SPRING MODULES COMPOSITE MATERIAL FOR CUSHIONS
FIELD OF THE INVENTION The present invention generally pertains to flexible support structures having a frame structure with springs attached to members of the frame and an underlying grid, and more particularly to support structures with composite material or plastic springs directly attached to members. of the frame and assembled with specialized equipment and methods.
BACKGROUND OF THE INVENTION Springs for use as flexible support elements in support structures such as seats and cushions and furniture have traditionally and conventionally been constructed of steel for springs and wire. See, for example, U.S. Patent Nos. 188,636; 1,887,058; 4,535,978, 4,339,834; 5,558,315. Attempts have been made to construct flexible support elements without plastic material. See, for example, U.S. Patent Nos. 4,530,490; 4,736,932; 5,162,125 and 5,265,291. Although the fiber-reinforced plastic springs are well developed equitably, the use thereof in flexible support structures such as seats, furniture and pads presents the formidable design challenge of providing suitable means for joining the springs to a structure of frame and to an underlying support surface. The plastic springs have therefore simply mechanically attached to a support structure such as that described in U.S. Patent No. 4,411,159 on a fiber-reinforced plastic sheet spring for a vehicle. Any type of mechanical bonding is complicated by the extreme hardness and strength of fiber reinforced plastics. In the end, it is almost always necessary to drill union holes in the spring for a mechanical fastener (as described in US Patent No. 4,736,932) which requires additional manufacturing and assembly steps. Also, perforation through the fiber reinforced structure breaks down the preferred long strand / thread fibers that are critical to provide optimum flexible characteristics. The related application discloses jaws for the attachment of quilted base springs to a frame and an underlying grid. Although fully operational and novel, this procedure requires additional parts and increased assembly tasks, and does not completely solve the negative parts of the possible loss of performance between the spring and the jaws, and the generation of noise by relative movement. Conventional pad systems commonly include a mattress supported by a base or "spring mattress". The bases are provided to give support and firmness to the mattress as well as elasticity to be able to deviate under excessive load or by shock. The bases typically consist of a rectangular wooden frame, a steel wire grating supported above the wooden frame and an arrangement of steel wire springs, such as compression-type springs that are secured to the wooden frame. In order to adequately support and maintain the level of firmness in the mattress, a large number of compression springs is needed in the base, resulting in high production cost. This is the main disadvantage for using compression springs in padded frames. Also, bases using compression springs typically have a low carbon wire grid or matrix attached to the tops of the springs. Both the wires and the matrix welds can bend or break under excessive conditions. In such steel / metal systems, fasteners are required to secure the springs to the grid and the frame. This leads to a metal-to-metal contact which can easily produce squeaking sounds under dynamic load. In an effort to avoid the high cost of using compression springs on bases, another type of spring used is the steel torsion spring formed of heavy gauge steel spring wire bent into multiple continuous sections that deflect by twisting when they are compressed See, for example, U.S. Patent Nos. 4,932,535; 5,346,190 and 5,558,315. Because the twisting means are dimensionally longer and stiffer than the compression springs, some torsion springs are needed in the base. However, the manufacture of steel wire twist type springs requires expensive tool and bending equipment. Elaborate progressive bending dies are required to produce the complex torsion spring module shapes that can include four or more joint sections. The manufacturing process is not economically adaptable to produce different configurations of springs without new tool, treatment and / or changes of establishment of machinery and stopping the process, etc. Therefore, the configuration and degree of flexibility resulting from such springs can not be altered easily or economically to produce bases with different support characteristics. In addition, the various bends in these types of springs make dimensional quality control and flexibility tolerance control very difficult to achieve. Also, variations in the properties of the steel material and the need for protection against corrosion and heat treatment add to the cost and difficulty of producing steel wire spring modules. And, in addition, the complicated geometry of the relatively long torsion springs makes assembling the springs in the base frame relatively difficult. Another disadvantage of the use of steel wire springs in the bases, and a particular disadvantage of the torsion springs, is the phenomenon of "flexible distortion" in which a spring does not return completely to an uncompressed height after excessive loading . While a spring deviates within its tolerance range of degree of flexibility, it can be repeatedly loaded during a certain number of cycles without noticeable change in operating characteristics, however, if it deviates past the maximum deviation margin, it will experience deformation permanent or "distortion" resulting in a permanent change in operating characteristics such as lack of reflective support, permanent change in shape or catastrophic failure in the form of a break. The flexible distortion in the steel wire springs can also occur simply after prolonged normal use, ie continuous heavy load. This phenomenon is also generally referred to as fatigue and can result in catastrophic failure. Mattresses of increased thickness dimension such as mattresses with "top cushions", when placed on the top of traditional bases of six to eight inches in height, may be too high in proportion to the head boards and feet of the cushions, resulting in a complicated appearance and an excessively high resting surface. This trend towards longer mattresses and bases increases distribution and storage costs. Padded bases in the United States are typically measured in the order of five to eight inches in thickness, with an average thickness (or height) of six or one and a half to seven and one and a half inches. In conventional bases, most of this dimension is attributable to the height of the wire spring modules. In general, the deflection of the torsion wire spring modules is limited to approximately 20% of the total height dimension. Compression that exceeds the 20% margin can cause spring distortion or breakage. By reducing the overall height of the torsion spring modules, it can make the springs too rigid and decrease the desired deflection characteristics and the ability to absorb heavy loads with recovery. In addition, the number of cycles to fail during the existence test is generally more difficult to predict with shortened height spring wire modules and is usually much fewer cycles to fail than higher height spring wire modules. However, it may be desirable to have a base with reduced height while retaining the desired support and deflection characteristics. In the prior art, the wire type springs have been directly attached to the frame members, as for example in US Patent No. 4,067,424. In the related applications, the composite springs are configured with a "joint attachment" that engages a metal rail such as the patented Sealy Steel Span ™ base frame rail. However, there has not been provided a composite spring which is adapted for direct connection to a generic frame member not specifically adapted for coupling the spring structures.
