Bendable mattress innerspring with edge support

Abstract

A bendable mattress innerspring with edge support enables enhanced edge support and smoother and more silent bending of a mattress. The innerspring includes: a plurality of coil springs arranged in longitudinal rows and transverse columns, defining a sleeping surface; upper connecting wires connecting upper portions of the coil springs of one row to upper portions of the coil springs of an adjacent row; and a plurality of central edge reinforcement members. Each central edge reinforcement member in the plurality of central edge reinforcement members: a) is retained adjacent to at least two coil springs of a single row; and b) is longitudinally separated away from an adjacent central edge reinforcement member to enable, in use, the innerspring to bend about a transverse axis such that the sleeping surface becomes a bent surface while adjacent central edge reinforcement members remain separated from each other. During bending of the innerspring, the central edge reinforcement members induce a concertina folding of upper portions of the coil springs of some columns relative to upper portions of the coil springs of adjacent columns.

Description

TITLEBendable Mattress Innerspring with Edge SupportFIELD OF THE INVENTION

[0001] The present invention relates generally to mattresses for bedding. In particular, although not exclusively, the invention relates to mattress innersprings that are bendable about a transverse axis and that include edge supports.BACKGROUND

[0002] Bedding mattresses commonly include some form of edge support, which serves to increase the usable area of the sleep surface. Such edge support can minimize ‘roll out’ as a person moves closer to the edge of the bed.

[0003] Some mattresses feature edge support which is heat-welded to a mattress base plank. That forms a ‘unicased’ construction, as the edge support and base plank effectively become one integral part of a finished mattress.

[0004] With the proliferation of adjustable bases in the bedding industry, a requirement arose for mattresses to be able to bend about a transverse axis, while still maintaining some form of effective edge support. This need has been addressed in some mattress models by using a ‘flexicased’ system, whereby individual ‘flex keys’ are heat welded to the mattress base plank, forming a ‘unicased’ system that allows for articulation of the mattress.

[0005] However, more recently, a need to enable articulating or bendable mattresses in lower-cost market segments has arisen, calling for a flexible edge support solution that does not use heat-welded unicased construction.

[0006] Therefore, there is a need for an improved, lower cost bendable mattress innerspring with edge support.OBJECT OF THE INVENTION

[0007] It is an object of the present invention to overcome and / or alleviate one or more of the disadvantages of the prior art or provide the consumer with a useful or commercial choice.SUMMARY OF THE INVENTION

[0008] In one aspect, although it need not be the only or the broadest aspect, the invention resides in a bendable mattress innerspring with edge support, comprising:a plurality of coil springs arranged in longitudinal rows and transverse columns, defining a sleeping surface;upper connecting wires connecting upper portions of the coil springs of one row to upper portions of the coil springs of an adjacent row; anda plurality of central edge reinforcement members;wherein each central edge reinforcement member in the plurality of central edge reinforcement members:a) is retained adjacent to at least two coil springs of a single row; andb) is longitudinally separated away from an adjacent central edge reinforcement member to enable, in use, the innerspring to bend about a transverse axis such that the sleeping surface becomes a bent surface while adjacent central edge reinforcement members remain separated from each other; andwherein, during bending of the innerspring, the central edge reinforcement members induce a concertina folding of upper portions of the coil springs of some columns relative to upper portions of the coil springs of adjacent columns.

[0009] Optionally, the central edge reinforcement members are symmetrically positioned on each side of the innerspring, such that a longitudinal positioning of each central edge reinforcement member on one side of the innerspring is identicalto a longitudinal positioning of each central edge reinforcement member on an opposite side of the innerspring.

[0010] Optionally, during bending of the innerspring, the central edge reinforcement members induce a concertina folding of the upper portions of the coil springs of some rows by preventing some of the upper connecting wires from moving downward into the central edge reinforcement members

[0011] Optionally, each central edge reinforcement member is “C” shaped.

[0012] Optionally, each central edge reinforcement member is initially cylindrical, and is stretched into a “C” shape when it is retained adjacent to the at least two coil springs of a single column during assembly of the innerspring.

[0013] Optionally, each central edge reinforcement member is separated away from an adjacent edge reinforcement member by a width of at least one coil spring in the plurality of coil springs.

[0014] Optionally, each central edge reinforcement member has a height that is approximately equal to a height of a coil spring in the plurality of coil springs.

[0015] Optionally, each central edge reinforcement member has an elongated middle portion that extends between the at least two coil springs along a side of the at least two coil springs that faces away from a nearest edge of the innerspring.

