Mattress frame

Abstract

A demountable, recyclable mattress frame is provided for a mattress (100) which has a resilient core (110) comprising an array of metal coil springs in individual pockets (not shown) On each of the major upper, and lower, surfaces a the demountable frame (120) helps to maintain the core's shape. The frame (120) is joined to the core by a plurality of hog rings (130) that pass around the frame and penetrate the pocketing material to engage one or more coils of the springs within (not shown). The frame (120) comprises four frame members (122) and four frame connectors (124). In this embodiment, the frame members (122) comprise hollow steel rods and the connectors (124) are of a hollow plastics material. The frame members and connectors are dimensioned such that the former can slide into the latter to varying degrees and be held there in a friction fit.

Description

[0001] Mattress Frame

[0002] The present invention relates to a mattress frame and to a method of assembling and disassembling a mattress .

[0003] Mattresses for beds often comprise a resilient core including an array of coil springs in individual pockets . Upper and lower frames are used to maintain the shape of the pocketed spring core . The frames are typically of flat steel ribbon and one frame extends around the periphery of the upper maj or surface of the mattress , while another extends around the periphery of the lower maj or surface of the mattress .

[0004] The frames are connected to the core by steel rings , known as "hog" rings , that are made to pass around the frame and into the pocketing material to connect to one or more turns of a spring .

[0005] Figures 1-3 show schematically a previously considered mattress M of this type . The core C has peripheral continuous frames F extending around both upper and lower maj or surfaces ( only the upper surface is shown in Figure 1 ) , which is j oined to the core by hog rings HR that pass around the frame and penetrate the pockets P to encircle one or more coils of the spring S . In Figure 3 , only one pocketed spring is shown for simplicity . Note that in the drawings the hog rings are exaggerated in si ze so that they can be identi fied .

[0006] For environmental , as well as cost , benefits the components of a mattress must be recycled or reused at the end of the useful working li fe of the mattres s as far as possible . When the springs are removed from their pockets their steel may be recycled, as may the pocketing material , which is often of nonwoven polyester . The steel of the hog rings may also be recycled .

[0007] The frames are expensive , and it i s desirable to reuse them in another mattress , However, before the frame can be reused it is necessary to cut all of the hog rings . As there is usually one ring per peripheral spring, the process is time consuming .

[0008] Embodiments of the present invention aim to provide a frame for a mattress , and a method of assembling / disassembling a mattress , in which the aforementioned problem is addressed .

[0009] The present invention is defined in the attached independent claims , to which reference should now be made . Further, preferred features may be found in the sub-claims appended thereto .

[0010] According to one aspect of the present invention, there is provided a mattress having a resilient core comprising a plurality of coil springs arranged in an array, and at least one frame extending at least part way around a periphery of the core , the frame comprising at least two frame members releasably connected by a connector member .

[0011] The resilient core preferably comprises a plurality of coil springs in pockets .

[0012] Preferably, the connector member and at least one frame member are arranged to engage one another in a releasable push fit , more preferably in a releasable friction fit , with one being inserted at least partly within the other . Preferably, the extent to which the connector member and frame member are able to fit one within the other is variable .

[0013] In a preferred arrangement the connector member is arranged to receive at least partly within it one or more of the frame members .

[0014] The connector member may include a channel , recess or socket for receiving a part of a frame member . Preferably the extent to which the frame member may be inserted into the connector member is variable .

[0015] Alternatively, the frame member may comprise a channel , recess or socket for receiving part of the connector member . The extent to which the connector member may be inserted into the frame member may be variable .

[0016] In a preferred arrangement , the frame is made up of four frame members . The frame preferably includes four connector members , each of which is preferably arranged in use to connect two frame members . The connector members may be arranged in use to comprise corner portions of the frame when the frame is assembled .

[0017] The frame may be arranged to extend around a periphery of a maj or surface of the mattress , more preferably a top surface or a bottom surface , still more preferably there may be a frame extending around the periphery of each of top and bottom major surfaces.

[0018] The mattress may comprise two frames, with one frame extending around a periphery of an upper surface of the mattress and the other frame extending around a periphery of a lower surface of the mattress.

[0019] The frame may be secured to the core by one or more joining members. The joining members may secure one or more of the frame members and / or one or more of the connector members to springs of the core. The joining members may comprise rings, such as "hog" rings .

[0020] The or each frame member preferably comprises a rod, more preferably of metal, such as steel. The or each connector member may comprise a moulding or an extrusion and is preferably of plastics.

[0021] The connector member is preferably substantially rigid. This may allow that the frame, when connected, permits little or no flexibility in its corners.

[0022] The frame may be adjustable in size. More preferably the frames size is adjustable by varying the extent to which the frame member and connector member are connected / inserted, one within the other.

[0023] The invention also includes a frame for a mattress, the frame comprising at least two frame members releasably connected by a connector member. The frame may be according to any statement herein .

[0024] According to another aspect of the present invention, there is provided a method of assembling a mattress , the mattress having a resilient core comprising a plurality of coil springs arranged in an array, and at least one frame extending at least part way around a periphery of the core , wherein the method comprises releasably connecting at least two frame members by a connector member .

[0025] Preferably, the method includes engaging the frame member with the connector member in a releasable push fit , more preferably in a releasable friction fit , with one being inserted at least partly within the other . Preferably, the extent to which the connector member and frame member are able to fit one within the other is variable .

[0026] The method may include adj usting the si ze of the frame by varying the extent to which the connector member and frame member are inserted, one within the other .

[0027] The method preferably comprises securing the frame to the core by one or more j oining members . The j oining members may secure one or more of the frame members and / or one or more of the connector members to springs of the core . The j oining members may comprise rings , such as "hog" rings .