SUMMARY OF THE INVENTION The present invention provides composite spring modules for use as flexible support elements in support structures such as seats and pads. Composite spring modules include a flexible body composed of a plastic that is wrapped and cured on reinforcing fibers and a second plastic or polymeric material from which the joining accessories are integrally formed or molded on, or attached to the body flexible. The material of the joining accessories can be the same or different from the plastic material of the flexible body. For spring modules for a padded base, the attachment fittings are selectively configured for attachment to members of a base frame structure, and a grid or support structure that underlies the structure of the frame. The integral formation of the plastic attachment fittings on the flexible body eliminates the need for physically separate fasteners to secure the springs to the grid. A specially configured upright allows the composite material to be mounted directly to a flat surface of a frame member. In one embodiment, a composite spring module is configured to directly attach to a frame member, which is not otherwise specially configured to engage or receive the spring. The spring module is attached to the frame member by a fastener such as a clip passing through a pillar portion of the spring module in the frame member. The invention also provides assembly templates for the dimensionally fixed connection of the spring modules to the frame members, and the alignment of the frame members with the spring modules attached for attachment to an underlying grid. The invention, furthermore, allows the production of novel low-profile / low-height cushion bases resistant to excess and long-lived which incorporate the spring modules of the composite material with integral joining accessories. Composite spring modules are used instead of traditional wire springs as the main reflective support components. In one embodiment, the entire low height of a quilted base of composite material is approximately 50-60% of the height of the traditional bases, yet it has improved the characteristics of deviation / elasticity over traditional bases. The invention furthermore provides a high profile or conventional height padded base which utilizes the composite spring modules mounted on a novel raised profile frame. The invention furthermore includes a novel method for manufacturing the base spring modules from composite materials such as epoxy / polyester and glass fiber combinations, by molding the materials into various flexible forms, particularly adapted and especially suitable for the Use as support elements in a padded base. As used herein, the term "composite" means a combination of at least two materials mixed together in a solid form, such as any plastic material that can be molded, extruded or extruded by drawing and a fibrous material attached or embedded or otherwise linked to the plastic material. The term "composite" also refers to the integral formation of bonding fittings from a mouldable material around a flexible body having encapsulated fibers. The invention further includes a novel method of selectively assembling padded base units using composite spring modules wherein the spring modules are selectively accommodated on and fixedly attached to a frame structure and to an underlying grid. In a preferred embodiment of the spring modules, the composite material is extruded by stretching into a generally flat elongated spring module to provide a low depth / height dimension and an efficient tension and load distribution. The use of spring modules of molded / extruded composite material by stretching, and in articulating the flat elongated configuration of the composite spring module, provides numerous fabrication and assembly advantages over the prior art wire springs, including simplified base construction, module fabrication and handling, and easy adaptability to automated manufacturing and assembly processes for the subassembly and final assembly of the base units. In addition, the novel method for manufacturing the base spring modules from composite materials is easily adaptable to the manufacture of a wide variety of spring modules having different shapes and characteristics of support and deflection with various flexible proportions, without substantial treatment or modification of the fundamental process. The process allows very high reproducibility of performance characteristics. The invention furthermore includes a novel raised profile and low profile base frames for support spring modules and an underlying grid. A low profile frame has parallel longitudinal and central members / transverse members with a main width parallel to the main widths of the longitudinal members, and end eave boards with a main width orthogonal to the main widths of the transverse members. A high profile frame has perimeter members and parallel longitudinal centrals, and transverse members and end eaves boards orthogonally joined to the longitudinal members, with major widths of the transverse members and eaves tables perpendicular to the widths of the members longitudinal, and a narrow lower edge of the eaves boards flush with the bottom surfaces of the longitudinal members. Because wood exists in abundance, it is easy to work and economical, it is an attractive material for use in quilted frame racks. In the above embodiment, the frame attaching fittings are configured for locking and keying engagement with the openings in the upper part of the longitudinal frame members. This requires that the upper part of the upper longitudinal frame members have holes for coupling with the attachment fittings. However, once a series of holes is placed along the length of a wooden frame member, the frame member is no longer able to provide the desired support in the padded base. The invention provides an alternative embodiment of the composite spring module adapted for secure coupling to wooden frame members. This allows the production of quilted wooden bases that have all the advantageous characteristics of the composite springs and with a lower cost to the manufacturing than comparable quilted steel frame bases. The invention further includes a novel method for manufacturing bases comprising wooden frame members and composite springs. The method allows the economic and efficient production of padded frames well suited both for manual or automated manufacturing. These and other aspects of the invention are described herein, in particular detail with reference to the appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS In the attached Drawings: FIGS. 1A-1C are perspective views of the composite spring modules with integrally formed joining fittings of the present invention;
FIGURE 2 is a perspective view of a padded base having spring modules of composite material with integrally formed attachment fittings of the present invention; FIGURES 3A and 3B are perspective views of the composite spring modules of the invention coupled with intersecting members of a padded base grid; FIGURE 4 is a perspective view of a high profile quilted base with composite springs with integrally formed attachment fittings of the present invention; FIGURE 5 is a perspective view of a portion of an alternative embodiment of a padded base of the present invention; FIGURE 6A is a perspective view of an alternative embodiment of a composite spring module with integrally formed attachment fittings of the present invention; FIGURE 6B is a perspective view of another embodiment of a spring module of the invention; FIGURE 6C is an elevation view of a spring module of the invention coupled with a frame member and a grid in a padded base of the present invention;