[0016] Optionally, each central edge reinforcement member is made of polyethylene.

[0017] Optionally, the innerspring further includes corner reinforcement members, wherein each corner reinforcement member extends from an end coil spring in an edge column across an end coil spring in a column adjacent to the edge column.

[0018] Optionally, the innerspring further includes a plurality of straight edge reinforcement members that extend between an edge column or row of the coil springs and a column or row, respectively, adjacent to the edge column or row.

[0019] Optionally, the plurality of coil springs also define a lower surface, and the innerspring further includes lower connecting wires connecting lower portions of the coil springs of one row to lower portions of the coil springs of an adjacent row.

[0020] Optionally, each central edge reinforcement member is longitudinally separated away from an adjacent central edge reinforcement member by one edge coil spring.

[0021] Optionally, each central edge reinforcement member is longitudinally separated away from an adjacent central edge reinforcement member by more than one edge coil spring.

[0022] Optionally, the upper connecting wires comprise helical lacing wires wound around the upper portions of the coil springs of one row and around the upper portions of the coil springs of an adjacent row.BRIEF SUMMARY OF THE DRAWINGS

[0023] To assist in understanding the invention and to enable a person skilled in the art to put the invention into practical effect, preferred embodiments of the invention are described below by way of example only with reference to the accompanying drawings, in which:

[0024] FIG. 1 is a top perspective view of a bendable mattress innerspring with edge support, according to one embodiment of the present invention.

[0025] FIG. 2 is a top perspective view of the bendable mattress innerspring of FIG. 1, but with all of the coil springs and lacing wires removed.

[0026] FIG. 3 is a top perspective view of the bendable mattress innerspring of FIG. 1, with all of the coil springs and lacing wires removed, as shown in FIG. 2, and with the innerspring being bent about a transverse axis through the middle of the innerspring.

[0027] FIG. 4 is a close up top view of a portion of the mattress innerspring of FIG. 1, illustrating a sample of only nine of the coil springs arranged in three longitudinal rows and three transverse columns.

[0028] FIG. 5 is a close up top perspective schematic illustration of a portion of the mattress innerspring of FIG. 1 in a bent configuration, similar to the configuration shown in FIG. 3.

[0029] FIG. 6 is a close up top perspective schematic illustration of a portion of a mattress innerspring in a bent configuration, according to an alternative embodiment of the present invention.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0030] The present invention relates to a bendable mattress innerspring with edge support. Elements of the invention are illustrated in concise outline form in the drawings, showing only those specific details that are necessary to understanding the embodiments of the present invention, but so as not to clutter the disclosure with excessive detail that will be obvious to those of ordinary skill in the art in light of the present description.

[0031] In this patent specification, adjectives such as first and second, upper and lower, longitudinal and transverse, above and below, top and bottom, vertical and horizontal, etc., are used solely to define one element or method step from another element or method step without necessarily requiring a specific relative position or sequence that is described by the adjectives. Words such as “comprises” or “includes” are not used to define an exclusive set of elements or method steps. Rather, such words merely define a minimum set of elements or method steps included in a particular embodiment of the present invention.

[0032] According to one aspect, the present invention is a bendable mattress innerspring with edge support, comprising:a plurality of coil springs arranged in longitudinal rows and transverse columns, defining a sleeping surface;upper connecting wires connecting upper portions of the coil springs of one row to upper portions of the coil springs of an adjacent row; anda plurality of central edge reinforcement members;wherein each central edge reinforcement member in the plurality of central edge reinforcement members:a) is retained adjacent to at least two coil springs of a single row; andb) is longitudinally separated away from an adjacent central edge reinforcement member to enable, in use, the innerspring to bend about a transverse axis such that the sleeping surface becomes a bent surface while adjacent central edge reinforcement members remain separated from each other; andwherein, during bending of the innerspring, the central edge reinforcement members induce a concertina folding of upper portions of the coil springs of some columns relative to upper portions of the coil springs of adjacent columns.

[0033] Advantages of some embodiments of the present invention include enhanced edge support for a mattress, by enabling the edge support to remain effective both when the mattress is flat and defines a generally planar sleeping surface and when the mattress is bent and defines a curved sleeping surface.

[0034] Also, according to some embodiments, the induced concertina folding of upper portions of the coil springs of some rows relative to upper portions of the coil springs of adjacent rows enables a smoother and more silent bending of the innerspring.

[0035] Also, according to some embodiments, the enhanced edge support of the present invention is enabled at relatively low cost.

