Foundation unit with snap-fit modular springs

Claim 2

A bedding foundation unit comprising: (a) a frame; (b) a planar top portion spaced above said frame, and comprising a first plurality of spaced parallel grid wires and a second plurality of spaced parallel grid wires lying perpendicular to and connected to said first plurality of spaced parallel grid wires; (c) a plurality of modular springs extending between said planar top portion and said frame, each said modular spring comprising a planar top section, two vertical legs, and two foot sections, each of said vertical legs comprising a vertical straight portion and at least one arcuate portion having an arc of at least about 180 , said planar top section comprising a centermost longitudinal section and two longitudinal end sections, each said longitudinal end section being generally parallel to and offset from said centermost longitudinal section and being connected thereto by a transverse straight portion, each said longitudinal end section being connected to one of said vertical legs, each of said vertical legs being connected to said frame by one of said foot sections, and each of said vertical legs being located beneath said planar top section; and (d) snap-fit means securing each said modular spring to said planar top portion, said snap-fit means comprising a first parallel grid wire from said second plurality of spaced parallel grid wires extending over both transverse straight portions of said modular spring, a second parallel grid wire from said second plurality of spaced parallel grid wires extending under both transverse straight portions of said modular spring, and a pair of parallel grid wires from said first plurality of spaced parallel grid wires, wherein one of said pair of parallel grid wires extends over one of said longitudinal end sections of said modular spring and another of said pair of parallel grid wires extends over another of said longitudinal end sections of said modular spring.

Claim 3

The foundation unit of claim 1 wherein each of said vertical straight portions is connected to one of said longitudinal end sections and each of said arcuate portions is connected to one of said foot sections.

Claim 4

The foundation unit of claim 1 wherein each of said vertical legs has two arcuate portions, with each arcuate portion having an arc of at least about 180°.

Claim 5

The foundation unit of claim 3 wherein the two arcuate portions of each of said vertical legs generally form an S.

Claim 6

The foundation unit of claim 1 wherein said foot sections are generally coplanar and lie generally parallel to the plane of said frame.

Claim 7

A foundation unit comprising: (a) a frame; (b) a planar top portion spaced above said frame, and comprising a first plurality of spaced parallel grid wires and a second plurality of spaced parallel grid wires lying perpendicular to and connected to said first plurality of spaced parallel grid wires; (c) a plurality of modular springs extending between said planar top portion and said frame, each said modular spring comprising a planar top section, two vertical legs, and two foot sections, each of said vertical legs comprising a vertical straight upper portion and a generally S-shaped lower portion, said planar top section comprising a centermost longitudinal section and two longitudinal end sections, each said longitudinal end section being generally parallel to and offset from said centermost longitudinal section and being connected thereto by a transverse straight portion, each said longitudinal end section being connected to one of said vertical straight upper portions of one of said vertical legs, each of said S-shaped lower portions being connected to said frame by one of said foot sections, and each of said vertical legs being located beneath said planar top section; and (d) snap-fit means securing each said modular spring to said planar top portion, said snap-fit means comprising a first parallel grid wire from said second plurality of spaced parallel grid wires extending over both transverse straight portions of said modular spring, a second parallel grid wire from said second plurality of spaced parallel grid wires extending under both transverse straight portions of said modular spring, and a pair of parallel grid wires from said first plurality of spaced parallel grid wires, wherein one of said pair of parallel grid wires extends over one of said longitudinal end sections of said modular spring and another of said pair of parallel grid wires extends over another of said longitudinal end sections of said modular spring.

Claim 8

A foundation unit comprising: (a) a frame; (b) a planar top portion spaced above said frame, and comprising a first plurality of spaced parallel grid wires and a second plurality of spaced parallel grid wires lying perpendicular to and connected to said first plurality of spaced parallel grid wires; (c) a plurality of modular springs extending between said planar top portion and said frame, each said modular spring comprising a planar top section, two vertical legs, and two foot sections, each of said vertical legs comprising a vertical straight upper portion and a generally S-shaped lower portion, said planar top section comprising a centermost longitudinal section and two longitudinal end sections, each said longitudinal end section being generally parallel to and offset from said centermost longitudinal section and being connected thereto by a transverse straight portion, each said longitudinal end section being connected to one of said vertical straight upper portions of one of said vertical legs, each of said S-shaped lower portions being connected to said frame by one of said foot sections, and each of said vertical legs being located beneath said planar top section; and (d) snap-fit means securing each said modular spring to said planar top portion, said snap-fit means comprising a first parallel grid wire from said second plurality of spaced parallel grid wires extending over both transverse straight portions of said modular spring, a second parallel grid wire from said second plurality of spaced parallel grid wires extending under both transverse straight portions of said modular spring, and a pair of parallel grid wires from said first plurality of spaced parallel grid wires, wherein one of said pair of parallel grid wires extends over one of said longitudinal end sections of said modular spring and another of said pair of parallel grid wires extends over another of said longitudinal end sections of said modular spring.

