MXPA99009466A - Composite material spring modules with integrally formed attachment fittings - Google Patents

Abstract

Se describen módulos de muelle (16) de material compuesto asícomo los métodos de manufactura de los mismos, los módulos de muelle (16) de material compuesto tienen un cuerpo (32) de muelle de material compuesto reforzado con fibra, con aditamentos de conexión (34, 36) formados integralmente alrededor del cuerpo (32) del muelle. Los aditamentos de conexión (34, 36) se moldean de un material flexible que responde dinámicamente a los cambios de forma del cuerpo (32) de muelle, durante la deflexión. La formación integral de los aditamentos (34, 36) con el cuerpo (32) de muelle proporciona un módulo unificado de una sola pieza que puede conectarse fácilmente a cualquier estructura en donde se desee proporcionar un soporte con muelles. Los módulos de muelle (16) de material compuesto se describen como una base de colchón (10), mediante la conexión con armazones (12) de perfil elevado y bajo y con una rejilla de sobreposición (14). Se describen los métodos de manufactura de los módulos de muelle (16) de material compuesto que tienen aditamentos de conexión (34, 36) integralmente formados. Se describen también los métodos para armar estructuras flexibles de soporte de peso, tales como bases de colchón (10) que utilizan los módulos de muelle (16) de material compuesto.

Description

^ • 4 l - MATERIAL SPRING MODULES COMPOSED WITH CONNECTION FITTINGS INTEGRALLY FORMED CROSSOVER REFERENCE OF THE RELATED APPLICATIONS 5 The present application is a continuation in part of the United States patent application, serial number 08 / 487,022, filed on June 7, 1995.

FIELD OF THE INVENTION In general, the present invention pertains to springs of composite plastic material that are used as flexible elements in weight-bearing structures and more particularly those that are used in flexible structures for supporting human weight, such as beds , seats and furniture.

BACKGROUND OF THE INVENTION Springs for use as flexible support elements in support structures such as seats, beds and furniture are traditionally and conventionally constructed of steel and spring wire. See, for example, U.S. Patent Nos. 188,636; 488,378; 1,887,058; 4,535,978; 4,339,834; 25,558,315. Attempts have been made to construct spring-like support elements of plastic material. See, for example, U.S. Patent Nos. 4,530,490; 4,736,932; 5,165,125 and 5,265,291.

