Box spring assembly

Claim 2

A box spring assembly comprising a rectangular bottom frame, said bottom frame having side boards and end boards connected at their ends and a plurality of transverse slats extending between said side boards, a rectangularly configurated border wire having a pair of oppositely disposed side sections and end sections overlying said rectangular frame, a top grid of transverse and longitudinal wires extending between and connected to said side and end sections of said border wire, and a plurality of modular spring units interconnecting said border wire and top grid to said bottom frame, each of said modular spring units comprising a single wire extending between the sides of said assembly and having a plurality of individual springs formed throughout the length of said wire, each of said modular spring units being connected at its ends to said bottom frame and connected intermediate its ends to said bottom frame and to said top grid.

Claim 3

The box spring assembly of claim 1 in which said modular spring units extend transversely between the sides of said border wire, each of said modular spring units having connecting sections located between said individual springs, said connecting sections being parallel to and in juxtaposition to said transverse wires of said top grid.

Claim 4

The box spring of claim 2 in which said transverse wires of said grid each have a plurality of channels formed therein, each of said channels being open to the bottom of said grid, and said connecting sections of said modular spring units being received in said channels of said transverse grid wires.

Claim 5

The box spring assembly of claim 1 in which said modular spring unit comprises a single strand of wire having generally colinear straight sections located in a horizontal plane and interconnected by a plurality of springs formed throughout the length of the wire, each of said springs having a first generally vertical portion extending downwardly from one of said straight sections, a loop portion connected to the lower end of said first vertical portion, and a second generally vertical portion extending upwardly from said loop portion to another of said straight sections, said loop portion of each of springs being bent through an arc of between 30* and 90* out of the common vertical plane through both of said first and second portions of said spring so that the deflection of said springs occurs in the arcuate loop portion of said spring.

Claim 6

The box spring assembly of claim 4 in which said opposite ends of each of said modular spring units terminate in an end spring, each of said end springs having a vertical portion located beneath said border wire and terminating in an arcuate spring section bent through an arc of between 30* and 90*, said arcuate spring sections of said end springs being connected at their outer ends to said bottom frame so that said end springs provide substantial edge support for said box spring assembly.

Claim 7

A box spring assembly comprising a rectangular bottom frame, said bottom frame having side boards and end boards connected at their ends and a plurality of transverse slats extending between said side boards, a rectangularly configurated border wire having a pair of oppositely disposed side sections and end sections overlying said rectangular frame, a top grid of transverse and longitudinal wires extending betwEen and secured to said side and end sections of said border wire, a plurality of modular spring units, each of said modular spring units comprising a single wire extending between the sides of said assembly and having a plurality of individual springs formed throughout the length of said wire, each of said modular spring units being connected intermediate its ends to said bottom frame and to said top grid, the opposite ends of each of said modular spring units terminating in an end spring, each of said end springs having a portion located immediately beneath said border wire and terminating at its lower end in an arcuate spring section, said arcuate spring sections being connected at their outer ends to said bottom frame so that said end springs provide substantial edge support for said box spring assembly.

Claim 8

A box spring assembly comprising a rectangular bottom frame, said bottom frame having side boards and end boards connected at their ends and a plurality of transverse slats extending between said side boards, a rectangularly configurated border wire having a pair of oppositely disposed side sections and end sections overlying said rectangular frame, a top grid of transverse and longitudinal wires extending betwEen and secured to said side and end sections of said border wire, a plurality of modular spring units, each of said modular spring units comprising a single wire extending between the sides of said assembly and having a plurality of individual springs formed throughout the length of said wire, each of said modular spring units being connected intermediate its ends to said bottom frame and to said top grid, the opposite ends of each of said modular spring units terminating in an end spring, each of said end springs having a portion located immediately beneath said border wire and terminating at its lower end in an arcuate spring section, said arcuate spring sections being connected at their outer ends to said bottom frame so that said end springs provide substantial edge support for said box spring assembly.