Claim 9

The foundation unit of claim 6 wherein said first plurality of spaced parallel grid wires are connected to said second plurality of spaced parallel grid wires by welding.

Claim 10

The foundation unit of claim 6 wherein each said parallel grid wire from said second plurality of spaced parallel grid wires is crimped at each point where said parallel grid wire crosses said transverse straight portion of said longitudinal modular spring, such that said planar top portion lies substantially in a plane defined by said planar top sections of said modular springs.

Claim 11

The foundation unit of claim 6 wherein said foot sections are generally coplanar and lie generally parallel to the plane of said frame.

Claim 12

The foundation unit of claim 9 wherein each said foot section is generally L-shaped and has a free end, with the free ends of each modular spring being connected together.

Claim 13

The foundation unit of claim 10 wherein the free ends of each modular spring are welded together.

Claim 14

A box spring unit comprising: (a) a rectangular frame; (b) a planar top portion spaced above said frame, and comprising a first plurality of spaced parallel grid wires and a second plurality of spaced parallel grid wires lying perpendicular to and connected to said first plurality of spaced parallel grid wires; (c) a first plurality of modular springs extending between said planar top portion and said frame, each said modular spring comprising a planar top section, two vertical legs, and two foot sections, each of said vertical legs comprising a vertical straight upper portion and a generally S-shaped lower portion, said planar top section comprising a centermost longitudinal section and two longitudinal end sections, each said longitudinal end section being generally parallel to and offset from said centermost longitudinal section and being connected thereto by a transverse straight portion, each said longitudinal end section being connected to one of said vertical straight upper portions of one of said vertical legs, each of said S-shaped lower portions being connected to said frame by one of said foot sections, and each of said vertical legs being located beneath said planar top section; (d) snap-fit means securing each of said first plurality of modular springs to said planar top portion, said snap-fit means comprising a first parallel grid wire from said second plurality of spaced parallel grid wires extending over both transverse straight portions of each of said first plurality of modular springs, a second parallel grid wire from said second plurality of spaced parallel grid wires extending under both transverse straight portions of each of said first plurality of modular springs, and a pair of parallel grid wires from said first plurality of spaced parallel grid wires, wherein one of said pair of parallel grid wires extends over one of said longitudinal end sections of each of said first plurality of modular springs and another of said pair of parallel grid wires extends over another of said longitudinal end sections of each of said first (e) a pad overlying said planar top portion; and (f) a fabric cover covering said pad, said planar top portion and all said modular springs.

Claim 15

A box spring unit comprising: (a) a rectangular frame; (b) a planar top portion spaced above said frame, and comprising a first plurality of spaced parallel grid wires and a second plurality of spaced parallel grid wires lying perpendicular to and connected to said first plurality of spaced parallel grid wires; (c) a first plurality of modular springs extending between said planar top portion and said frame, each said modular spring comprising a planar top section, two vertical legs, and two foot sections, each of said vertical legs comprising a vertical straight upper portion and a generally S-shaped lower portion, said planar top section comprising a centermost longitudinal section and two longitudinal end sections, each said longitudinal end section being generally parallel to and offset from said centermost longitudinal section and being connected thereto by a transverse straight portion, each said longitudinal end section being connected to one of said vertical straight upper portions of one of said vertical legs, each of said S-shaped lower portions being connected to said frame by one of said foot sections, and each of said vertical legs being located beneath said planar top section; (d) snap-fit means securing each of said first plurality of modular springs to said planar top portion, said snap-fit means comprising a first parallel grid wire from said second plurality of spaced parallel grid wires extending over both transverse straight portions of each of said first plurality of modular springs, a second parallel grid wire from said second plurality of spaced parallel grid wires extending under both transverse straight portions of each of said first plurality of modular springs, and a pair of parallel grid wires from said first plurality of spaced parallel grid wires, wherein one of said pair of parallel grid wires extends over one of said longitudinal end sections of each of said first plurality of modular springs and another of said pair of parallel grid wires extends over another of said longitudinal end sections of each of said first (e) a pad overlying said planar top portion; and (f) a fabric cover covering said pad, said planar top portion and all said modular springs.

Claim 16

The box spring unit of claim 12 wherein said first plurality of spaced parallel grid wires are connected to said second plurality of spaced parallel grid wires by welding.

Claim 17

The box spring unit of claim 12 wherein each said parallel grid wire from said second plurality of spaced parallel grid wires is crimped at each point where said parallel grid wire crosses said transverse straight portion of each of said first plurality of modular springs, such that said planar top portion lies substantially in a plane defined by said planar top sections of said first plurality of modular springs.

Claim 18

The box spring unit of claim 12 wherein said foot sections are generally coplanar and lie generally parallel to the plane of said frame.

Claim 19

The box spring unit of claim 15 wherein each said foot section is generally L-shaped and has a free end, and the free ends of each modular spring are connected together.