[0028] The invention also includes a method of disassembling a mattress , the mattress having a resilient core comprising a plurality of coil springs arranged in an array, and at least one frame extending at least part way around a periphery of the core , the frame comprising a number of frame members and at least one connector, wherein the method comprises disconnecting at least one frame member from a connector member .

[0029] The method may include sliding the disconnected frame members through one or more rings attaching them to the core .

[0030] The invention may include any combination of the features or limitations referred to herein, except such a combination of features as are mutually exclusive , or mutually inconsistent .

[0031] A preferred embodiment of the present invention will now be described, by way of example only, with reference to the accompanying diagrammatic drawings , in which :

[0032] Figure 1 is a schematic view from above of a mattress according to the prior art ;

[0033] Figure 2 is an end schematic view of the mattress of Figure 1 ;

[0034] Figure 3 is a detailed view of part of the prior art mattress shown in Figures 1 and 2 ;

[0035] Figure 4 is schematic view from above of a mattress according to an embodiment of the present invention; and

[0036] Figure 5 is a schematic cross -sectional view of part of the mattress of Figure 4 . Turning to Figure 4 , there is shown generally at 100 a mattress according to an embodiment of the present invention . In this example , the mattress 100 has a resilient core 110 comprising an array of metal coil springs in individual pockets (not shown) , similar to the one depicted in Figures 1-3 . On each of the maj or upper, and lower, surfaces a demountable frame 120 helps to maintain the core' s shape . The frame 120 is j oined to the core by a plurality of hog rings 130 that pass around the frame and penetrate the pocketing material to engage one or more coils of the springs within (not shown) .

[0037] The frame 120 comprises four frame members 122 and four frame connectors 124 . In this embodiment , the frame members 122 comprise hollow steel rods and the connectors 124 are of a hollow plastics material . The frame members and connectors are dimensioned such that the former can slide into the latter to varying degrees and be held there in a friction fit .

[0038] Figure 5 shows a cross-section of one connector 124 and part of two frame members 122 that are fully inserted into channels 126 within the connector .

[0039] When disassembling the mattress , it is necessary to detach the frame from the resilient core , before any processing of the core can take place . However, unlike the previously considered mattress , it is not necessary to cut each of the hog rings to release the frame . Instead, the frame members 122 are first pulled from the connectors 124 and they may then simply be slid from the hog rings , leaving the rings in place . The connectors 124 may also simply removed in this way . The frame components 122 and 124 may then be stored for reuse .

[0040] Since the extent to which the frame members 122 can be pushed into the connectors 124 is variable , a single set of components may be assembled into a frame of di f ferent lengths and widths , so that frames for di f ferently si zed core units may readily be made from the same parts .

[0041] The connectors are preferably substantially rigid, so that flexing of the frame , especially at the corners , is minimised .

[0042] Whilst endeavouring in the foregoing speci fication to draw attention to those features of the invention believed to be of particular importance , it should be understood that the applicant claims protection in respect of any patentable feature or combination of features referred to herein, and / or shown in the drawings , whether or not particular emphasis has been placed thereon .

Claims

CLAIMS1 . A mattress having a resilient core comprising a plurality of coil springs arranged in an array, and at least one frame extending at least part way around a periphery of the core , the frame comprising at least two frame members releasably connected by a connector member .2 . A mattress according to Claim 1 , wherein the resilient core comprises a plurality of coil springs in pockets .3 . A mattress according to Claim 1 or 2 , wherein the connector member and at least one frame member are arranged to engage one another in a releasable push fit , with one being inserted at least partly within the other .4 . A mattress according to Claim 3 , wherein the extent to which the connector member and frame member are able to fit one within the other is variable .5 . A mattress according to any of preceding claims , wherein the connector member is arranged to receive at least partly within it one or more of the frame members .6 . A mattress according to Claim 5 , wherein the connector member includes a channel , recess or socket for receiving a part of a frame member .7 . A mattress according to any of the preceding claims , wherein the frame is made up of four frame members .8 . A mattress according to any of the preceding claims , wherein the frame includes four connector members , each of which is arranged in use to connect two frame members .9 . A mattress according to any of the preceding claims , wherein the connector members are arranged in use to comprise corner portions of the frame when the frame is assembled .10 . A mattress according to any of the preceding claims , wherein the mattress comprises two frames , with one frame extending around a periphery of an upper surface of the mattress and the other frame extending around a periphery of a lower surface of the mattress .11 . A mattress according to any of the preceding claims , wherein the frame is secured to the core by one or more j oining members .12 . A mattress according to any of the preceding claims , wherein the or each frame member comprises a rod .13 . A mattress according to any of the preceding claims , wherein the or each connector member comprises a moulding or an extrusion .14 . A frame for a mattress , the frame comprising at least two frame members releasably connected by a connector member .15 . A method of assembling a mattress , the mattress having a resilient core comprising a plurality of coil springs arranged in an array, and at least one frame extending at least part way around a periphery of the core , wherein the method comprises releasably connecting at least two frame members by connector member .16 . A method according to Claim 15 , wherein the method includes engaging the frame member with the connector member in a releasable push fit with one being inserted at least partly within the other .17 . A method of disassembling a mattress , the mattress having a resilient core comprising a plurality of coil springs arranged in an array, and at least one frame extending at least part way around a periphery of the core , the frame comprising a number of frame members and at least one connector, wherein the method comprises disconnecting at least one frame member from a connector member .18 . A method according to Claim 17 , wherein the method includes sliding the disconnected frame members through one or more rings attaching them to the core .

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