FIGURE 6D is a perspective view of an alternative embodiment of a spring module of the invention attached to a frame member of a padded base; FIGURE 7 is a perspective view of a low profile version of a padded base frame and flexible structure constructed in accordance with the present invention; FIGURE 8A is a perspective view of a preferred embodiment of a composite spring module configured for direct mounting to a support surface of a frame member of a structure; FIGURE 8B is an internal perspective view of a preferred embodiment of the composite spring module of FIGURE 8A; FIGURE 9A is a cross-sectional view of a composite spring module directly attached to a frame member of a flexible structure; FIGURE 9B is an overhead view of a composite spring module attached directly to a frame member of a flexible structure; FIGURE 10 is a perspective view of a composite spring mounted on a frame member and attached to a frame member; intersecting wires of an underlying grid; FIGURE 11A is a perspective view of a jig used to position and secure the composite spring modules to a frame member of a flexible structure; FIGURE 11B is an overhead view of a template used to position and secure the composite spring modules to a frame member of a flexible structure; FIGURE 11C is a side view of a jig used to position and secure the composite spring modules to a frame member of a flexible structure; FIGURE 12 is a perspective view of a portion of an assembly jig of the invention; FIGURE 13 is a cross-sectional view of an assembly jig of the invention; FIGURE 14 is a perspective view of two blocks mounted and spaced apart in a template channel of an assembly jig of the invention; FIGURE 15 is a perspective view of an end portion of an assembly jig of the invention; FIGS. 16, 17 and 18 are perspective views of a padded base assembly template showing the frame members with composite composite spring modules and a grid attached to the spring modules, and FIG. 19 is a view in perspective of a high profile version of a padded base frame and flexible structure constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED MODALITIES AND
ALTERNATIVES OF THE INVENTION FIGURES 1A-1C illustrate preferred embodiments of a composite spring module 16 of the invention having a flexible body 32 of fiber reinforced plastic composite, elongate, generally planar, a joining attachment 34 integrally formed centrally arranged frame, and grid connection assembly accessories 36 integrally formed on opposite distant ends of the body 32. The frame attaching fitting 34 and the mounting accessories 36 (hereinafter referred to collectively as "attachment fittings") ) can be made of any suitable material, such as plastic and metal, and molded around, attached, fastened or secured to the body 32 in the respective positions. In the preferred embodiment, the attachment fittings 34 and 36 are formed integrally around the flexible body 32 by an insert molding process. For example, a flexible body 32 (of the rectangular, single flat, configuration shown or any of the other configurations described herein and in the related application) is placed in a mold having a cavity for receiving the body 32 and the cavities. connected in accessory shapes 34 and 36. The mold is then injected with any suitable moldable material such as polypropylene, polyethylene, Santoprene ™, nylon or partial ABS or completely encapsulating the flexible body 32. Alternatively, the entire module 16 (including the body 32 and the fittings 34, 36) can be molded as a single piece such as from fiber reinforced plastic material. The accessories can also be molded separately or extruded by stretching and then joined (or glued) to the body of the spring module. The spring module body 32 can be produced from a wide variety of composite materials such as fiber reinforced plastic, fibers in combination with epoxy or vinyl or polyesters, high density plastics such as polyethylene, high density plastic foam, steel encapsulated or steel alloys, or any other material that shows the desired flexible proportions and the duration of cycles. When manufactured from a fiber reinforced composite material, the modules can be composite molded and / or compression molded into the configuration of a male / female mold cavity under heating and pressure, or extruded by stretching. For example, continuous fiberglass strands, approximately 60% to 80% of the product volume, are saturated with a resin system by rolling or extruding by drawing through an epoxy or vinyl ester bath that is approximately 20% by weight. % to 40% of the volume of the product. The material is then loaded into a mold by compression, molded and cured. The flash is removed by conventional methods such as vibrating pumice bed. The molding material can be selected and mixed to produce modules of different flexible grades. The flexible bodies of generally linear configuration such as that of FIGURE 1, are preferably formed by a stretch extrusion process, wherein the reinforcing fibers are pulled through a plastic bath in a liquid state and through a matrix that defines the cross-sectional configuration of the body, and the elastic body is cut to the desired length. Pigments can be used in the molding material to easily identify the modules of different flexible grades, which greatly helps the assembly process described in the following. As used herein the term "compound" refers to the combination of flexible body plastic material and fibers in the flexible body. The term "composite" is also referred to herein as the combination of the third material that is molded onto the flexible body to form the attachment fittings, as described in the following in detail. Certain configurations of the composite spring modules, as further described below, may be formed by a stretch extrusion process and a continuous extrusion process of, for example, fiber reinforced plastic where the fiber strands (including, but not limited to glass fibers) Kevlar®, Mylar®, graphite, carbon or steel strands) are pulled from a rail through a resin impregnation bath, and continuously pulled through a forming and healing matrix. The continuous strand of the composite material is then cut transversely (along the cross section of the part) to any desired length to provide the finished flexible body. The process of extruding by drawing is especially well suited for mass production of very high volume of flexible bodies, which have substantially linear configurations. The configurations of the curvilinear spring module can be extruded by stretching and / or extruded by stretching and compression molding as described. Another significant advantage of the formation of the flexible modules by these processes is the ability to easily alter the flexible characteristics of the modules simply by altering the number of fibers, and / or the location or orientation of the fibers within the modules. In the preferred embodiment, the fibers are aligned with a longitudinal dimension of the module, and extend substantially the entire length of the module body. In alternative embodiments, the fibers