Box spring assembly with interlocked formed wire components and method of assembling same

Claim 1

In a box spring assembly which includes a generally horizontal rectangular frame and a generally horizontal spring wire mattress support deck disposed a predetermined distance above said frame, said deck including a plurality of substantially straight wires arranged criss-cross fashion, some of said wires extending lengthwise of said frame and others of said wires extending crosswise of said frame; a plurality of deck support springs arranged in a regular pattern between said deck and said frame so as to yieldably support said deck on said frame, each of said springs including a vertically yieldable portion secured at the lower end to said frame and terminating at the upper end in a deck-attaching portion, each said deck-attaching portion including a pair of generally parallel spaced wire sections and a connecting wire section integral with and extending diagonally between said spaced wire sections, each said attaching portion being located so that a mid portion of the connecting wire section therein is at the juncture of a lengthwise wire with a crosswise wire in said deck and the parallel wire sections extend crosswise of one of said crosswise or lengthwise wires on opposite sides of said juncture, said parallel wire sections and said connecting wire section being located on opposite top and bottom sides of the deck wires at said juncture so as to clamp said spring to said deck.

Claim 10

The method of assembling a box spring assembly which consists of the following components: a. a rectangular generally horizontally disposed frame having side rails, end rails, and a plurality of cross rails that are generally parallel and are substantially perpendicular to said side rails; b. a spring wire deck of generally horizontal shape and corresponding in size substantially to the size of said frame, said deck being in a generally horizontal position spaced a predetermined distance above said frame and including a plurality of cross wires that are directly above and substantially parallel to said cross rails, and lengthwise wires extending lengthwise of said frame at positions generally perpendicular to and overlapped with said cross wires; and c. a plurality of wire springs mounted on said cross rails and arranged in a supporting relation with said deck for yieldably supporting the deck on the frame, each of said springs including a vertically yieldable portion terminating at the upper end in a deck-attaching portion, each said deck-attaching portion including a pair of generally parallel spaced wire sections and a connecting wire section integral with and extending diagonally between said spaced wire sections, said method comprising the steps of: positioning said springs on said cross rails and attaching said springs to said deck at the junctures of some of said cross wires with some of said lengthwise wires by: i. first locating each said attaching portion so that a mid portion of the connecting wire section therein is engaged with the top side of the juncture of a lengthwise wire with a cross wire in said deck and the parallel wire sections are on opposite sides of the cross wire; ii. subsequently rotating each said spring substantially about a vertical axis extending through said juncture to a position in which said parallel wire sections extend crosswise of the cross wire for said juncture at positions engaging the underside of said cross wire so that said parallel wire sections and said connecting wire section are located on opposite top and bottom sides of the deck wires at said juncture so as to clamp said spring to said deck; and iii. connecting said springs at the lower ends of said vertically yieldable portions to said cross rails.

Claim 11

The method of assembling a box spring assembly which consists of the following components: a. a rectangular generally horizontally disposed frame having side rails, end rails, and a plurality of cross rails that are generally parallel and are substantially perpendicular to said side rails; b. a spring wire deck of generally horizontal shape and corresponding in size substantially to the size of said frame, said deck being in a generally horizontal position spaced a predetermined distance above said frame and including a plurality of cross wires that are directly above and substantially parallel to said cross rails, and lengthwise wires extending lengthwise of said frame at positions generally perpendicular to and overlapped with said cross wires; and c. a plurality of wire springs mounted on said cross rails and arranged in a supporting relation with said deck for yieldably supporting the deck on the frame, each of said springs including a vertically yieldable portion terminating at the upper end in a deck-attaching portion, each said deck-attaching portion including a pair of generally parallel spaced wire sections and a connecting wire section integral with and extending diagonally between said spaced wire sections, said method comprising the steps of: positioning said springs on said cross rails and attaching said springs to said deck at the junctures of some of said cross wires with some of said lengthwise wires by: i. first locating each said attaching portion so that a mid portion of the connecting wire section therein is engaged with the top side of the juncture of a lengthwise wire with a cross wire in said deck and the parallel wire sections are on opposite sides of the cross wire; ii. subsequently rotating each said spring substantially about a vertical axis extending through said juncture to a position in which said parallel wire sections extend crosswise of the cross wire for said juncture at positions engaging the underside of said cross wire so that said parallel wire sections and said connecting wire section are located on opposite top and bottom sides of the deck wires at said juncture so as to clamp said spring to said deck; and iii. connecting said springs at the lower ends of said vertically yieldable portions to said cross rails.

Claim 12

The method of assembling a spring with the frame and the spring deck in a box spring assembly in which the frame is generally horizontal, the deck consists of a plurality of generally straight wires arranged criss-cross fashion in a horizontal plane located above the frame, and the spring consists of at least one vertically extending yieldable member supportable at its lower end on the frame and having at its upper end a generally horizontal attaching portion consisting of a pair of generally parallel spaced-apart wire sections and a connecting wire section integral with and extending diagonally between said spaced wire sections, said method comprising the steps of: a. locating the attaching portion so that a mid portion of the connecting wire section therein is engaged with the top side of the juncture of a pair of intersecting wires in said deck, and said parallel wire sections are located in diagonally opposite ones of the four quadrants formed by said intersecting wires, b. rotating said attaching portion about a vertical axis extending approximately through said mid portion to a position in which said parallel wire sections extend under and are engaged with the underside of one of said intersecting wires to thereby effect a clamping of said attaching portion to said deck, and c. securing the lower end of said yieldable member to said frame.

Claim 13

The method of assembling a spring with the frame and the spring deck in a box spring assembly in which the frame is generally horizontal, the deck consists of a plurality of generally straight wires arranged criss-cross fashion in a horizontal plane located above the frame, and the spring consists of at least one vertically extending yieldable member supportable at its lower end on the frame and having at its upper end a generally horizontal attaching portion consisting of a pair of generally parallel spaced-apart wire sections and a connecting wire section integral with and extending diagonally between said spaced wire sections, said method comprising the steps of: a. locating the attaching portion so that a mid portion of the connecting wire section therein is engaged with the top side of the juncture of a pair of intersecting wires in said deck, and said parallel wire sections are located in diagonally opposite ones of the four quadrants formed by said intersecting wires, b. rotating said attaching portion about a vertical axis extending approximately through said mid portion to a position in which said parallel wire sections extend under and are engaged with the underside of one of said intersecting wires to thereby effect a clamping of said attaching portion to said deck, and c. securing the lower end of said yieldable member to said frame.