WO1998041127A1

WO1998041127A1 - Improved coil spring unit and base support

Info

Publication number: WO1998041127A1
Application number: PCT/CA1998/000216
Authority: WO
Inventors: Donald G. Eady
Original assignee: Eady Donald G
Priority date: 1997-03-14
Filing date: 1998-03-13
Publication date: 1998-09-24
Also published as: AU6490998A

Abstract

A bed coil spring unit (10) comprising a plurality of joined and interconnected spring cell units (11) and a method of manufacturing the same. Each spring cell unit (11) comprises a plurality of coil springs (21) within long legs (14) which long legs (14) are used to form the coil springs (21). Each spring cell unit (11) has a generally vertical axis (40). The coil springs (21) which make up each spring cell unit (11) are positioned symmetrically about the central axis (40). The plurality of coil springs (21) in each spring cell unit (11) conveniently number four (4).

Description

TITLE

IMPROVED COIL SPRING UNIT AND BASE SUPPORT

INTRODUCTION

This invention relates to an improved bed and, more particularly, to a bed coil spring unit and a base or mattress support.

BACKGROUND OF THE INVENTION

There has been a long and continuing search for the optimum sleeping mattress . The search has taken many forms but, generally, it can be said that a principal comfort factor contributing to a coil spring type is the support which the coil spring unit used in the mattress may give to the user. If the support is comfortable and maintains the body in a condition which applies no unusual force, it will enhance the rest required by the user. Elasticity of the bed coil spring unit is important. This is so since with greater elasticity, more constant support over the area of the body of the user being supported is obtained. To obtain such elasticity, rigid elements comprising the bed coil spring unit should be minimized.

Yet a further comfort factor is the symmetry of the bed coil spring unit. The prior art discloses various configurations of bed coil spring units . A typical one of such configurations is illustrated and disclosed in United States Patent 4,960,267 entitled EDGE-REINFORCED SPRING BEDDING PRODUCT (Scott) . Scott teaches a plurality of helicoils which extend transversely to the body of the user and which are separated a predetermined distance. The helicoils are used to connect adjacent cell units which together comprise the bed coil spring unit. So-called "long legs" extend transverse to the helicoils and define the opposite legs of the individual cell . A pair of coil springs are positioned within the cell with the circumference of each of the coil springs contacting and joined with the helicoils.

A problem with the bed coil spring unit according to the aforementioned Scott reference is that there is no symmetry in the bed coil spring unit within the individual cells . The coil springs are each located closer to one long leg thereby creating an upwardly directed force which acts on one side of the center axis and tends to create a moment acting outside the cell and on the body of a user. This moment has a tendency to move the user toward the side of the bed coil spring unit opposed from the side on which the coil springs are located which is not a comfort contributing factor.

SUMMARY OF THE INVENTION

According to one aspect of the invention, there is provided a bed coil spring unit having ends and sides for use with the reclining body of a user, said bed coil spring unit having a generally longitudinal axis extending between the ends of said unit and being equidistant from said sides of said unit, a plurality of helicoil members spaced a predetermined distance apart, a plurality of long legs extending between said helicoils and being generally parallel to said longitudinal axis of said bed coil spring unit and a plurality of coil springs positioned between said long legs and said helicoils , each of said coil springs having an axis and being positioned between said long legs and said helicoils to form a combination spring cell unit, each of said spring cell units having a central axis extending generally perpendicular to said helicoils and said long legs, said coil springs being located symmetrically about said central axis .

According to a further aspect of the invention, there is provided a method of constructing a bed coil spring unit comprising forming a generally rectangular spring cell unit and interconnecting said spring cell units to form said bed coil spring unit, each of said spring cell units comprising a generally vertical central axis and a plurality of coil springs, said coil springs being positioned symmetrically about said central axis .

According to yet a further aspect of the invention, thee is provided a mattress or base support having a longitudinal axis, said base support comprising a support frame having a pair of side slat supports, a plurality of parallel slats extending between said slat supports and extending transverse to said longitudinal axis , one of said pair of slat supports on each end of each of said plurality of parallel slats, connectors to connect said parallel slats, a central slat support positioned generally between said side slat supports and at least one intermediate slat support arranged between one of said pair of side slat supports and said central slat support.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

A specific embodiment of the invention will now be described, by way of example only, with the use of drawings in which:

Figure 1 is a partial plan view of one corner of the bed coil spring unit illustrating a plurality of spring cell units ;

Figure 2 is a partial side view of the bed coil spring unit of Figure 1 taken along II-II of Figure 1;

Figure 3 is a diagrammatic side view of a mattress supported by the base according to the present invention;

Figure 4 is a diagrammatic isometric view of the base support according to the invention with the slats removed and particularly illustrating the side, central and intermediate slat supports with springs positioned thereon;

Figure 5 is a diagrammatic isometric view of the base support particularly illustrating the plurality of slats extending transverse to the longitudinal axis of the bed according to the invention;

Figure 6 is a diagrammatic plan view of the central and intermediate slat supports in a first configuration according to the present invention;

Figure 7A is a side view of the slats used in the base with the woven connection according to the present invention;

Figure 7B is a plan view of the slats of Figure 7A;

Figure 7C is a side view of a further embodiment of the invention illustrating the slats removed from within various of the woven connectors thereby to vary the supporting force on the user; and Figure 8 is a diagrammatic plan view of a double bed incorporating the teachings according to the present invention.