[0036] Also, according to some embodiments, the enhanced edge support of the present invention is relatively robust as some of the edge reinforcement members are positioned inside the innerspring and not along an outside perimeter of the innerspring.

[0037] Further, according to some embodiments, the enhanced edge support of the present invention is designed for low-cost manufacture, as the edge supports require no separate connectors or adhesives to hold them in place on the innerspring.

[0038] Those skilled in the art will appreciate that not all of the above advantages are necessarily included in all embodiments of the present invention.

[0039] FIG. 1 is a top perspective view of a bendable mattress innerspring 100 with edge support, according to one embodiment of the present invention. The innerspring 100 includes a plurality of coil springs 105 arranged in longitudinal rows 110 and transverse columns 115. As shown, the top of the innerspring 100 defines asleeping surface, which like typical bedding mattresses known in the art is covered and tailored during final manufacture, and sometimes during use, with various padding and fabric portions.

[0040] Upper connecting wires, in the form of helical lacing wires 120, connect upper portions of the coil springs 105 of one row 110 to upper portions of the coil springs 105 of an adjacent row 110. (See FIG. 4 for a close up view of some of the coil springs 105 and helical lacing wires 120.) As described herein, edge coil springs 105 are defined as coil springs 105 that are positioned immediately adjacent an outer edge of the innerspring 100.

[0041] Lower connecting wires, also in the form of helical lacing wires 120, connect lower portions of the coil springs 105 of one row 110 to lower portions of the coil springs 105 of an adjacent row 110.

[0042] The centre third of the outer side edge rows 125 of the coil springs 105 include edge support in the form of a plurality of central edge reinforcement members 130. Each central edge reinforcement member 130 is shown connected to two coil springs 105 of its respective edge row 125. Further, each central edge reinforcement member 130 is shown longitudinally separated away from an adjacent central edge reinforcement member 130 by a spacing of one column 115 of the coil springs 105.

[0043] Also, the elongated middle portion of each central edge reinforcement member 130 is positioned away from an edge of the innerspring 100 and between first and second longitudinal rows 110 of the coil springs 105. That helps shield and protect the central edge reinforcement members 130 from damage during use.

[0044] Each of the end thirds of the outer side edge rows 125 of the coil springs 105 include edge support in the form of straight edge reinforcement members 135 and corner reinforcement members 140. The central edge reinforcement members 130, the straight edge reinforcement members 135, and the corner reinforcement members 140 thus provide a reinforced bedding edge on both ends and both sides of the innerspring 100. That enables a comfortable and consistent vertical spring response across the entire sleeping surface, as the additional edge support works together with and modulates the spring response of the coil springs 105 positioned at all edges and corners of the innerspring 100.

[0045] FIG. 2 is a top perspective view of the bendable mattress innerspring 100, but with all of the coil springs 105 and lacing wires 120 removed. As shown,both sides and both ends of the innerspring 100 include edge support using a combination of the central edge reinforcement members 130, the straight edge reinforcement members 135, and the corner reinforcement members 140.

[0046] Those skilled in the art will appreciate that, according to some embodiments, all of the central edge reinforcement members 130, the straight edge reinforcement members 135, and the corner reinforcement members 140 can be fabricated from the same material, such as polyethylene. Also, to reduce costs, the central edge reinforcement members 130 and the corner reinforcement members 140 can be identical products, such as longitudinally cut polyethylene cylinders that are then stretched into a “C” shape as illustrated. Such stretching is also advantageous as each stretched end of the “C” shape can effectively grasp the side of a coil spring 105, and thus no fasteners or adhesives are required to hold in place the installed central edge reinforcement members 130 and corner reinforcement members 140.

[0047] Further, the straight edge reinforcement members 135 can be held in place simply by tightly installing them between the first and second longitudinal rows 110 of coil springs 105. The thickness of each of the central edge reinforcement members 130, the straight edge reinforcement members 135, and the corner reinforcement members 140 can be adjusted in order to tune an appropriate edge support response for each edge of the innerspring 100.

[0048] FIG. 3 is a top perspective view of the bendable mattress innerspring 100, with all of the coil springs 105 and lacing wires 120 removed, as shown in FIG.2, and with the innerspring 100 being bent about a transverse axis through the middle of the innerspring 100. The innerspring 100 thus accommodates transverse bending to allow, for example, the head of a bed to be lifted well above the foot of the bed. As known in the art, such bending generally occurs through the use of remote controlled electric motors (not shown) installed under the innerspring 100.