P1617 / 99MX Although reinforced plastic fiber springs are reasonably well developed, the use of these in flexible support structures such as seats, furniture and beds presents a formidable engineering challenge as they have to provide appropriate means for connecting the springs in a frame structure and an overlay support surface. To date, plastic springs are simply mechanically connected to a support structure such as that described in U.S. Patent No. 4,411,159 in a fiber-reinforced plastic sheet spring for a vehicle. Any type of mechanical connection is complicated by the extreme rigidity and hardness of fiber reinforced plastics. In the end, it will almost always be necessary to drill connection holes in the spring for a mechanical fastener (such as that described in U.S. Patent No. 4,736,932), which requires additional fabrication and assembly steps. Also, drilling through the fiber reinforced structure breaks the preferred parallel long strands / fibers which are indispensable to provide optimum spring characteristics. The related application discloses pins for connecting the base of the mattress with a frame and an overlay grid. Although it is fully operational and novel, this approach requires additional parts and increases the assembly workforce and does not completely overcome P1617 / 99MX the disadvantages of a possible sliding between the spring and the clasps and the generation of noise due to the related movement. Commonly used bed systems include a mattress supported by a base or box of springs (known as box spring). The mattress bases are provided to impart support and firmness to the mattress as well as elasticity in order to flex under an excessive load or blow. Typically, the bases are composed of a rectangular wooden frame, a steel wire grid supported on the wooden frame with an arrangement of steel wire springs, such as compression-type springs, which are secured to the wooden frame. . In order to adequately support and maintain the level of firmness in a mattress, a large number of compression springs are needed in the base, which results in a very high production cost. This is the main disadvantage of using compression springs in mattress bases. Also, bases that use compression springs typically have a grid or carbon wire matrix connected to the upper parts of the springs. Both the wires and the welds of the structure can bend or break under abusive conditions. In these steel / metal systems, fasteners are required to secure the springs to the grid and frame. This leads to a metal contact P1617 / 99MX with metal that can easily produce high-pitched sounds under dynamic loads. In an effort to avoid the high cost of using compression springs on the bases, another type of spring is used, the torsion spring spring formed with a high-caliber steel spring wire bent into multiple continuous sections that flex by the torsion when compressed. See for example, U.S. Patent Nos. 4,932,535; 5,346,190 and 5,558,315. Because the torsion springs are larger and stiffer than the compression springs, fewer torsion springs are needed in the base. However, the manufacture of steel wire twist type springs requires very expensive tools and bending equipment. Very elaborate progressive bending dies are required to produce the complex torsion spring module shapes, which may include four or more joint sections. The manufacturing process is not economically adaptable to produce different spring configurations without using a new tool, readapting the tool and / or changing settings in the machinery and causing an interruption in the process, etc. Therefore, the configuration and the coefficient of the spring or resultant of these springs can not be easily altered or without representing some expense to produce the bases with different characteristics of P1617 / 99MX. < support. In addition, so many folds in these types make the quality control of the dimensions and the tolerance control of the spring coefficient or very difficult to reach. Also, variations in the properties of steel material, the need for corrosion protection and heat treatment are added to the cost and difficulty of producing steel wire spring modules. And also, the awkward geometry of the relatively large torsion springs does not facilitate the assembly of the springs on the base frame. Another disadvantage of the use of steel wire springs in the bases and a particular disadvantage of the torsion springs, is the "springback" phenomenon in which the spring does not return completely to a height when being uncompressed after a load excessive As long as a spring is flexed within the tolerance range of its classification, it can be repeatedly loaded during a certain number of cycles, without showing a noticeable change in operating characteristics. However, if the flexion exceeds the maximum deflection interval, it will suffer permanent or "expired" bending, which results in a permanent change in operating characteristics such as lack of reflective support, permanent change in shape or catastrophic failure. in the form of rupture. The expired spring steel wire is also P1617 / 99MX can present after prolonged normal use, ie a continuous heavy load. Generally, this phenomenon is also called fatigue and can result in a catastrophic failure. When mattresses with an increased thickness dimension are placed like "over-bed" mattresses on traditional bases of six to eight inches in height, these can be very high in relation to the headboard and footboard of the bed, resulting in a cumbersome appearance and an excessively high resting surface. This trend towards larger mattresses and bases increases distribution and storage costs. Mattress bases in the United States typically measure in the order of five to eight inches in thickness, with an average thickness (or height) of six and a half to seven and a half inches. In conventional bases, most of this dimension can be attributed 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% range can cause the spring to expire or rupture. Reducing the total height of the torsion spring modules can cause the spring to be very stiff and decrease the desired deflection characteristics and the ability to absorb heavy loads with recovery. In addition, the number of failure cycles P1617 99MX during the life test is generally more difficult to predict with the short height spring modules and usually the failure occurs before fewer cycles than with the higher wire spring modules. However, it would be desirable to have a base with reduced height that maintains the support and the desired deflection characteristics.

SUMMARY OF THE INVENTION The present invention provides composite spring modules for use as flexible support elements in support structures such as seats and beds. The composite spring modules include a spring body composed of a plastic wrap and cured around reinforcing fibers and a second plastic or polymeric material to which the connecting attachments are integrally formed or molded around or attached to the body of the spring. For the spring modules for a mattress base, the connection attachments are selectively configured for a mechanical connection with the elements of a base frame structure and a grid or support structure that is superimposed on the frame structure. The integral formation of the plastic connection attachments around the spring body eliminates the need for physically separate fasteners to secure the springs in a wraparound assembly, such as a frame or grid.