DESCRIPTION OF SPECIFIC EMBODIMENT

Referring now to the drawings , a bed coil spring unit intended to be incorporated within a sleeping mattress is illustrated generally at 10 in Figure 1. It comprises a plurality of spring cell units , conveniently six (6), which are illustrated in their entirety, each cell being generally illustrated at 11. The spring cell units 11 extend between the sides 12 and ends 13 of the bed coil spring unit 10, it being understood Figure 1 is a partial view of the bed coil spring unit only. Each of the opposed sides 12, only one of which is shown, is defined by a plurality of wire elements , commonly called "long legs" 14, which are joined together using a plurality of wire formed helicoils 20, which helicoils 20 are interwoven with the coil springs 21 as will be described. The helicoils 20 extend across the bed coil spring unit 10 between the sides 12 a predetermined distance apart and are intended to be generally perpendicular to the longitudinal axis 25 of the coil spring bedding unit 10 , it being further understood that the bed coil spring unit 10 illustrated in Figure 1 is a mirror image about the longitudinal axis 25.

In addition to the long legs 14 on the sides 12 of the bed coil spring unit 10, there are also "internal" long legs 22 formed on each side of the spring cell units 11 which internal long legs 22 are parallel to the side long legs 14. These internal long legs 22 together with the associated helicoils 20 generally form the rectangular spring cell unit 11.

Each spring cell unit 11 therefore includes two opposed long legs 22 and two opposed helicoils 20. The long legs 22 in adjacent spring cell units 11 run parallel to longitudinal axis 25 and are separated a predetermined distance, which distance may be calculated so as to conveniently maintain the overall size of the bed coil spring unit 10 and, as well, to increase or decrease the stiffness or elasticity of the unit 10 depending on the application. Also included within each spring cell unit 11 are four (4) coil springs 21. Each coil spring 21 is formed from the wire making up the adjacent and respective long leg 14, 22. For example, and with reference to spring cell unit 24 illustrated in Figure 1, the lower lefthand coil 23 is formed from the wire making up long leg 14. The upper lefthand coil 30 is formed from the wire making up the long leg 22 forming the upper edge 31 of the cell 24 and the coils 32, 33 are formed from the wire making up the long legs 14, 22, respectively, the latter long leg 22 being the upper edge 31 of the cell 24, it being understood that the terms lower, upper, left hand, right hand, etc. , are with reference to the figure being viewed and not with reference to the position of the bed coil spring unit 10 which is generally located in a horizontal position.

Each spring cell unit 11 has a centrally located axis 40 which extends generally perpendicular to the plane of Figure 1 , i.e., vertically when the coil spring bedding unit 10 is in its operating or horizontal position. The coil springs 21 are symmetrical about axis 40; that is, each spring axis 42 of each coil 21 in cell 41, for example, is equidistant from axis 40 of cell 41. Thus , the coil spring bedding unit 10 comprises a plurality of generally symmetrical spring cell units 11 which are connected together using helicoils 20 and which extend the length and width of the bed coil spring unit 10.

To provide support for the spring cell units 24, 41 on the end 13 of the bed coil spring unit 10, a frame generally illustrated at 43 is located. Frame 43 comprises steel upper end member 13 , which is formed with a corner 50, the member 13 extending to and joining with the long leg 14 which makes up spring cell unit 24. The upper end member 13 is connected to long leg 14 using a tubular section 51 which is positioned over member 13 and the respective long leg 14 and then crimped with an appropriate tool to provide suitable connecting force .

A plurality of wire formed coils 52 extend downwardly from upper end member 13 and the end of the wire forming coils 52 is coiled about end member 13 as is illustrated, the wire also extending through the helicoil 20. The wire extending from the bottom of coil spring 52 forms a lower long leg 46 (Figure 2) in the same configuration as member 13 and joins the lower helicoil 54 lying approximately one-half the distance between the upper helicoils 20 when viewed in plan.

With reference to Figure 2 , it will be seen that the coils 21, 23, 32 and 52 are interconnected to provide strength as at positions 60, 61. the coils 21, 23, 32 and 52 connect with the lower helicoils 54 and extend into long legs 45 in a manner consistent with the configuration of the upper surface of the bed coil spring unit 10 illustrated in Figure 1.