[0049] As shown, because each central edge reinforcement member 130 is longitudinally separated away from an adjacent central edge reinforcement member 130, the sleeping surface is enabled to become a bent surface while the tops of central edge reinforcement members 130 remain separated from each other. In such a curved or bent configuration, the mattress innerspring 100 thus remains able to provide effective edge support.

[0050] FIG. 4 is a close up top view of a portion of the mattress innerspring 100, illustrating a sample of only nine of the coil springs 105 arranged in three longitudinal rows 110 and three transverse columns 115. Four helical lacing wires 120 are also illustrated connecting the tops of the coil springs 105 together.

[0051] As described in detail below, when the sleeping surface of the mattress innerspring 100 is bent, each helical lacing wire 120 near the transverse bending axis of the innerspring 100 functions as a hinge, and enables a concertina folding of upper portions of the coil springs 105 of some transverse columns 115 relative to upper portions of the coil springs 105 of adjacent transverse columns 115.

[0052] FIG. 5 is a close up top perspective schematic illustration of a portion of the mattress innerspring 100 in a bent configuration, similar to the configuration shown in FIG. 3. The rectangles each represent a central edge reinforcement member 130, the jagged lines each represent a coil spring 105, and the dashed lines each represent a helical lacing wire 120. The concertina folding described above is clearly illustrated, where during bending of the mattress innerspring 100 the upper portions of one top side of the coil springs 105 of some transverse columns 115 (and a respective helical lacing wire 120 that loops around that top side of the springs 105) all move upward relative to the upper portions of the other top side of the coil springs 105 (and an adjacent helical lacing wire 120) of the same transverse columns 115.

[0053] The concertina folding of FIG. 5 can be further clarified with reference to FIG. 4, where during bending of the innerspring 100 some of the helical lacing wires 120 will move upward (i.e. , out of the page of FIG. 4) while, simultaneously, adjacent helical lacing wires 120 will move downward (i.e., into the page of FIG. 4). The central edge reinforcement members 130 induce such concertina folding by, for example, preventing some of the helical lacing wires 120 from moving downward into the central edge reinforcement members 130.

[0054] Further, according to some embodiments of the present invention, the central edge reinforcement members 130 are symmetrically positioned on each side of the innerspring 100, such that a longitudinal positioning of each central edge reinforcement member 130 on one side of the innerspring 100 is identical to a longitudinal positioning of each central edge reinforcement member 130 on the opposite side of the innerspring 100. During bending of the innerspring 100, such symmetrical positioning of the central edge reinforcement members 130 about a longitudinal centre line of the sleeping surface guides the above described concertinafolding, where each helical connecting wire 120 is induced to move along its entire transverse length in a same direction, either upwards or downwards.

[0055] Thus, the symmetrical positioning of the central edge reinforcement members 130 about a longitudinal centre line of the sleeping surface induces the coil springs 105 to behave the same at both ends of the helical connecting wires 120, thereby minimising the risk of sudden re-positioning of the coils springs 105 and connecting wires 120 during bending of the innerspring 100.

[0056] Such sudden re-positioning can occur in bendable mattress designs of the prior art when two ends of a transverse column of coil springs are not in synch with each other across a mattress. In such circumstances, one of the ends of a spring column will ‘pop’ into alignment with the other end at some stage during bending. Such re-positioning is highly undesirable as it often can be both heard and felt by the user.

[0057] FIG. 6 is a close up top perspective schematic illustration of a portion of a mattress innerspring 600 in a bent configuration, according to an alternative embodiment of the present invention. The only difference between the innerspring 100 and the innerspring 600, is that in the innerspring 600 each central edge reinforcement member 130 is not separated away from an adjacent central edge reinforcement member 130 by a width of at least one coil spring 105. Rather, in the innerspring 600, each central edge reinforcement member 130 is positioned immediately adjacent to another central edge reinforcement member 130.Nevertheless, given a proper innerspring design, all the central edge reinforcement members 130 in a single longitudinal row 110 are adequately longitudinally separated to enable unhindered bending of the innerspring about a transverse axis.

[0058] Further embodiments of the present invention include mattress innersprings where each central edge reinforcement member 130 is longitudinally separated away from an adjacent central edge reinforcement member 130 by more than one edge coil spring 105.

[0059] Still other examples of additional or alternative features of alternative embodiments of the present invention include embodiments where each central edge reinforcement member is not “C” shaped, but is shaped similar to a bracket “[“. Other alternative embodiments include central edge reinforcement members that comprise a simple straight plank that is connected to the coil springs 105 by fasteners oradhesives, while remaining longitudinally separated from adjacent central edge reinforcement members.