P1617 / 99MX The material of the connection attachments can be the same as or different from the plastic material of the spring body. Also, the invention allows the production of novel low-profile / low-height, abuse-resistant, long-life mattress bases that incorporate the composite spring modules with the integrated connection attachments. Composite spring modules are used in place of traditional wire springs as the main components of reflective support. In one embodiment, the total height of a low mattress base of composite material is approximately 50-60% of the height of traditional bases and furthermore, it has improved deflection / elasticity characteristics over traditional bases. The invention also provides a raised profile or mattress base with conventional height using composite spring modules mounted on a novel high profile frame. The invention also includes a novel method for manufacturing spring modules for bases from composite materials, such as epoxy / polyester and fiberglass combinations, by molding these materials into various spring forms particularly adapted and especially suitable for use as elements of support on a mattress base. As used herein, the term "compound" means P1617 / 99MX a combination of at least two materials mixed in a solid form, such as any plastic material that can be molded, extruded or extruded by drawing and a fibrous material bonded or embedded or otherwise glued to the plastic material. The term "composite" also refers to the integral formation of the connection attachments from a moldable material around the body of the spring, with encapsulated fibers. The invention also includes a novel method for selectively assembling the mattress base units when using composite spring modules, wherein the spring modules are selectively arranged and fixedly attached to a frame structure and a grid. of superposition. In a preferred embodiment of the spring modules, the composite material is extruded by stretching into an elongated spring module, generally flat, to provide a low depth / height dimension and an efficient load distribution and tension. The use of the molded / extruded composite spring modules, and in particular those of elongated and flat configuration of the composite spring module, provides many manufacturing and assembly advantages over the prior art of wire springs, including a Simplified construction of the base, manufacturing and handling of the module and quick adaptation for a P1617 / 99MX automatic manufacturing and assembly of base units. Furthermore, the novel method of manufacturing the spring modules of the composite base is easily adapted to the manufacture of a wide variety of spring modules with different shapes and characteristics of support and deflection, with variable spring rates, without tools or modification of the fundamental process. The process allows a high reproduction of the performance characteristics. The invention also includes novel frames of low profile and high profile bases, to support the spring modules and an overlay grid. A low profile frame has parallel longitudinal and central members, transverse members with a greater width parallel to the greater widths of the longitudinal members and end band boards with an orthogonal width greater than the greater widths of the transverse members. A raised profile frame has longitudinal, parallel perimeter members, a central member and transverse members and end band boards orthogonally joined to the longitudinal members; the larger widths of the cross members and the band boards are perpendicular to the widths of the longitudinal members and a narrow lower edge of the band boards is flush with the surfaces P1617 / 99MX inferior of the longitudinal members. The invention also provides a cross member or grid grating for mattress base with horizontal recesses and with the necessary dimensions to be coupled with the connection attachments of the spring modules to restrict the movement of the connection attachments along the length of the reticle. The invention also provides a composite spring for supporting the grid edge wire for the base of the mattress, for connecting to a frame member and for frictional connection with a flexible support for a grid edge. These and other aspects of the invention are described within the present with particular details with reference to the accompanying Figures.

BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawings: Figures 1A-1C are perspective views of the composite spring modules with connection fittings formed integrally of the present invention; Figure 2 is a perspective view of a mattress base with the composite spring-loaded spring module with integrally formed connection fitting of the present invention; Figure 3A and 3B are perspective views P1617 / 99MX of the composite spring modules connected to the intersecting members of a mattress base grid; Figure 4 is a perspective view of a high profile mattress base with springs of composite material with integrally formed connection attachments of the present invention; Figure 5 is a perspective view of a portion of an alternative embodiment of the mattress base of the present invention; Figure 6A is a perspective view of an alternative embodiment of a composite spring module with integrally formed connection attachments of the present invention; Figure 6B is a perspective view of another embodiment of a spring module of the invention; Figure 6C is an elevated view of a spring module of the invention connected to a frame member and a grid in a mattress base of the present invention; Figure 6D is a perspective view of an alternative embodiment of a spring module of the invention connected to a frame member of a mattress base; and Figure 7 is a cross-sectional view of a support spring of the grid edge for the mattress base of the present invention.

P1617 / 99MX DETAILED DESCRIPTION OF THE PREFERRED AND ALTERNATIVE MODALITIES OF THE INVENTION FIGS. 1 through 1C illustrate the preferred embodiments of a composite spring module 16 of the invention with an elongated, generally flat body 32 of fiber reinforced plastic. , spring composite material; a frame connection fitting 34 centrally located integrally formed and integrally formed grid connection post fittings 36, at the distal, opposite ends of the body 32. The frame connection fitting 34 and the post attachment 36 ( in the present collectively referred to as "connection attachments") may be made of any suitable structural material, such as plastic or metal and molded around, attached, secured or secured in the body 32 in their respective positions. In the preferred embodiment, the connecting fittings 34 and 36 are formed integrally around the body 32 of the spring by an insert molding process. For example, a body 32 of the spring (of the simple, flat, rectangular configuration shown or any other configuration described herein and in the related application), is placed in a mold having a cavity for receiving the body 32 and cavities connected in the form of attachments 34 and 36.