OPERATION

In operation, it will be seen that the formation of each spring cell unit 11 is symmetrical about its axis 40; that is, there are no moments created by the force on the coil springs 21 which extend outside the spring cell unit 11. Thus, there is no tendency to move the body of the user towards or away from the position wherein the body is positioned on the coil spring bedding unit 10. Likewise, it will be seen that the elasticity of the individual coils 21 is enhanced since the coil springs within each spring cell unit 11 are not attached to each other and more or less independently operate given the necessary restraints due to manufacturing considerations. Thus, the force exerted by the coils 21 depends on the downwardly directed force applied to the coils 21 by the body of the user positioned on the bed coil spring unit 10. Such elasticity provides enhanced support for the user and a more comfortable reclining position.

It is contemplated that the various dimensions between the long legs 14, 22, the helicoils 20, the long legs 22 in adjacent spring cell units 11, the coil springs 21 and the bed coil spring unit 10 are, of course, variable according to the various uses or applications to which the bed coil spring unit 10 may be particularly directed. These dimensions, including the diameter of the coil springs 21 and the distance of the axes 42 of the coil springs 21 from the central axis 40 of the spring cell units 11 can be optimized for the particular application.

A combination mattress and mattress or base support is generally illustrated at 100 in Figure 3 and is commonly referred to as a bed. The combination 100 includes a mattress 101 and a base or mattress support 102. It will be appreciated that the base or mattress support 102 of Figure 3 has had the side rails removed to better assist in illustrating aspects of the base or mattress support 102.

The mattress support 102 is illustrated in greater detail in Figure 4. It comprises end rails 103, 104 and side rails 120, 121. The side rails 120, 121 act to support side longitudinal wooden slat support members 122 , 123 , one located on each inner side of the side rails 120, 121, respectively. Side slat support members 122, 123 extend parallel to the side rails 120, 121. Each of the side slat support members 122 , 123 on each of the side rails 120 , 121 supports a plurality of compression springs 124 which are individually positioned on the support members 122 and which, if desired, may be removed, individually or collectively, from the side slat support members 122 , 123.

The side slat support members 122 , 123 also serve to support transverse support members 130.

Transverse support members 130 are used to support intermediate slat support members 131, 132, 133, 134. Intermediate slat support members 131 , 132 , 133 , 134 also support a plurality of compression springs 124 which may be individually removed from the intermediate slat support members 131, 132, 133, 134 as desired. The intermediate slat support members 131, 132, 133, 134 may be moved longitudinally in the direction of the longitudinal axis of the base 102 and sidewise in a direction perpendicular to the longitudinal axis of the base 102. Intermediate slat support members 131, 132, 133, 134 may also be rotated as illustrated in Figure 6 about a vertical axis such that they may be angularly oriented relative to the longitudinal axis of the base 102. Thus, the intermediate slat support members 131, 132, 133, 134 may be positioned in a variety of configurations depending on the particular user. Likewise, the compression springs 124 on the intermediate slat support members 131, 132, 133, 134 may be individually removed or added depending on whether greater or lesser force on the mattress 101 is desired.

A central slat support member 136 is supported by the end rails 103, 104. It likewise serves to hold a plurality of compression springs 124 acting on the slats 140 (Figure 5) .

The slats 140 are positioned on top of the slat support members 123, 123, 131, 132, 133. The individual slats 140, therefore, biased by the compression springs 124 on the slat support members of Figure 4. The slats 140 are conveniently single slats woven together using non-stretch, non-rip woven connectors 141, shown more clearly in Figures 7A, 7B and 7C. Figure 7A illustrates two slats 140 within each connector 141 which encompasses the slats 140. Conveniently, however, only one slat 140 is required and the use of an additional slat is made in further adjustment of the force which is exerted on the bottom of the mattress 101 by the slats 140. Figure 7C illustrates a further embodiment of the invention. In this embodiment, a slat 140 has been removed from the woven connector 141 and is placed underneath the woven connector 141. Since the connector 141 is initially under tension due to the slats 140 being within the connector 141 such as is illustrated with slats 140 of Figure 7A, it is apparent that by removing one or both of the slats 140 from the non-stretch, non- rip woven connector webbing 141, it will allow the force acting upwardly on the mattress 101 to be reduced while still offering support for the mattress 101. Thus, adding to or removing the slats 140 from the woven connector 141 allows further force adjustment to be made in the base 102 which force is exerted on the mattress 101. The slats 140 may therefore move up and down, side to side and with a rocking motion with one side moving vertically relatively to the opposite side .