[0060] Also, according to some alternative embodiments of the present invention, the helical lacing wires 120 can be replaced with alternative types of connecting wires, including for example independent loops that connect together the top and bottom sides of adjacent coil springs 105.

[0061] Those skilled in the art will appreciate that various embodiments of the present invention can be manufactured from a wide range of materials, including various polymers or natural fibrous materials for the reinforcement members and various metals, metal alloys or composites for the coil springs and connecting wires.

[0062] Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0063] The above description of various embodiments of the present invention is provided for purposes of description to one of ordinary skill in the related art. It is not intended to be exhaustive or to limit the invention to a single disclosed embodiment. Numerous alternatives and variations to the present invention will be apparent to those skilled in the art in light of the above teaching. Accordingly, while some alternative embodiments have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art.Accordingly, this patent specification is intended to embrace all alternatives, modifications and variations of the present invention that have been discussed herein, and other embodiments that fall within the spirit and scope of the abovedescribed invention.

Claims

CLAIMSWe claim:

1. A bendable mattress innerspring with edge support, comprising:a plurality of coil springs arranged in longitudinal rows and transverse columns, defining a sleeping surface;upper connecting wires connecting upper portions of the coil springs of one row to upper portions of the coil springs of an adjacent row; anda plurality of central edge reinforcement members;wherein each central edge reinforcement member in the plurality of central edge reinforcement members:a) is retained adjacent to at least two coil springs of a single row; andb) is longitudinally separated away from an adjacent central edge reinforcement member to enable, in use, the innerspring to bend about a transverse axis such that the sleeping surface becomes a bent surface while adjacent central edge reinforcement members remain separated from each other; andwherein, during bending of the innerspring, the central edge reinforcement members induce a concertina folding of upper portions of the coil springs of some columns relative to upper portions of the coil springs of adjacent columns.

2. The mattress innerspring of claim 1, wherein the central edge reinforcement members are symmetrically positioned on each side of the innerspring, such that a longitudinal positioning of each central edge reinforcement member on one side of the innerspring is identical to a longitudinal positioning of each central edge reinforcement member on an opposite side of the innerspring.

3. The mattress innerspring of claim 1, wherein, during bending of the innerspring, the central edge reinforcement members induce a concertina folding of the upper portions of the coil springs of some rows by preventing some of the upper connecting wires from moving downward into the central edge reinforcement members.

4. The mattress innerspring of claim 1, wherein each central edge reinforcement member is “C” shaped.

5. The mattress innerspring of claim 4, wherein each central edge reinforcement member is initially cylindrical, and is stretched into a “C” shape when it is retained adjacent to the at least two coil springs of a single column during assembly of the innerspring.

6. The mattress innerspring of claim 1, wherein each central edge reinforcement member is separated away from an adjacent edge reinforcement member by a width of at least one coil spring in the plurality of coil springs.

7. The mattress innerspring of claim 1, wherein each central edge reinforcement member has a height that is approximately equal to a height of a coil spring in the plurality of coil springs.

8. The mattress innerspring of claim 1, wherein each central edge reinforcement member has an elongated middle portion that extends between the at least two coil springs along a side of the at least two coil springs that faces away from a nearest edge of the innerspring.

9. The mattress innerspring of claim 1, wherein each central edge reinforcement member is made of polyethylene.

10. The mattress innerspring of claim 1, further comprising corner reinforcement members, wherein each corner reinforcement member extends from an end coil spring in an edge column across an end coil spring in a column adjacent to the edge column.

11. The mattress innerspring of claim 1, further comprising a plurality of straight edge reinforcement members that extend between an edge column or row of the coil springs and a column or row, respectively, adjacent to the edge column or row.

12. The mattress innerspring of claim 1, wherein the plurality of coil springs also define a lower surface, andfurther comprising:lower connecting wires connecting lower portions of the coil springs of one row to lower portions of the coil springs of an adjacent row.

13. The mattress innerspring of claim 1, wherein each central edge reinforcement member is longitudinally separated away from an adjacent central edge reinforcement member by one edge coil spring.

14. The mattress innerspring of claim 1, wherein each central edge reinforcement member is longitudinally separated away from an adjacent central edge reinforcement member by more than one edge coil spring.

15. The mattress innerspring of claim 1, wherein the upper connecting wires comprise helical lacing wires wound around the upper portions of the coil springs of one row and around the upper portions of the coil springs of an adjacent row.

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