P1617 / 99MX Next, the mold is injected with a suitable moldable material such as polypropylene, polyethylene, Santoprene ™, nylon or ABS, completely or partially encapsulating the body 12 of the spring. Alternatively, the entire module 16 (including the body 32 and the attachments 34, 36) can be molded as a single piece from fiber-reinforced plastic material. Also, the abutments can be molded or extruded by stretching, separately, and then joined (bonded) to the body of the spring module. The body 32 of the spring module 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 plastic such as polyethylene, high density plastic foam, Encapsulated steel or steel alloys or any other material that exhibits the desired springing coefficients and cycle time. When made of a composite material with fiber reinforcement, the modules can be a molded and / or compression molded component in the configuration of a male / female mold cavity under heat 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 winding or extrusion by stretching P1617 / 99MX through an epoxy or vinyl ester bath that is approximately 20% to 40% of the volume of the product. The material is then loaded into a compression mold, molded and cured. The flash is removed with conventional methods such as the vibration pumice bed. The molding material can be selected and mixed to produce modules of different spring coefficients. The bodies of the springs of a generally linear configuration such as those of the Figure 1, are preferably formed by a stretch extrusion process wherein the reinforcing fibers are extracted through a bath of plastic material i in a liquid state and through a die that defines the transverse configuration of the body, The body of the spring is cut to the desired length. Pigments can be used in the molding material to quickly identify the modules of different spring coefficients, which greatly cooperates with the assembly process described below. As used herein, the term "composite" refers to the combination of the plastic material of the spring body and the fibers in the body of the spring. The term "composite" also refers, herein, to the combination of a third material that is molded around the body of the spring to form the connection attachments, as described in detail below.