Claim 9

The box spring assembly of claim 6 in which said modular spring units extend transversely between the sides of said border wire, each of said modular spring units having connecting sections located between said individual springs, said connecting sections being parallel to and in juxtaposition to said transverse wires of said top grid.

Claim 10

The box spring of claim 7 in which said transverse wires of said grid each have a plurality of channels formed therein, each of said channels being open to the bottom of said grid, and said connecting sections of said modular spring units being received in said channels of said transverse grid wires.

Claim 11

A box spring assembly comprising a rectangular bottom frame, said bottom frame having side boards and end boards connected at their ends and a plurality of transverse slats extending between said side boards, a rectangularly configurated border wire having a pair of oppositely disposed side sections and end sections overlying said rectangular frame, a top grid of transverse and longitudinal wires extending between and connected to said side and end sections of said border wire, and a plurality of modular spring units interconnecting said border wire and top grid to said bottom frame, each of said modular spring units comprising a single strand of wire extending between the sides of said assembly and having generally colinear straight sections located in a horizontal plane and interconnected by a plurality of springs formed throughout the length of the wire, each of said springs having a first generally vertical straight portion extending downwardly from one of said straight sections, a loop portion connected to the lower end of said first vertical portion, and a second generally vertical straight portion extending upwardly from said loop portion to another of said straight sections, said loop portion of each of springs being bent through an arc of between 30* and 90* out of the common vertical plane through both of said first and second generally vertical portions of said spring so that the deflection of said springs occurs in the arcuate loop portion of said spring.

Claim 12

A box spring assembly comprising a rectangular bottom frame, said bottom frame having side boards and end boards connected at their ends and a plurality of transverse slats extending between said side boards, a rectangularly configurated border wire having a pair of oppositely disposed side sections and end sections overlying said rectangular frame, a top grid of transverse and longitudinal wires extending between and connected to said side and end sections of said border wire, and a plurality of modular spring units interconnecting said border wire and top grid to said bottom frame, each of said modular spring units comprising a single strand of wire extending between the sides of said assembly and having generally colinear straight sections located in a horizontal plane and interconnected by a plurality of springs formed throughout the length of the wire, each of said springs having a first generally vertical straight portion extending downwardly from one of said straight sections, a loop portion connected to the lower end of said first vertical portion, and a second generally vertical straight portion extending upwardly from said loop portion to another of said straight sections, said loop portion of each of springs being bent through an arc of between 30* and 90* out of the common vertical plane through both of said first and second generally vertical portions of said spring so that the deflection of said springs occurs in the arcuate loop portion of said spring.

Claim 13

The box spring assembly of claim 9 in which said opposite ends of each of said modular spring units terminate in an end spring, each of said end springs having a vertical portion located beneath said border wires and terminating in an arcuate spring section bent through an arc of between 45* and 90*, said arcuate spring sections of said end springs being connected at their outer ends to said bottom frame so that said end springs provide substantial edge support for said box spring assembly.

Claim 14

A box spring assembly comprising a rectangular bottom frame, said bottom frame having side boards and end boards connected at their ends and a plurality of transverse slats extending between said side boards, a rectangularly configurated border wire having a pair of oppositely disposed side sections and end sections overlying said rectangular frame, a top grid of transverse and longitudinal wires extending between and connected to said side and end sections of Said border wire, and a plurality of modular spring units interconnecting said border wire and top grid to said bottom frame, each of said modular spring units comprising a single strand of wire extending between the sides of said assembly and having generally colinear straight sections located in a horizontal plane and interconnected by a plurality of springs formed throughout the length of the wire, each of said springs having a first generally sinuous wave-shaped portion extending downwardly from one of said straight sections, a loop portion connected to the lower end of said generally sinuous wave-shaped portion, and a second generally sinuous wave-shaped portion extending upwardly from said loop portion to another of said straight sections.