are oriented to intersect at fixed or random angles. The attachment of the spring modules 16 of the composite material with integrally formed joining accessories will now be described in the context of the padded bases having an underlying frame structure supporting the flexible modules, and an underlying grid supported reflexively by the dock modules. However, it will be appreciated that it is suitably within the scope of the invention to attach the spring modules to any type of support structure or frame, and to optionally attach any type of structure or assembly to the spring modules whereby the modules of spring provide a reflective surface or object. Some specific examples of structures and assemblies to which the dock modules can be attached include all types of furniture, seats including vehicle and aircraft seats, energy absorbing walls, floors, or other surfaces such as vibration damping supports and systems. of suspension. FIGURE 2 illustrates a mode of a low profile quilted base of the invention having a plurality of composite spring modules 16 constructed in accordance with the invention. The base 10 includes a novel low profile frame, generally indicated at 12 that supports a plurality of composite spring modules 16 attached to a grid or array 14 arranged in parallel to, and above the frame 12 as a supporting surface padded In this embodiment, the frame 12 includes two longitudinally extending perimeter members 18, a central longitudinal member 19, and a plurality of intermediate transverse members 21, all of which can be constructed of wood or steel or metal such as aluminum or other suitable materials such as bead-extruded or extruded beam-like parts or structural foam or blow-molded parts or secured together to form a rectilinear frame. In the low profile frame, the transverse members 21 lie in plane with a main width wt parallel and flush against the main widths wp of the longitudinal members 18 and 19 and the narrow edges orthogonal to the upper surfaces of the members 18 and 19. A plurality of longitudinally extending upper longitudinal frame members 22 (which may be constructed of wood or steel)., or extruded or extruded plastic, such as polyethylene or polypropylene, PVC or fiber reinforced plastic), are orthogonally joined to the main wt widths (upper surfaces) of the transverse members 21. A board of end eaves or band 23 is attached to each transverse end of the frame, against the outer narrow edge of the members 21 of transverse perimeter at the ends of the members 18 of longitudinal perimeter. A main width wt of the eaves board 23, therefore, is perpendicular to the main width wt of the transverse end members 21 and a narrow bottom edge of the eaves board is flush with the bottom surfaces of the longitudinal members. . The lower edge of the eaves band 23 is flush with the bottom surfaces of the perimeter frame members to create a smooth continuous surface for the attachment of upholstery. The eaves board 23 may extend vertically above the transverse end members 21 to provide a crash portion to which the ends of the upper longitudinal frame members 22 are spliced. With the upper longitudinal frame members 22 cut to equal length, the end splice cuts the eaves bands 23 ensures that the frame will be checked and squared when assembled. The spring modules 16 are attached to the upper surfaces of the upper longitudinal frame members 22 as further described in the following. The grid 14 is formed by a peripheral limit element 24 also called "boundary wire" of generally the same width and longitudinal dimensions of the frame 12, a plurality of longitudinal elements 26 secured to the boundary element by jaws or welds or simply bent or hooked around the boundary wire 24 and a plurality of transverse grid elements 28 (also referred to herein as "cross wires") that intersect the longitudinal elements 26 to define a generally orthogonal grid 14 that forms a supporting surface for a mattress . The grid 14 (including the elements 24, 26 and 28) can alternatively be constructed of low carbon steel, or high carbon content, but can alternatively be formed of composite material such as fiber reinforced plastic which is then glued or soldered ultrasonically or otherwise is held in an orthogonal matrix or other arrangement, or is formed as an individual integrated structure by plastic or composite molding process suitable for relatively long structures such as rotation molding or injection molding of structural foam . The terminal ends of the transverse elements or crossed wires 28 are bent downwardly to form the vertical support elements 30 with the strut foot 31 secured to the frame 12 to support the peripheral limit wire 24 and to hold the grid 14 on the frame 12. The support elements 30 can be selectively formed at any desired height above the frame 12 to extend from the boundary wire 24 to the members 18 and configured to deflect in the shape of a spring as is known in the art. As further shown in FIGURE 2, the grid 14 is supported on the frame 12 by a plurality of spring modules 16 attached to a bottom point of the upper longitudinal frame members 22 and at upper points around the intersection of the legs. elements 26 and 28 of the grid 14. As further shown in FIGS. 1A-1C and FIGS. 3A and 3B, each of the mounting fittings 36 of the grid connection includes a base 41 secured to, or formed in a Distant end of the body 32 of the module, a straight member 42 (also referred to as an "upright") attached at one end through a flexible hinge 43 to the base 41, and a pair of fastening pins 44 at an opposite end of the straight mounting member 42 configured to be joined around a longitudinal grid member 26 and to mount the cross grid member 28 at the intersections with the longitudinal grid member 26 as it is shown closely in FIGURES 3A and 3B. In this embodiment, the longitudinal grid member 26 overlaps the transverse grid member 28 to secure it in the channel 47. On the grid attachment mounting accessories of the dock modules of FIGURE 1A and FIGURES 3A-3B, each one of the fastening pins 44 includes a laterally extending attachment tab 44dh, which is generally aligned with the length of the module body 32 and extends over an interior lateral opening 46c in the channel 46 in which a member 26 of longitudinal grid is received in the base assembly. The inner side opening 46c allows the longitudinal grid members 26 to easily enter the channel 46, and the locking tabs 44dh each formed with an inner side to the falling edge, and the grid members 26 through the opening 460 in the channel 46. Preferably, the height of the opening 46c is less than a width of the cross section of the member 26, whereby the locking tabs 44dh are forced upwardly as the member 26 passes through the opening 460, and then it is adjusted upward to capture and retain the grid members 26 within the channel 46. As shown in FIGURE IB, each of the fastening pins 44 can be formed alternately with a head 45 with radius extending over the channel 46 dimensioned to receive and engage in friction form the grid member 26, similarly, a second channel 47, orthogonal to the channel 46, is dimensioned to receive the grid member 28 ransversal. As shown in FIGURE 1C, the second heads 48 with radius may be provided, which extend over the channel 47 to engage the transverse member 28 in a frictional manner. As shown in FIGURE 3A, vertically offset notches 29 in the transverse