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Bed foundation having a structural foam perimeter utilizing mechanical interlockingRelated Patent Categories: Beds, Mattress (for Whole Body), Having Innerspring-type CoreBed foundation having a structural foam perimeter utilizing mechanical interlocking description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20050246839, Bed foundation having a structural foam perimeter utilizing mechanical interlocking. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to a bed support or foundation having a perimeter formed of structural foam, and more particularly to a structural foam perimeter which utilizes mechanical interlocking to attach the various structural foam portions to each other and/or to a box spring set carried therewithin. [0003] 2. Description of the Related Art [0004] Most beds available today employ a form of a bed support. With the use of a standard mattress, this bed support typically comes in the form of a set of box springs. In the case of a waterbed, this bed support is generally designed to enclose a waterbed bladder carried therewithin. Other bed supports may incorporate another type of interior support member such as an air bladder or a foam insert. [0005] When the bed support is a standard set of box springs, there are certain associated drawbacks therewith. Such drawbacks include, but are not limited to, the "edge roll" that occurs as consumers sit or lay on or very near the edge of the bed. This edge roll effect is the tendency of the consumer to feel as though he/she is rolling/leaning off of the edge of the bed. This edge roll effect occurs due to springs along the perimeter of the box spring becoming loosened from the interior springs within the box-spring array and actually leaning outward toward the edges of the box springs. While there have been some attempts in the art to correct this "edge roll" the results have been less than ideal and have been generally labor intensive (as an example, the use of twist ties to attempt to attach the perimeter springs with adjacent interior springs within the box-spring array). [0006] Other shortcomings are generally associated with the standard set of box springs. One drawback is the spring noise which can be associated therewith. Additionally, the standard set of box springs generally requires the employment of a significant amount of wood and carpentry expertise, thereby contributing to the expense thereof. [0007] In an attempt to counteract some of the problems associated with bed supports and especially box spring sets, polyurethane foam products have been developed as bed support perimeters. However, such polyurethane perimeters have generally required a gluing step for their attachment to one another. There are several problems associated with such gluing. Gluing is a labor intensive process; gluing creates emissions of gas that may potentially be noxious to those working with and around them; and such glue requires a certain period in which to set, thereby necessitating a large number of premade supports taking up a large area of factory space and thereby decreasing the potential throughput of bed supports created during a production cycle. [0008] What is needed in the art is a bed support unit incorporating a structural foam perimeter which avoids the need for gluing to attach the portions thereof together and which, even more ideally, provides a means to decrease "edge roll" associated with standard bed foundation units. SUMMARY OF THE INVENTION [0009] The present invention generally relates to a perimeter for a bed support that is made of structural foam and provides for mechanical interlocking portions as part of the sections of the perimeter. Such interlocking members are structured and arranged to selectively facilitate the interconnection of the perimeter members to one another, to couple the perimeter members with the outlying perimeter springs within the array of box springs to reduce "edge roll", and/or to ease the joinder between the perimeter members and a top and/or bottom structural foam piece, (e.g., the topper or bottom, respectively). [0010] The present invention, in one particular form thereof, relates to a bed foundation including a first bed frame member and a second bed frame member. The first bed frame member is composed of a structural foam and has a pair of first frame member ends. At least one first frame member end has a first mechanical interconnect portion associated therewith. The second frame member is composed of a structural foam and has a pair of second frame member ends. At least one second frame member end has a second mechanical interconnect portion associated therewith. One of the first mechanical interconnect portion and the second mechanical interconnect portion is preferably one of slidably received and snap-fit within the other of the first mechanical interconnect portion and the second mechanical interconnect portion. The first mechanical interconnect portion and the second mechanical interconnect portion thereby form an interlocking connection. [0011] The present invention, in another form thereof, sets forth a bed foundation including a sidewall frame, a box-spring array, and at least one spring interconnect mechanism. The sidewall frame defines a frame interior, and the box-spring array is received with such a frame interior. The box-spring array includes a plurality of perimeter springs, each being adjacent the sidewall frame. The at least one frame interconnect mechanism extends from the sidewall frame and into the frame interior. At least one spring interconnect mechanism interacts with at least one perimeter spring to thereby aid in retaining the at least one perimeter spring in place relative to the sidewall frame. [0012] The present invention, in another form thereof, sets forth a bed foundation including a sidewall frame and a first structural foam layer. The sidewall frame has a frame top and a frame bottom. The first structural foam layer is mechanically interlocked with the sidewall frame and extends across one of the frame top and the frame bottom. [0013] The present invention, in still another form thereof, sets forth a bed foundation including a sidewall frame, a box-spring array, at least one spring interconnection mechanism, and at least a first structural foam layer. The first sidewall frame is made up of a plurality of mechanically interlocking frame members. The sidewall frame has a frame interior, a frame top, and a frame bottom. The box-spring array is received within the frame interior, and such an array includes a plurality of springs. The at least one spring interconnect mechanism extends from the sidewall frame and into the frame interior. At least one spring interconnect mechanism interacts with at least one spring to thereby aid in retaining the at least one spring in place relative to the sidewall frame. The at least first structural foam layer is mechanically interlocked with the sidewall frame at one of the frame top and the frame bottom and correspondingly extends thereacross. [0014] An advantage of the present invention is that the cost of manufacturing such a bed foundation, utilizing the mechanically interconnecting members of the present invention, is reduced over the cost associated with supports using standard box springs and with those using structural foam members attached via a resin, glue, or other adhesive, due to cost savings related to both assembly and parts. [0015] Another advantage of the present invention is that the ability of the foam perimeter to interlock at least with a portion of the perimeter springs within the box-spring array helps to reduce the occurrence of "edge roll". [0016] Yet another advantage of the present invention is that it permits the creation of a tub/box that is capable of supporting/containing any one of a foam support insert, a box-spring array, an air bladder, a water bed bladder, or other interior support mechanism/system. [0017] A series of advantages are associated with the use of a foam tub/box is that such a tub or box has an inherently cushiony feeling and is reasonably durable, sufficiently supportive, and inexpensive to produce. [0018] An even further advantage of the present invention is that structural foam pieces can be cut to shape using computer controlled machinery (e.g., die cutting machines), thereby increasing the efficiency and accuracy possible with their production. [0019] An additional advantage of the present invention is that the foam members will aid in dampening spring noise associated with a standard set of box springs. BRIEF DESCRIPTION OF THE DRAWINGS [0020] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of various embodiments of the invention taken in conjunction with the accompanying drawings, wherein: [0021] FIGS. 1A-H are schematic, top views of sidewall frames according to the first aspect of the present invention, incorporating various types of mechanical interlocks for attaching adjoining frame member ends; Continue reading about Bed foundation having a structural foam perimeter utilizing mechanical interlocking... 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