Claim 15

A box spring assembly comprising a rectangular bottom frame, said bottom frame having side boards and end boards connected at their ends and a plurality of transverse slats extending between said side boards, a rectangularly configurated border wire having a pair of oppositely disposed side sections and end sections overlying said rectangular frame, a top grid of transverse and longitudinal wires extending between and connected to said side and end sections of Said border wire, and a plurality of modular spring units interconnecting said border wire and top grid to said bottom frame, each of said modular spring units comprising a single strand of wire extending between the sides of said assembly and having generally colinear straight sections located in a horizontal plane and interconnected by a plurality of springs formed throughout the length of the wire, each of said springs having a first generally sinuous wave-shaped portion extending downwardly from one of said straight sections, a loop portion connected to the lower end of said generally sinuous wave-shaped portion, and a second generally sinuous wave-shaped portion extending upwardly from said loop portion to another of said straight sections.

Claim 16

The box spring assembly of claim 11 in which said opposite ends of each of said modular spring units terminate in an end spring, each of said end springs having a sinuous wave-shaped portion located beneath said border wires, and each of said end springs being connected at its lower end to said bottom frame so that said end springs provide substantial edge support for said box spring assembly.

Claim 17

A modular spring unit adapted to be used to form the spring section of an item of furtniture, said unit comprising a single strand of wire having generally colinear straight sections located in a horizontal plane and interconnected by a plurality of springs formed throughout the length of the wire, each of said springs having a first generally vertical portion extending downwardly from one of said straight sections, a loop portion connected to the lower end of said first vertical portion, and a second vertical portion extending upwardly from said loop portion to another of said straight sections, said loop portion of each of springs being bent through an arc of between 30* and 90* out of the common vertical plane through both of said first and second portions of said spring so that the deflection of said springs occurs in the arcuate loop portion of said spring.

Claim 18

A modular spring unit adapted to be used to form the spring section of an item of furtniture, said unit comprising a single strand of wire having generally colinear straight sections located in a horizontal plane and interconnected by a plurality of springs formed throughout the length of the wire, each of said springs having a first generally vertical portion extending downwardly from one of said straight sections, a loop portion connected to the lower end of said first vertical portion, and a second vertical portion extending upwardly from said loop portion to another of said straight sections, said loop portion of each of springs being bent through an arc of between 30* and 90* out of the common vertical plane through both of said first and second portions of said spring so that the deflection of said springs occurs in the arcuate loop portion of said spring.

Claim 19

The modular spring unit of claim 13 in which the opposite ends of said strand of wire terminate in an end spring, each of said end springs having a vertical portion terminating in an arcuate spring section bent through an arc of between 30* and 90*, said arcuate spring section of said end springs terminating in means for attaching said spring units to a frame.

Claim 20

A modular spring unit adapted to be used to form the spring section of an item of furniture, said unit comprising a single strand of wire having generally colinear straight sections located in a horizontal plane and interconnected by a plurality of springs formed throughout the length of the wire, each of said springs having a first generally wave-shaped vertical portion extending downwardly from one of said straight sections, a loop portion connected to the lower end of said first vertical portion, and a second generally vertical wave-shaped portion extending upwardly from said loop portion to another of said straight sections, said loop portion of each of springs being bent through an arc of between 30* and 90* out of a vertical plane which passes through said colinear straight sections of said wire so that at least a part of the deflection of said springs occurs in the arcuate loop portion of said spring.

Claim 21

A modular spring unit adapted to be used to form the spring section of an item of furniture, said unit comprising a single strand of wire having generally colinear straight sections located in a horizontal plane and interconnected by a plurality of springs formed throughout the length of the wire, each of said springs having a first generally wave-shaped vertical portion extending downwardly from one of said straight sections, a loop portion connected to the lower end of said first vertical portion, and a second generally vertical wave-shaped portion extending upwardly from said loop portion to another of said straight sections, said loop portion of each of springs being bent through an arc of between 30* and 90* out of a vertical plane which passes through said colinear straight sections of said wire so that at least a part of the deflection of said springs occurs in the arcuate loop portion of said spring.