member 28 are separated to be mounted closely to the upper distal end of the straight member 43 to restrict movement of the grid attachment fittings along the length of the member 28 cross. The grid attachment assembly accessories 36 flexibly secure the intersecting grid members 26 and 28 in the correct relative position and facilitate quick assembly of the base. The flexible hinge 43 disposed between the spring module body and the grid allows the multidimensional live response to any load placed on the grid. The formation of the entire grid-connection assembly of a flexible plastic is particularly advantageous for the infinite degrees of load deflection, and the complete elimination of any possibility of noise generation in the fixing / interconnecting spigot 44 rack. As shown in FIGURE 3B, the invention further includes a transverse grid member or cross wire 28 having lateral horizontal displacements 291 of a linear extension sufficient to cross the second channel 47 which runs between the fastening pins 44. By this arrangement, the grid connection assembly fittings 36 are restricted from lateral displacement along the longitudinal grid members 26 and from movement along the length of the crossed wire 28. In addition, the horizontal side deployments 291 overlap by a portion of the locking tabs 44 that reinforce the mechanical engagement of the intersecting grid members within the attachment fittings. The lateral displacements 291 are horizontal in the sense that they extend laterally in a plane defined by the upper surface of a grid in which the crossed wire 28 is incorporated. The attachment attachment 34 of the frame is preferably configured for fixed engagement with an opening in the upper part of the longitudinal frame members 22. For ple, a key 37 is formed in the lower part of the attachment 34 of the frame with a length generally aligned with the length of the module body 32. A correspondingly dimensioned hole is provided in the upper part of the upper longitudinal frame members 22 through which the key 37 is passed and then rotated ninety degrees to mechanically engage with the support frame member. For ple, a neck 39 (shown in FIGS. 6A and 6B) extending from the key 37 has a length dimension greater than a width dimension of the hole in the frame member 22 such that the edges of the hole collide in the frame. The neck is rotated ninety degrees inside the hole, to mechanically and frictionally engage the module with the frame member. Similarly, as shown in FIGURE 6A, the length of the key 37 can be made longer than the interior width of the channel shape of the longitudinal member 22 to achieve a compression fitting of the key along one dimension in length with the frame member 22 on the ninety degree rotation. Alternatively, the hole in the frame member 22 can be dimensioned to a point to receive the key 37 and the neck 39 with space, and, in addition, includes a very small adjacent area that captures the key when the entire module slides into the very small area of the hole. A key configured for sliding engagement in a hole of the frame member is shown in FIGS. 6B and 6C. This simple way of joining the modules to the frame structure with integrally formed attachment fittings 34 and 36 eliminates the need for any separate fasteners to secure the modules to the frame. The accessories 34 and 36 allow the extremely simple and fast connection of the modules 16 to the frame and the underlying grid. The interengaging mechanical coupling of the attachment fittings of the spring modules with a padded base or any other structure such as seats and furniture, is ideally suited for any manual or automated assembly of the bases of the invention. Also, the inherent flexibility of the accessories 34 and 36 formed of flexible / plastic material (and preferably of a more flexible material than the non-fibrous material of the flexible body) provides all the multiple degrees of freedom of the spring module relative to the frame and the grid, and eliminates any possibility of noise generation in the connection points of the attachment accessories to a frame or grid. The base described as shown in FIGURE 2 has a relatively low height or profile for the reason that the entire height, measured from the bottom surface of the frame to the top of the grid is substantially less than the height of the frames. conventional bases that have wire spring modules that support as high as seven or more inches in height. The low profile height dimension of the base of the invention can be obtained as a result of the minimum height dimension of the composite spring modules 16 and the attachment fittings, even which have deflection characteristics comparable to and greater than the wire-shaped springs with substantially greater height. However, the base 10 can be constructed with any desired height dimension where the modules 16 are free to deviate around the point of attachment to the members 22 of the support frame. FIGURE 4 illustrates a relatively high profile version of the base 10 having a raised profile frame, generally indicated at 25, wherein the transverse frame members 21 are oriented with a main width wt oriented vertically to achieve a height dimension greater than elevating the longitudinal frame members 22 (and the spring modules 16) mounted on the narrow edge. In other words, the perimeter members 18 are flat, while the transverse members 21 are straight. The narrow bottom edges of the transverse members 21 rest on the major upper or wide surfaces wp of the longitudinal perimeter frame members 18 and the central longitudinal member 19. The upper longitudinal frame members 22 are joined to the narrow upper and upper edges of the transverse members 21. The end eave bands 23 are similarly oriented vertically along the side of the end transverse members 21, with a main width wf oriented vertically, perpendicular to the main wp widths of the longitudinal members, and the narrow bottom edges of the transverse members flush with the bottom of the members IB of the longitudinal perimeter frame. This construction provides a very rigid frame with the transverse ends reinforced by the thickness of the double board vertically oriented side by side. Of course, the rigidity of the transverse members 21 is optimized by loading on the narrow edges, in which the longitudinal frame members 22 rest. The additional frame members can be used to achieve even greater height and rigidity. In a raised profile base constructed with the raised profile frame 25, the vertical support elements 30 of the transverse grid elements 28 are increased in height to extend from the grid 14 raised downwards to the longitudinal perimeter frame members 18. . Alternatively, the length of the straight members 42 of the grid attachment assembly accessories 36 can be designed to produce any reasonable desired height of the grid over the spring modules and the upper frame members. For example, FIGURE 5 illustrates another embodiment in which the grid attachment assembly accessories 36 are replaced by a single grid bond wire 50, the ends 51 of which are formed to engage with an alternative form of the accessory 36 of Union and even the attached grid fixed internally by an intermediate section 52 between the ends 51. The vertical extension of the ends 51 can then be selectively varied in manufacturing to produce a desired height base. The fundamental concept of the invention