members 64 may be designed to provide the desired coverage or overlay area of the foam grid members 64 on the wire members 56 of the wire grid 58 of the box springs 40. For example, the foam grid members 64 in the foam cushioning grid 62 in
The foam cushioning grid 62 may be formed from any foamed material desired. These material examples include, but are not limited to, a polymer, a polymer foam, latex, viscoelastic, polystyrene, polyolefin, polyethylene, polybutane, polybutylene, polyurethane, polyester, ethylene acrylic copolymer, ethylene-vinyl-acetate copolymer, ethylene-methyl acrylate copolymer, ethylene-butyl-acrylate copolymer, ionomer, polypropylene, copolymer of polypropylene, latex rubber, thermoset material, and the like, as non-limiting examples. Further, the foam cushioning grid 62 may be formed from a combination of thermoset and thermoplastic foamed material(s), to provide composite cushioning characteristics. For example, the foam cushioning grid 62 may be comprised of a composite foamed material as provided in U.S. Pat. No. 8,356,373, entitled “Unitary Composite/Hybrid Cushioning Structure(s) and Profile(s) Comprised of a Thermoplastic Foam(s) and a Thermoset Material(s),” and U.S. patent application Ser. No. 13/026,979, entitled “Composite Cushioning Structure(s) With Spatially Variable Cushioning Properties and Related Materials, Cushioning Assemblies, and Methods for Producing Same,” both of which are incorporated herein by reference in their entirety. Further, the foam cushioning grid 62 may include filler, including but not limited to, a ground foam reclaim material, a nano clay, a carbon nano tube, calcium carbonate, flyash, and corc dust, as examples.
Other foam cushioning grids having different sizes of foam grid members are also possible. In this regard,
The foam cushioning grid can be provided of any size or shape for different sizes of box springs (e.g., king, queen, full, twin, single, etc.). The aforementioned foam cushioning grid can be compatible with and provide cushioning to other structures other than box springs, including various mattress cores including, but not limited to, innersprings, including coil and pocketed-coil innersprings, and other partial or all foam mattress cores.
Those skilled in the art will recognize improvements and modifications to the embodiments disclosed herein. Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having benefit of the teachings presented in the foregoing descriptions and the associated drawings.
Attachment members can be provided in the elastic foam edge-support band, but are optional and not required. If included, the number of attachment members can be varied as desired. The materials or compositions of the aforementioned components can be varied as well, including but not limited to whether exclusively thermoset or thermoplastic materials, or a composite of both. All such improvements and modifications are considered within the scope of the concepts disclosed herein.
Claims
1. A box springs assembly for supporting a mattress, comprising:
- a frame having a first elongated end and a second elongated end opposite the first elongated end;
- a plurality of elongated support members extending from the first elongated end of the frame to the second elongated end of the frame;
- a wire support structure, comprising: a plurality of wire springs each having a first end supported by the plurality of elongated support members, the plurality of wire springs configured to support a mattress; and a planar-shaped wire grid interconnecting the plurality of wire springs on a second end of the plurality of wire springs opposite the first end of the plurality of wire springs;
- a foam cushioning grid disposed on the planar-shaped wire grid to provide cushioning between the planar-shaped wire grid and a mattress disposed on top of the planar-shaped wire grid.
2. The box springs assembly of claim 1, wherein the foam cushioning grid is comprised of an interconnected plurality of foam grid members.
3. The box springs assembly of claim 2, wherein the wire grid is comprised of an interconnected plurality of wire members.
4. The box springs assembly of claim 3, wherein the interconnected plurality of foam grid members are each disposed on at least a portion of a wire member among the interconnected plurality of wire members.
5. The box springs assembly of claim 3, wherein the interconnected plurality of foam grid members disposed on the planar-shaped wire grid completely cover each of the interconnected plurality of wire members.
6. The box springs assembly of claim 3, wherein the interconnected plurality of foam grid members disposed on the planar-shaped wire grid do not completely cover each of the interconnected plurality of wire members.
7. The box springs assembly of claim 3, wherein at least a portion of at least one of the interconnected plurality of foam grid members is not disposed directly over any interconnected plurality of wire members.
8. The box springs assembly of claim 2, wherein the interconnected plurality of foam grid members are only disposed in parallel and orthogonal to the first elongated end of the frame and the second elongated end of the frame.
9. The box springs assembly of claim 2, wherein the interconnected plurality of foam grid members are up to 0.5 inches in thickness.
10. The box springs assembly of claim 2, wherein the interconnected plurality of foam grid members are up to (6) inches in width.
11. The box springs assembly of claim 2, wherein the interconnected plurality of foam grid members are wider than a width of any portion of the interconnected plurality of wire members.
12. The box springs assembly of claim 2, comprising a plurality of voids disposed between the interconnected plurality of foam grid members.
13. The box springs assembly of claim 12, wherein a surface area of the interconnected plurality of foam grid members is greater than an area of the plurality of voids.
14. The box springs assembly of claim 12, wherein the plurality of voids comprise a plurality of rectangular-shaped voids and a plurality of triangular-shaped voids.
15. The box springs assembly of claim 12, wherein the plurality of voids comprise a plurality of arc-shaped voids.
16. The box springs assembly of claim 12, wherein the interconnected plurality of foam grid members comprise a plurality of arc-shaped foam grid members.
17. The box springs assembly of claim 1, wherein the foam cushioning grid is symmetrical about a center longitudinal axis of the foam cushioning grid and a center latitudinal axis of the foam cushioning grid.
18. The box springs assembly of claim 2, wherein the interconnected plurality of foam grid members comprises a plurality of foam grid members disposed parallel to the first elongated end and the second elongated end, and a plurality of foam grid members disposed orthogonal to the first elongated end and the second elongated end.
19. The box springs assembly of claim 18, wherein the interconnected plurality of foam grid members further comprises a plurality of foam grid members angularly disposed to the first elongated end and the second elongated end.
20. A method of assembling a box springs assembly for supporting a mattress, comprising:
- providing a frame having a first elongated end and a second elongated end opposite the first elongated end;
- providing a plurality of elongated support members extending from the first end of the frame to the second end of the frame;
- providing a wire support structure on the frame, comprising: providing a plurality of wire springs each having a first end supported by the plurality of elongated support members, the plurality of wire springs configured to support a mattress; and interconnecting the plurality of wire springs on a second end of the plurality of wire springs opposite the first end of the plurality of wire springs to provide a planar-shaped wire grid; and
- disposing a foam cushioning grid on the planar-shaped wire grid to provide cushioning between the planar-shaped wire grid and a mattress disposed on top of the planar-shaped wire grid.
Type: Application
Filed: Mar 11, 2013
Publication Date: Sep 12, 2013
Inventor: Julian Thomas Young (Zebulon, NC)
Application Number: 13/792,868
International Classification: A47C 23/00 (20060101); A47C 23/05 (20060101);