The base support 102 which has been described is particularly applicable to a single bed. In the event the teaching of the invention are to be applied to a double bed, reference is made to Figure 8 in which a double bed is generally illustrated at 150 with only a few of the slats 140 illustrated for ease of explanation. In Figure 8 , there are positioned two central slat supports 151, 152, one for each individual intended to sleep in the bed 150. Each of the central slat supports 151 , 152 has a plurality of compression springs 153 positioned thereon which may be added or removed as required for the individual user. The intermediate slat supports 154, 155 are angled for each user according to the support requirements of that user and the number of compression springs 153 on each of the intermediate slat supports 154, 155 may likewise be varied. The slats 140 will extend across the entire bed 150 and be supported by the support members (not illustrated) of the side rails 160, 161. Thus, each user has a substantially independent support system which is tailored to the particular shape and weight of the user .

While compression springs 124 on the side slat support members 122, 123 are described, it is also contemplated that the springs 124 could be replaced with rubber material used to support the slats 140.

While specific embodiments of the invention have been described, many modifications will readily occur to those skilled in the art to which the invention relates and the embodiments should be taken as illustrative of the invention only and not as limiting its scope as defined in accordance with the accompanying claims .

Claims

I CLAIM:

1. A bed coil spring unit having ends and sides for use with the reclining body of a user, said bed coil spring unit having a generally longitudinal axis extending between the ends of said unit and being equidistant from said sides of said unit, a plurality of helicoil members spaced a predetermined distance apart, a plurality of long legs extending between said helicoils and being generally parallel to said longitudinal axis of said bed coil spring unit and a plurality of coil springs positioned between said long legs and said helicoils , each of said coil springs having an axis and being positioned between said long legs and said helicoils to form a combination spring cell unit, each of said spring cell units having a central axis extending generally perpendicular to said helicoils and said long legs , said coil springs being located symmetrically about said central axis .

2. A bed coil spring unit as in claim 1 wherein said coil springs in each of said spring cell units numbers four (4) , each of said spring cell units being positioned symmetrically about said central axis of said bed coil spring unit.

3. A bed coil spring unit as in claim 2 wherein said long legs are formed from wire material, said coil springs being formed from said wire material of said long legs .

4. A bed coil spring unit as in claim 3 wherein said helicoils connect between adjacent ones of said spring cell units .

5. A bed coil spring unit as in claim 4 and further comprising an end member located on each end of said unit, said end comprising an upper member and formed coils extending from said upper member, said formed coils being interconnected and constructed from wire material, said wire material being looped about said upper member.

6. Method of constructing a bed coil spring unit comprising forming a generally rectangular spring cell unit and interconnecting said spring cell units to form said bed coil spring unit, each of said spring cell units comprising a generally vertical central axis and a plurality of coil springs, said coil springs being positioned symmetrically about said central axis .

7. Method of constructing a bed coil spring unit as in claim 6 wherein said plurality of coil springs in each of said spring cell units numbers four (4) .

8. Method of constructing a bed coil spring unit as in claim 7 wherein said spring cell units are interconnected using helicoil members .

9. Method of constructing a bed coil spring unit as in claim 8 and further comprising connecting an upper member to said spring cell units on the opposed distant ends of said bed coil spring unit and positioning a plurality of formed coils extending from said upper end member, said formed coils comprising a wire material .

10. Method of constructing a bed coil spring unit as in claim 9 wherein said wire material of said formed coils is connected to said upper member .

11. A base support for a mattress comprising a support frame having a pair of side slat supports, a plurality of parallel slats extending between said slat supports, one side slat support on each end of each of said plurality of parallel slats, connectors to connect said parallel slats, a central slat support member positioned generally between side slat support members and at least one intermediate slat support member arranged between said each of said side slat supports and said central slat support.

12. Base support as in claim 11 wherein said central slat support includes a plurality of springs extending longitudinally along said slat support between said slat support and said plurality of parallel slats, said springs acting to provide an upwardly directed force on said parallel slats when said parallel slats are in operable position on said springs .

13. Base support as in claim 11 wherein said intermediate slat supports include a plurality of springs positioned between said intermediate slat supports and said plurality of slats , said springs of said intermediate slat supports acting to provide an upwardly directed force on said parallel slats when said parallel slats are in operable position on said intermediate slat supports .

14. Base support as in claim 13 wherein said intermediate slat supports are movable parallel and perpendicular to said central slat support.

15. Base support as in claim 14 wherein said intermediate slat supports are rotatable about a vertical axis perpendicular to the plane of said plurality of slats .

16. Base support as in claim 15 wherein at least some of said plurality of springs in said central support are individually removable.

17. Base support as in claim 16 wherein at least some of said plurality of springs in said intermediate supports are individually removable .

18. Base support as in claim 17 wherein at least some of said plurality of springs in said side supports are individually removable.