to integrally form the joining accessories with a composite spring module body can be executed with the spring module bodies of any shape or configuration. For example, FIGURES 6A-6D illustrate generally U-shaped or C-shaped configurations of the spring module 16 having a generally curved body 32 with two generally planar coplanar flexible ends of which the attachment fittings 36 The grating extends vertically, with the frame attachment fitting 34 in the approximate center of the body 32. The U-shaped spring module 16 is configured so that the compressive tension imparted on the grid of the inventive bed system is absorbed. by the spring generally in the deep dimension, and generally along the central line of the module. In addition, the U-shaped spring module is configured and manufactured from a material that can be compressed to an essentially flat position without reaching its "flexible distortion" condition. Accordingly / even if the inventive bed base is subjected to excessive loading conditions, the U-shaped spring modules will not deform or otherwise cause it to fail due to a maximum deviation that will not take a flexible distortion. FIGURE 6B illustrates a U-shaped spring module 16 mounted on a frame member 22 by inserting the key 37 through a hole in the frame member as described above, and the friction coupling of the frame member 22. the intersecting grid wires by the grid connection assembly accessories 36 also as described above. As shown in FIGURE 6C, an additional mechanical fastener 35, such as in wire form, or staple, can be attached through the fitting 34 to further secure the module to the frame member. For such securing of the fastener, as shown in FIGS. 1A and IB, an adjustment slot 38 may be provided in the fitting 34 to receive the fastener 35, as shown secured to a frame member in FIGURE 6D. For fastening the spring module fastener to, for example, a flat surface of a support structure, such as a frame member, key 37 and neck 39 can be removed to achieve stable flush mounting. In this case, the body of the frame attachment fitting 34 in which the slot 38 is formed still performs a function of attachment or seat of the fastener. FIGURE 7 illustrates a low profile padded base 10 having a plurality of composite spring modules 16 constructed in accordance with the invention. The base 10 includes a low profile frame, generally indicated at 12 that supports a plurality of spring modules 16 of the composite material attached to a grid or matrix 14 arranged in parallel and above the frame 12 as a flexible support surface. As with the other embodiments, the invention is not limited to padded bases, and can be effectively employed as any type of flexible support surface such as in domestic and commercial furniture including a frame structure that supports the spring elements. In this embodiment, the frame 12 includes two longitudinally extending perimeter members 18, a central longitudinal member 19, and a plurality of transverse members 21 extending from one perimeter member 18 to the other. The members of the frame can be made of wood, metal, plastic or designed plastic such as molded compounds that include inorganic or molded organic materials. In the low profile frame, the transverse members 21 lie in plan with a width wt parallel to, and flush against, the main widths wp of the perimeter members 18 and the central longitudinal member 19, and the narrow edges orthogonal to the upper surfaces of the members 18 and 19. The upper longitudinal frame members 67 are joined orthogonally to the main widths wt (upper surfaces) of the transverse members 21. A board of end eaves or band 23 is attached to each transverse end of the frame against the outer narrow edge of the transverse end perimeter members 21 at the ends of the longitudinal perimeter members 18. A main width wf of the eaves board 23, therefore, is perpendicular to the main width wt of the transverse end members 21 and a narrow edge of the bottom of the eaves board is flush with the bottom surfaces of the longitudinal members. . The lower edge of the eaves band 23 is flush with the bottom surfaces of the perimeter frame members to create a smooth continuous surface for the attachment of upholstery. The eaves board 23 can extend vertically above the transverse end members 21 to provide a crash portion to which it joins the ends of the upper longitudinal frame members 67. With the upper longitudinal frame members 67 cut to equal length, the splicing of the ends against the eaves bands 23 ensures that the frame will be checked and squared when the members are held together. FIGURES 8A-8B show a composite spring module 16 designed with a foot support member 68 that is configured for direct mounting and engagement with a flat surface, such as the upper part of the longitudinal frame members 67, which have a generally rectangular cross section. The base 69 of the foot support member 68 is generally flat. The contact surface 70 of the base 69 is mainly planar. A channel 71 runs longitudinally through the center of the contact surface 70. The upper surface 72 of the base 69 is also generally planar, but where the contact surface 70 has a channel 71, the upper surface 72 of the base 69 has an adjustment flange 73. The channel 71 and the adjustment flange 73 both run through the center of the base 69 and align with the adjustment slot 38 so that it is centered directly above the channel 71 and the flange 73 of the aforementioned. When the foot support member 68 is secured to the frame member 67, the foot support member 68 is aligned so that the center of the base 69 is located in the center of the width wL of the frame member 67. As shown in FIGS. 9A and 9B, the base fasteners 75 are used to secure the foot support member 68 directly to the flat surface of the support frame member 67. U-shaped staples are used in the preferred embodiment, however, nails, screws, bolts, rivets, spikes, glue or any other fasteners and equivalents that can be presented to someone skilled in the art can be used. To secure the base 69 to the frame member 67, fasteners such as the U-shaped clips 75 are directed through the upper surface 72 of the base 69 in the frame support member 67. The adjustment flange 73 is designed to accept the U-shaped staple so that it is flush in contact between the flange 73 and the staple 75. The adjustment flange 73 acts as a guide for the placement of the staples 70. When the staples are directed through the base 69, the tips 76 of the staple 75 are located on opposite sides of the adjustment rim 73. The adjustment flange 73, therefore ensures that the staples 75 are aligned with each other, as well as with the center of the spring 16 and the lateral center of the foot mounting member 68. This alignment mechanism facilitates manual and automated attachment of the foot support member 68 to the frame member 67, as for example by the use of a mechanical staple gun. FIGURE 10 illustrates a single spring module 16 attached to a frame member 67 and engaged with the intersecting wires 26, 28 of the underlying grid 14. This drawing illustrates that the positioning of the foot mounting member 68 on the flat surface of the frame member 67 must be precise in order to be able to precisely position the fastening pins 44 of the grid connection assembly fittings 36 at the intersection of the wires 26 and 28. As for example, in the case where the frame member 67 is