Claim 22

The modular spring unit of claim 15 in which the opposite ends of said strand of wire terminate in an end spring, each of said end springs having a generally wave-shaped vertical portion terminating in an arcuate spring section bent through an arc of between 30* and 90*, said arcuate spring section of said end springs terminating in means for attaching said spring units to a frame.

Claim 23

A spring assembly comprising a bottom frame, a border wire vertically spaced from said bottom frame, a top grid of transverse and longitudinal grid wires extending betweeN and connected to said border wire, said grid wires being welded to one another at the intersections therebetween, and a plurality of modular spring units interconnecting said top grid and said bottom frame, each of said modular spring units comprising a single wire extending between the sides of said assembly and having a plurality of individual springs formed throughout the length of said wire, each of said modular spring units being connected at its ends to one of said bottom frame and border wire and connected intermediate its ends to said bottom frame and to said top grid.

Claim 24

A spring assembly comprising a bottom frame, a border wire vertically spaced from said bottom frame, a top grid of transverse and longitudinal grid wires extending betweeN and connected to said border wire, said grid wires being welded to one another at the intersections therebetween, and a plurality of modular spring units interconnecting said top grid and said bottom frame, each of said modular spring units comprising a single wire extending between the sides of said assembly and having a plurality of individual springs formed throughout the length of said wire, each of said modular spring units being connected at its ends to one of said bottom frame and border wire and connected intermediate its ends to said bottom frame and to said top grid.

Claim 25

The box spring assembly of claim 17 in which said modular spring units extend transversely between the sides of said border wire, each of said modular spring units having connecting sections located between said individual springs, said connecting sections being parallel to and in juxtaposition to said transverse wires of said top grid.

Claim 26

The box spring of claim 18 in which said transverse wires of said grid each have a plurality of channels formed therein, each of said channels being open to the bottom of said grid, and said connecting sections of said modular spring units being received in said channels of said transverse grid wires.

Claim 27

A spring assembly comprising a bottom frame, a border wire vertically spaced from said bottom frame, a top grid of transverse and longitudinal grid wires extending between and secured to said side and end sections of said border wire, said grid wires being welded to one another at the intersections therebetween, and a plurality of modular spring units, each of said modular spring units comprising a single wire extending between the sides of said assembly and having a plurality of individual springs formed throughout the length of said wire, each of said modular spring units being connected intermediate its ends to said bottom frame and to said top grid, the opposite ends of each of said modular spring units terminating in an end spring, each of said end springs having a portion located immediately beneath said border wire and terminating at its lower end in an arcuate spring section, said arcuate spring sections being connected at their outer ends to said bottom frame so that said end springs provide substantial edge support for said box spring assembly.

Claim 28

A spring assembly comprising a bottom frame, a border wire vertically spaced from said bottom frame, a top grid of transverse and longitudinal grid wires extending between and secured to said side and end sections of said border wire, said grid wires being welded to one another at the intersections therebetween, and a plurality of modular spring units, each of said modular spring units comprising a single wire extending between the sides of said assembly and having a plurality of individual springs formed throughout the length of said wire, each of said modular spring units being connected intermediate its ends to said bottom frame and to said top grid, the opposite ends of each of said modular spring units terminating in an end spring, each of said end springs having a portion located immediately beneath said border wire and terminating at its lower end in an arcuate spring section, said arcuate spring sections being connected at their outer ends to said bottom frame so that said end springs provide substantial edge support for said box spring assembly.

Claim 29

The box spring assembly of claim 20 in which said modular spring units extend transversely between the sides of said border wire, each of said modular spring units having connecting sections located between said individual springs, said connecting sections being parallel to and in juxtaposition to said transverse wires of said top grid.