P1617 / 99MX Some configurations of the composite spring modules, as also discussed below, can be formed by extrusion by stretching and continuous extrusion by stretching, for example, fiber-reinforced plastic where the fiber strands (including, enunciatively glass fibers, Keviar®, Mylar®, graphite, carbon or steel strands) are pulled from the reel and passed through a resin impregnation bath, and continuously pulled through a forming die and curing. The continuous strand of the composite material is cut transverse (ie, along the cross section of the part) to any desired length to provide the finished spring body. Stretch extrusion is especially suitable for a high-volume mass production of spring bodies with essentially linear configurations. The curvilinear spring module configurations can be extruded by stretching and / or extruding by stretching and compression molding as described. Another important advantage of the formation of the spring modules by this process is the ability to easily alter the spring characteristics of the modules, simply by altering the number of fibers and / or their location or the orientation of the fibers within the modules. . In the preferred embodiment, the fibers are aligned with a length dimension of the module and extend substantially over P1617 / 99MX the full length of the module body. In alternative modalities, the fibers are oriented to intersect at fixed or random angles. The connection of the composite spring modules 16 with integrally formed connection attachments will now be described in the context of mattress bases having an underlying frame structure supporting the spring modules and an overlying grating supported in the form reflective by the spring modules. However, it can be appreciated that it is within the scope of the invention to attach the spring modules to any type of support structure or frame and optionally connect any type of structure or assembly to the spring modules, wherein the modules of spring provide a reflective surface or object. Some specific examples of structures and assemblies to which spring modules can be connected include all types of furniture, seats including vehicle and aircraft seats, energy absorbing walls, floors and other surfaces as cushioning supports. of vibration and suspension systems. Figure 2 illustrates another embodiment of a low profile mattress base of the invention, having a plurality of spring modules 16 of composite material constructed in accordance with P1617 / 99MX invention. The base 10 includes a novel low profile frame, indicated generally at 12, which supports a plurality of composite spring modules 16 connected to a grid or structure 14 arranged parallel to the frame 12 and thereon, as a supporting surface for the mattress. In this embodiment, the frame 12 includes two longitudinally extending perimeter members 18 and a plurality of intermediate transverse members 21, all of which may be constructed of steel or metal such as aluminum or other suitable materials such as stretch-extruded or extruded or stretched-type portions. blow molded or foam structural parts and secured together to form a rectilinear frame. In the low profile frame, the transverse members 21 lie flat with a width wt parallel to and flush with the larger wp widths 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 longitudinally extending upper members 22 (which may be constructed of wood or steel or extruded or extruded plastic such as polyethylene or polypropylene, PVC or fiberglass reinforced plastic) are connected orthogonally. with the larger Wt widths (upper surface) of the transverse members 21. An extreme band board or strip 23 is connected to each P1617 / 99MX transverse end l & frame, against the outer narrow edge of the transverse perimeter members 21 at the ends of the longitudinal perimeter members 18. The width wt greater of the band board 23 is per llf both perpendicular to the width wt greater of the end transverse members 21 and a narrow lower edge of the band board is flush with the lower surfaces of the longitudinal members. The lower edge of the strip strip 23 is flush with the bottom surfaces of the perimeter members of the frame to create a smooth, continuous surface for the connection of the upholstery. The band board 23 can extend vertically over the end transverse members 21 to provide a lock that abuts the ends of the upper longitudinal members 22 of the frame. With the upper longitudinal members 22 of the frame cut to the same length, the butting of the ends against the band strips 23 ensures that the frame is coincident and square at the time of its assembly. The spring modules 16 are connected to the upper surfaces of the upper longitudinal members 22 of the frame as described below. The grid 14 is formed by an element 24 of peripheral edge also called "edge rod" of generally the same dimensions of width and length of the frame 12, a plurality of elements P1617 / 99MX _ _J * _SSo?, S '- ** to the edge element 4- "by means of locks or welds or simply bent or hooked around the edge rod 24 and a plurality of grid elements 28, p. (also referred to as "rissiculas") intersecting with the longitudinal elements 26 to define a generally orthogonal grid 14 that forms a supporting surface for a mattress. The grid 14 (with elements 24, 26 and 28) it can alternatively be constructed of high or low carbon steel, but it can alternatively be formed of composite material such as fiber reinforced plastic which is then glued or ultrasonically welded or clamped to some other shape with the orthogonal structure or in another arrangement, or is formed as a unique integrated structure with plastic or composite material molding processes suitable for relatively large structures such as rotational molding or structural foam injection molding. The end ends of the transverse elements or gratings 28 are folded down to form the vertical support elements 30 with the mounting feet 31 secured to the frame 12 to support the peripheral edge rod 24 and secured with the grid 14 on the frame 12. The support elements 30 can be selectively formed at any desired height on the frame 12 to extend from the edge rod 24 and for P1617 / 99MX flex in the manner of a spring as is known in the art. As also shown in Figure 2, the grid 14 is supported on the frame 12 by a plurality of spring modules 16 connected at a lower point with the upper longitudinal members 22 and 28 of the grid 14. As also shown in FIG. Figures 1A-1C and Figures 3A-3B, each attachment post 36 with the grid includes a base 41 secured or formed around the distal end of the body 32 of the module, a vertical member 42 (also referred to as a "post ") connected at one end through a flexible