a hardwood existence part without calibration or markings, it must correlate the length with the dimensions of the grid 14 to determine the correct location of each one. of the spring modules for joining the frame member, before the coupling of the spring modules with the grid. FIGS. 11-15 illustrate an assembly jig for the calibrated or measured connection of the spring modules 16 to a frame member 67, so that the spring modules are correctly positioned to engage with the intersections of the grid wires , when the frame members are assembled together. FIGURES 11A-11C show the assembly jig 78 used to position and secure the composite springs 16 to the frame members 67. For maximum load distribution and stability, the composite springs 16 are aligned with one another along the longitudinal central axis of each frame member 67. The assembly jig 78 includes a channel 79, such as an extrusion, on which a plurality of blocks 80 is slidably mounted. The blocks 80 closest to the ends of the channel 79 fit with the end stops 81. During assembly, a frame member 67 is linearly positioned within each of the blocks 80 and between the end stops 81. The blocks
80 are separated so that the distance between the stops
81 end is equal to the length of the frame member 67 inserted in the assembly template. The number of blocks 80 in channel 79 is selected according to the number of springs that is attached to the frame member. Each block 80 is formed of a socket 88 attached to a template block 98. As shown in FIGS. 12 and 13, the template channel 79 in one form has a cross-sectional configuration of X-frame structures symmetrically joined with the networks 85 forming three channels 84 with slots in opposite halves of the channel. The template channel 79 is preferably made of extruded aluminum, but forming without high-strength polymer and synthetic materials is also possible. The sockets 88 are mounted on the template channel 79, with laterally opposite downwardly extending tabs 87 that mount and overlap the channels 84 with side slots. The sockets 88 can also be constructed of aluminum or an aluminum alloy. Sliding plates 91 are attached to the inner surfaces of the tabs 87 for the direct channel with the template channel 79 and the supporting surfaces of the channels 84 with slots. The displacement plates 91 are preferably made of a material having a low coefficient of friction when in contact with the channel surfaces. Many plastics possess this quality of contact with metal such as aluminum. A plastic is such as an Ultra High Molecular Weight Polyethylene. Nylon is also suitable. Lubricant such as silicone can be applied in the interconnection of the material to further reduce friction. The sliding plates 91 extend beyond the channels 84 with T-slots in at least a portion of the periphery of the template channel 79. The fasteners 93 connect the sliding plates 91 to the inner periphery 89 of the guide block 88. The sliding plates 91 have holes 92 that receive the fasteners 93. The guide block 88 has tapered openings 80 formed therein so that the fasteners 93 are mounted flush against the outer side of the surface of the guide block 88. The sliding plates 91 are the only parts of the assembly that may eventually need restitution. Restitution is achieved quickly and easily by removing the fasteners 93 that mount the plates 91 to the guide blocks 88. The sliding plates 91 each have alignment keys 94 which engage the channels 84 with slots for securing the guide block 88 to slide smoothly over the template channel 79. The alignment keys 94 can be formed integrally as extensions of the sliding plates 91. The alignment pins 94 are preferably substantially rectangular in cross section. In addition, the aligning keys 94 may extend along the longitudinal length of the sliding plate 91. In the preferred embodiment, three alignment keys 94 formed in the first surfaces 95 of the three sliding plates 91, couple three channels 84 with separate grooves of the template channel 79, therefore, containing the guide block 88 secured in the three xyz axes. Running through the guide block 88 and the sliding plates 91 on opposite sides of the guide block 88 are the fixing holes 107. The fixing holes 107 are used to position the guide block 88 and the wear plates 91 along the length of the template channel 79 by the adjustment pins 106 which extend through the holes 107 in calibrated holes in the body. channel 79 day template, to establish and fix the space of the blocks 80. As shown in FIGURES 13 and 14, four mounting bolts 97 extend from each template block 98 downwardly through the mounting openings 96. the flat horizontal portion of each socket 88. The template block 98 can be attached to the mounting bolts 97 or comprise mounting bolt openings configured to accept a threaded mounting bolt 97. The template blocks 98 are preferably formed of machined aluminum, but can be made of other materials such as plastic or wood. Each template block 98 comprises a base 96 that sits on the upper surface of the socket 88, and the laterally opposed walls 99. The opposing inner surfaces 100 of the walls 99 are cut biased towards the center of the template block 98 so that the distance dj between the central members on the upper surface 101 of the laterally opposite sides 99 is greater than the distance d between the laterally opposite sides 99 on the base 96. The opposing biased inner surfaces 100 facilitate the insertion and positioning of the frame member 67. The distance d between the laterally opposite sides 99 decreases toward the base of the block 80 so that a frame member 67 can be easily located between the laterally opposed sides 99, while providing a snap fit for the frame member 67 between the sides 99 laterally opposed when the frame member 67 is placed on the base 98 of the block 80. FIGURES 12 and 13 illustrate a position of the spring 16 composed on the frame member 67 within the template block 98. On the upper surface 101 of each of the two laterally opposite walls 99 of the template block 98 are two holes 102 configured to accept the spring positioning pins 103. The spring positioning pins 103 are generally cylindrical, however, other shapes such as rectangular pins may also be used. The spring positioning pins 103 are specifically configured to be fixed within the template detents 77 at the edges of the body 32 of each module 16 of the composite spring (best shown in FIGURE 9B). When a spring 16 is inserted into the template block 98, the template detents 77 align with the positioning pins 103 of the spring. Four pins 103 for positioning the spring were the spring 16 in orthogonal alignment with the member 67 of the frame. The locations of the spring positioning pins 103 and the template detents 77 function to center the channel 71 and secure the flange 73 of the foot support member 68 over the horizontal width wt of the frame member 67. This places the center of the mass of the spring 16 directly on the center of the mass of the frame member 67 for maximum stability. The positioning pins further function to prevent the spring 16 from moving before it is secured to the frame member 67 by the fasteners such as staples 75. FIGURE 12 shows a partial perspective view of the template 78, including the block 80 and the template channel 79. Because the mattresses vary in size, the length of the longitudinal frame members 67, as well as the locations of the springs 