Claim 30

The box spring of claim 21 in which said transverse wires of said grid each have a plurality of channels formed therein, each of said channels being open to the bottom of said grid, and said connecting sections of said modular spring units being received in said channels of said transverse grid wires.

Claim 31

A box spring assembly comprising a rectangular bottom frame, said bottom frame having side boards and end boards connected at their ends and a plurality of transverse slats extending between said side boards, a rectangularly configurated border wire having a pair of oppositely disposed side sections and end sections overlying said rectangular frame, a top grid of transverse and longitudinal wires extending between and connected to said side and end sections of said border wire, said top grid defining the top of said box spring assembly, and a plurality of modular spring units interconnecting said border wire and top grid to said bottom frame, each of said modular spring units comprising a single wire extending between the sides of said assembly and having a pair of end springs and a plurality of intermediate springs formed throughout the length of said wire, each of said end springs being connected to said bottom frame adjacent said border wire and said intermediate springs being connected to sAid bottom frame and to said top grid.

Claim 32

A box spring assembly comprising a rectangular bottom frame, said bottom frame having side boards and end boards connected at their ends and a plurality of transverse slats extending between said side boards, a rectangularly configurated border wire having a pair of oppositely disposed side sections and end sections overlying said rectangular frame, a top grid of transverse and longitudinal wires extending between and connected to said side and end sections of said border wire, said top grid defining the top of said box spring assembly, and a plurality of modular spring units interconnecting said border wire and top grid to said bottom frame, each of said modular spring units comprising a single wire extending between the sides of said assembly and having a pair of end springs and a plurality of intermediate springs formed throughout the length of said wire, each of said end springs being connected to said bottom frame adjacent said border wire and said intermediate springs being connected to sAid bottom frame and to said top grid.

Claim 33

A box spring assembly comprising a rectangular bottom frame, said bottom frame having side boards and end boards connected at their ends and a plurality of transverse slats extending between said side boards, a rectangularly configurated border wire having a pair of oppositely disposed side sections and end sections overlying said rectangular frame, a top grid of transverse and longitudinal wires extending between and connected to said side and end sections of said border wire, said top grid defining the top of said box spring assembly, and a plurality of modular spring units interconnecting said border wire and top grid to said bottom frame, each of said modular spring units comprising a single wire extending between the sides of said assembly and having a pair of end springs and a plurality of intermediate springs formed throughout the length of said wire, each of said end springs being connected to said bottom frame adjacent said border wire and said intermediate springs being connected to said bottom frame and to said top grid, said end springs of each of said modular spring units being spaced differing distances from the adjacent intermediate spring, said modular spring units being arranged in pairs, with each modular spring unit of a pair reversed end for end from the other modular spring unit of the pair, and the intermediate springs of one of each pair of modular spring units being interspaced between the intermediate springs of the other modular spring unit of the pair.

Claim 34

A box spring assembly comprising a rectangular bottom frame, said bottom frame having side boards and end boards connected at their ends and a plurality of transverse slats extending between said side boards, a rectangularly configurated border wire having a pair of oppositely disposed side sections and end sections overlying said rectangular frame, a top grid of transverse and longitudinal wires extending between and connected to said side and end sections of said border wire, said top grid defining the top of said box spring assembly, and a plurality of modular spring units interconnecting said border wire and top grid to said bottom frame, each of said modular spring units comprising a single wire extending between the sides of said assembly and having a pair of end springs and a plurality of intermediate springs formed throughout the length of said wire, each of said end springs being connected to said bottom frame adjacent said border wire and said intermediate springs being connected to said bottom frame and to said top grid, said end springs of each of said modular spring units being spaced differing distances from the adjacent intermediate spring, said modular spring units being arranged in pairs, with each modular spring unit of a pair reversed end for end from the other modular spring unit of the pair, and the intermediate springs of one of each pair of modular spring units being interspaced between the intermediate springs of the other modular spring unit of the pair.