link 43 to the base 41 and a pair of grip fingers 44 at an end opposite the vertical pole member 42 configured to be connected about the longitudinal grid member 26 and to engage the cross member 28 of grid at intersections with longitudinal member 26 of the grid, as shown in detail in Figures 3A and 3B. In this embodiment, the longitudinal grid member 26 is superimposed on the grid cross member 28 to be secured within the channel 47. On the connection post attachments with the grid of the spring modules of Figure IA and Figures 3AA-3B , each of the clamping fingers 44 includes a locking tab 44dh that is generally aligned with the length of the body 32 of the P1617 / 99MX module and extending over an interior side opening 460 within the channel 46, in which the longitudinal member 26 of the grid is received in the base assembly. The inner side opening 460 allows the longitudinal members 26 of the grid to easily enter the channel 46 and the locking tabs 44dh, each formed with a bottom side beveled downward, guides the grid members 26 through the opening 460 within the channel 46. Preferably, the height of the opening 460 is less than the width of the cross section of the member 26, whereby the tabs 44 < locks are forced upwardly as the member 26 passes through the opening 44Q and then engage to capture and retain the grid members 26 within the channel 46. As shown in Figure IB, the locking fingers 44 can alternatively be formed with a curved head 45 extending over channel 46 with dimensions for receiving and engaging friction the grid member 26, similarly, a second channel 47, orthogonal to the channel 46 has the dimensions to receive the transverse grid member 28. As shown in Figure 1C, the second curved heads 48 are provided so that they extend over the channel 47 to frictionally engage the transverse member 28. As shown in Figure 3A, the notches 29 moved vertically in the member 28 P1617 / 99MX, transverse, are very closely spaced to close the upper distal end of the F member 42 for restricting the movement of the grid connection attachments along the length of the transverse member 28. The grid post attachment fittings 36 flexibly secure the grid members 26 and 28 in the correct relative position and facilitate quick assembly of the base. Flexible articulation 43, • 10 arranged between the body of the spring module and the grid allows a live multi-dimensional response for any load placed on the grid. The formation of the complete grid post connection fitting from 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 gripper retainer / grille connection interface. As shown in Figure 3B, the invention also includes a transverse grid member or lattice with lateral, horizontal recesses 291 of a linear limit sufficient to traverse the second channel 47 running between the clamping fingers 44. With this arrangement, it is restricted to the attachments of the grid post 36 in its lateral displacement along the longitudinal grid members 26 and of the movement along the length of the grid 28. In addition, the recesses P1617 / 99MX 291 sideways, horizontally a portion of the locking tongues 44 that reinforces the mechanical coupling of the intersected grid members within the connection attachments. The side recesses 291 are horizontal in the direction that they extend laterally in a plane defined by the upper surface of the grid into which the grid 28 is incorporated. The frame connection fitting 34 is preferably configured for graded coupling with an opening in the upper part of the longitudinal members 22 of the frame. For example, a key 37 is formed in the lower part of the connection fitting 34 of the frame with a length generally aligned with the length of the body 32 of the module. A hole with corresponding dimensions is provided in the upper part of the longitudinal, upper frame members 22, through which the key 37 passes and then rotates ninety degrees to mechanically couple with the frame support member. For example, a neck 39 (shown in Figures 6A and 6B) extending from the key 37 has a length dimension greater than the dimension of the width of the hole in the length member 22 so that the edges of the hole collide with the The conformal collar rotates ninety degrees inside the hole, to mechanically and frictionally couple the module with the frame member. Similarly, P1617 / 99MX as shown in FIG. 6A, the length of key 37 may be longer than the internal width of the member channel shape. { V22 longitudinal, so that a compression adjustment of the key is achieved along a length dimension with the frame member 22, with a rotation of ninety degrees. Alternatively, the hole in the frame member 22 may have the dimension at a point to receive the key 37 and the neck 39 with sufficient space and also include a smaller adjacent area that captures the key when the complete module slides into the area smallest of the hole. A key configured for sliding engagement in the bore of the frame member is shown in Figures 6B and 6C. This simple way of coupling the modules to the frame structure with integrally formed connection fittings 34 and 36 eliminates the need for any separate fasteners to secure the modules to the frame. The attachments 34 and 36 allow an extremely easy and quick connection of the modules 16 to the frame and to the overlay grid. The mechanical locking coupling of the connection attachments of the spring modules with a mattress base or any other structure such as seats and furniture, is ideal for any manual or automated assembly of the bases of the invention. Also, the inherent flexibility of the P1617 / 99MX attachments 34 and 36 formed of plastic / flexible material (and preferably of a more flexible material than the non-fibrous material of the spring body) provide the spring module with multiple degrees of freedom relative to the frame and the grid and eliminates any possibility of generating noise at the connection points of the connection attachments to a frame or grid. The base described, as illustrated in Figure 2, has a low profile or low height because the total height, measured from the bottom surface of the frame to the top of the grid, is essentially smaller than the height of the frames. Conventional bases that have wire spring modules that are as high as seven or more inches. The height dimension of the low profile of the base of the invention can be achieved as a result of the minimum height dimension of the composite spring modules 16 and the connection attachments, which still have comparable and superior deflection characteristics to wire-shaped springs with a substantially higher height. However, the base 10 can be constructed with any desired height dimension where the modules 