Claim 20

The box spring unit of claim 16 wherein the free ends of each modular spring are welded together.

Claim 21

The box spring unit of claim 12 wherein said frame comprises two laterally spaced longitudinal frame members, two longitudinally spaced lateral frame members and a plurality of spaced apart longitudinal slats, and wherein said first plurality of modular springs are connected to and interspaced along the length of said longitudinal frame members and said longitudinal slats.

Claim 22

The box spring unit of claim 18 wherein each half of said box spring unit is generally a mirror image of the other half of said box spring unit.

Claim 23

The box spring unit of claim 18 wherein said longitudinal slats are located between said longitudinal frame members.

Claim 24

The box spring unit of claim 18 further comprising: a second plurality of modular springs extending between said planar top portion and said frame and having vertical legs which are connected to said frame such that the centermost longitudinal section of each of said second plurality of modular springs is generally parallel to said lateral frame members.

Claim 25

The box spring unit of claim 21 wherein each half of said box spring unit is generally a mirror image of the other half of said box spring unit.

Claim 26

The box spring unit of claim 21 wherein each of said second plurality of modular springs is secured to said planar top portion with at least one clip.

Claim 27

The box spring unit of claim 23 wherein the centermost longitudinal section of each of said second plurality of modular springs is connected to at least one parallel grid wire from said first plurality of spaced parallel grid wires.

Claim 28

A modular spring, for use in a bedding foundation unit, comprising: (a) a planar top section comprising a centermost longitudinal section and two longitudinal end sections, each said longitudinal end section being generally parallel to and offset from said centermost longitudinal section and being connected thereto by a transverse straight portion; (b) two vertical legs, each of said vertical legs comprising a vertical straight portion, at least three horizontal straight torsion portions, and at least two arcuate portions, each arcuate portion having a continuous arc of at least about 180° interconnecting two of said three horizontal straight torsion portions, and each of said longitudinal end sections being connected to one of said vertical legs; and (c) two foot sections, each of said foot sections being connected to one of said vertical legs.

Claim 29

A modular spring, for use in a bedding foundation unit, comprising: (a) a planar top section comprising a centermost longitudinal section and two longitudinal end sections, each said longitudinal end section being generally parallel to and offset from said centermost longitudinal section and being connected thereto by a transverse straight portion; (b) two vertical legs, each of said vertical legs comprising a vertical straight portion, at least three horizontal straight torsion portions, and at least two arcuate portions, each arcuate portion having a continuous arc of at least about 180° interconnecting two of said three horizontal straight torsion portions, and each of said longitudinal end sections being connected to one of said vertical legs; and (c) two foot sections, each of said foot sections being connected to one of said vertical legs.

Claim 30

The modular spring of claim 25 wherein the two arcuate lower portions and the three horizontal straight torsion portions of each of said vertical legs generally from an S.

Claim 31

The modular spring of claim 25 wherein said foot sections are generally coplanar.

Claim 32

A snap-fit modular spring, for use in a foundation unit, comprising: (a) a planar top section comprising a centermost longitudinal section and two longitudinal end sections, each of said longitudinal end sections being generally parallel to and offset from said centermost longitudinal section and being connected thereto by a transverse straight portion; (b) two vertical legs, each of said vertical legs comprising a vertical straight upper portion and a generally S-shaped lower portion, each of said generally S-shaped lower portions comprising an upper horizontal straight torsion portion, an upper arcuate portion, an intermediate horizontal torsion portion, a lower arcuate portion and a lower horizontal torsion portion, with each of said upper horizontal straight torsion portions being connected to one of said vertical straight upper portions and each of said longitudinal end sections being connected to one of said vertical straight upper portions of one of said vertical legs; and (c) two foot sections, with the lower horizontal straight torsion portion of each of said S-shaped portions being connected to one of said foot sections.

Claim 33

A snap-fit modular spring, for use in a foundation unit, comprising: (a) a planar top section comprising a centermost longitudinal section and two longitudinal end sections, each of said longitudinal end sections being generally parallel to and offset from said centermost longitudinal section and being connected thereto by a transverse straight portion; (b) two vertical legs, each of said vertical legs comprising a vertical straight upper portion and a generally S-shaped lower portion, each of said generally S-shaped lower portions comprising an upper horizontal straight torsion portion, an upper arcuate portion, an intermediate horizontal torsion portion, a lower arcuate portion and a lower horizontal torsion portion, with each of said upper horizontal straight torsion portions being connected to one of said vertical straight upper portions and each of said longitudinal end sections being connected to one of said vertical straight upper portions of one of said vertical legs; and (c) two foot sections, with the lower horizontal straight torsion portion of each of said S-shaped portions being connected to one of said foot sections.

Claim 34

The modular spring of claim 28 wherein said foot sections are generally coplanar.

Claim 35

The modular spring of claim 29 wherein each said foot section is generally L-shaped and has a free end, with said free ends being connected together.

Claim 36

The modular spring of claim 30 wherein said free ends are welded together.