16 along the frame members 67 will vary. Thus, in order to be able to use an individual jig 78 to manufacture various types of padded frames, the distances between the blocks 80 along the template channel 79 must be able to be adjusted. To create an adjustable jig 78, a plurality of locking holes 104 pass through and cross the channels 84 with opposing slots and the frame structure 85 of the jig channel 79. The positioning of the fixing channels 104 corresponds to the desired positioning of the composite springs 16 in the frame member 67. The fixing holes 107, which run through the sockets 68 and the sliding plates 91, are aligned with the desired fixing hole 104 in the channel 79. A fixing pin 106 is inserted through the fixing holes 107 and 104, ensuring therefore the socket 88 and the template block 98 in place. The pin 106 is a pin or a rod in the preferred embodiment, since it is easily placed through and removed from the fixing holes 107 and the fixing channel 104. Once the blocks 80 are secured in place along the template channel 79, the frame member 67 is placed in the template blocks 98 and between the end stops 81. The composite springs 16 are then positioned between the pins 103 of block 80 and secured to the frame member 67 using a fastener, such as a staple 75. The frame member with the composite secured springs 16 is then ready for assembly as a longitudinal frame member 67 in a padded base 10. As shown in FIGS. 16 and 17, with the spring modules thus joined, the frame members 67 are positioned in parallel within a grid attachment template, generally indicated at 120. The grid attachment template 120 is a structure that includes two separate rows of supporting structures 122 of the frame member, with pedestals 124 at the ends of the frame member 67 resting. pedestal 124 has a pair of spaced pins 125 between which the ends of the frame members are adjusted. With frame member 67 positioned on the pedestals 124, the grid 14 is positioned by the fixing guides 126 on the spring modules 16 in the frame members, and the intersections of the grid are interconnected with the attachment fittings 44 of the frames. 16 dock modules. The grid attachment template 120 is preferably mounted on a base or board, which may have support rails 130 as shown. This elevates the template to an appropriate table or working height for manual use. The side edges 132 of the template are provided with calibrated rules in the space in the spring modules (and corresponding grid sizes) for padded bases of different sizes, such as double, Queen and ing. The template 78 previously described for attaching the spring modules to the individual frame members 67, can be attached to the side edges 132 so that a frame member 67 is completed with the springs, is inserted directly into the template 120 of grid connection. The template channel 79 of the template 78 can be mounted to the side edges 132 in a downward or articulated manner, by which it effectively moves out of the way of a worker. This can be done by the use of hinged assemblies that lock into a straight position, where the jig 78 can be positioned near the side edge 132, and is fixed in a retracted downward position with the jig 78 located below or behind the edge 132 side, so as not to interfere with the assembler inserting the frame member 67 into the grid attachment jig 120. As shown in FIGURE 18, the grid joining jig 120 can be adapted to support different types of frame members, such as the steel member 167, shown as the two central members in the frame subassembly. The grid frame / subframe member that is completed in the template 120 is then removed and attached to the bottom portion of the frame, as shown in FIGS. 7 and 19, which include the longitudinal perimeter members 18, and the transverse members 21 supporting the frame members 67. The main width wt of the transverse members 21 can be oriented parallel to the upper flat surfaces of the perimeter members 18, as in FIGURE 2, or orthogonal to the flat surfaces surfaces of the perimeter members 18, as in FIGURE 19 , depending on the desired height of the flexible structure. In the fabrication and assembly methods and processes of the invention, the assembly of the composite cushioned base system is highly flexible and is greatly simplified by the relatively small size and simple geometry of the spring modules. For example, to selectively assemble a padded base of the composite material of the invention, the following steps are performed in any logical way. The spring modules 16 are attached to the frame members 67 held in the assembly jig 78. The frame members 67 are then inserted into the grid connection template 120., and the grid is secured at the intersections to each of the joining accessories of the spring modules. The grid / spring / sub-assembly of the frame member is then removed from the template 120 and placed in the sub-assembly of the base frame of the perimeter and the cross members described with reference to FIGS. 2, 7 and 19. The modules 16 are not located at the intersections of the upper longitudinal frame members 22/67 and the transverse members 21 so as not to interfere with the interconnection of the frame member at these points. The type of spring modules used can be selected by the shape and / or color (indicating the flexibility ratio) to be of any of the flexible properties that are uniform or dissimilar. For example, modules of a higher flexible ratio can be placed in the upper and / or lower regions of the base and the lower flexible proportions near the ends. Similarly, the stiffer spring modules can be located on the perimeter of the base to provide greater support for the padded edge where people sit. The grid 14 is then secured to each of the grid connection mounting fittings 36 of the modules 16 by the top or side entry coupling of the grid intersections (of the elements 26 and 28) with the holding pins 44 of assembly, as described in the above. The padding and coating is then joined. Each of the assembly stages leads to the automation itself given the small size, low weight and simple geometry of the spring modules, and the elimination of the dimensional constraints dictated by the complicated multiple bent steel wire springs. Although the invention has been described in detail with respect to certain preferred and alternative embodiments, certain modifications and variations of the described inventive principles will be appreciated by those skilled in the art. In particular, it will be recognized that spring modules of composite material with integrally formed joint fittings can be attached or used with any supporting structure or members and elements of any underlying structure such as a grid or matrix design for transferring loads to the springs. , such as, for example, but not limited to frames and structures such as those found in mattresses, furniture, seats, damping devices, and any structure or assembly where a reflective height or load bearing surface is required. Also, any form of attachment fittings that are integrally formed with or join the flexible body and configure for attachment to a member that supports the spring module, and for attachment to a structure supported by the spring module, go well inside of the scope of the invention. All variations and modifications are within the scope and extension of the invention as defined by the appended claims and all equivalents thereof.