16 are free to deform around the connection point of the frame support members 22. Figure 4 illustrates a relatively high profile version of a base 10 with a frame of P1617 / 99MX elevated profile, indicated_ -g. generally with the number 25, wherein the transverse members 21 of the frame are oriented with a width wt oriented vertically to reach a greater height height, which raises the longitudinal members 22 of the frame (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 and bottom edges of the transverse members 21 rest on the upper or wide surfaces wp of the perimeter, longitudinal members 18 of the frame and the central, longitudinal member 19. The longitudinal, upper members 22 of the frame are coupled with the narrow upper and upper edges of the transverse members 21. The end band strips 23 are oriented vertically in a similar manner along the side of the end transverse members 21, with a width wt oriented vertically, perpendicular to the greater wp widths of the longitudinal members and the narrow lower edges of the members. transverse flush with the lower part of the longitudinal, perimeter members 18 of the frame. This construction provides a very rigid frame with reinforced transverse ends with a double board thickness oriented vertically, side by side. Of course, the rigidity of the transverse members 21 is optimized with the load on the edges P1617 / 99MX e narrow, in the Cßtléfs the longitudinal members 22 of the frame rest. Additional frame members can be used to achieve uniform height and rigidity. In a high profile base constructed with frame 25 of high profile, the vertical support elements 30 of the transverse elements 28 of the grid increase in height to extend from the raised grid to the perimeter, longitudinal members 18 of the frame. Alternatively, the length of the straight members 42 of the grid post attachment fittings 36 can be designed to produce any desired reasonable height of the grid over the spring modules and the uppermost members of the frame. For example, Figure 5 illustrates another embodiment wherein the grid post attachments 36 of the grid are replaced by a single wire 50 connecting to the grid, the ends 51 of which are formed to engage with an alternative form of the attachment. of connection 36 and on the grille coupled with lock by an intermediate section 52 between the ends 51. Of course, the vertical limit of the ends 51, can selectively vary in its manufacture to produce a base of the desired height. The fundamental concept of the invention of connection fittings integrally formed with a composite spring module body P1617 / 99HX can be carried out with spring module bodies of any configuration. For example, Figures 6A-6D illustrate generally U-shaped or C-shaped shapes of the spring module 16, which has a generally curved body 32, on two generally flat coplanar spring ends from which post connection attachments 36 with the grid extend vertically, with the connection fitting 34 of the frame in the approximate center of the body 32. The U-shaped spring module 16 is configured in such a way that the compression tension imparted in the grid of the inventive bed system is absorbed by the spring generally in the dimension of the depth and generally along the center line of the module. In addition, the U-shaped spring module is configured and made of a material so that it can be compressed to an essentially flat position without reaching the condition of "spring expired". Accordingly, even if the inventive base of the bed is subjected to conditions of excessive loading, the U-shaped spring modules will not deform or cause failure, even with its maximum deflection the spring will not expire. Figure 6B illustrates a U-shaped spring module 16 mounted on the frame member 22 by inserting the key 37 through a hole in the frame member as described P1617 / 99MX before and coupling! - by friction of the intersecting wires of the grid with the grid connection attachments also as already described. As shown in Figure 6C, an additional mechanical fastener 35, for example in the form of a wire or staple, may be connected through the attachment 34 to also secure the module to the frame member. For such securing of the fastener, as shown in Figures IA and IB, a slot 38 can be provided graded on the attachment 34 to receive the fastener 35, as shown secured to a frame member in Figure 6D. To secure a fastener of the spring module, for example, to a flat surface of a support structure, such as a frame member, the key 37 and the neck 39 can be removed to achieve a stable, flush mount. In this case, the body of the connection fitting 34 of the frame in which the slot 38 is formed still performs a connection function or seat for the fastener. In combination with the spring reflective action of the modules 16 mounted on the frame 12 and on the grid 14 in this manner, the support elements 30 of the transverse wires 28 provide the base with a double spring / support action. Because the support elements 30 can be formed of polymeric material or steel wire, they can have a different springing coefficient than that of the modules P1617 / 99MX 16, especially the modules formed of composite material. The combination of these two different spring elements with different spring coefficients or c a better coefficient and an improved and unique springing action. For example, the support wire elements 30 can be replaced with a composite spring 60 as shown in Figure 7. The composite grid support spring 60 is formed with a generally flat mounting base 61, for the connection with a frame member and a vertical member 62 vertically supporting the edge wire 24 of the grid 14. An intermediate section 63 can be configured in a suitable geometry, which provides the desired deflection and spring characteristics. At the top of the straight element 62 is a connection fitting 64 having a channel for receiving the wire 24 from the edge and a retainer cap 66 which fits over the channel for retaining the edge wire in the channel 65. In addition, since the inventive design can use a high high-content grid, the grid itself acts as a spring to return completely to the horizontal plane when a load is removed, unlike the low-carbon welded gratings that can be bent and Deform permanently and break with the load.

P1617 / 99HX In the methods | and manufacturing and assembly processes of the invention, the arrangement of the composite mattress base system is highly flexible and simplified to a smaller size and the simple geometry of the spring modules. For example, to selectively assemble a mattress base of composite material of the invention in the following steps, it is carried out in any logical order. The spring modules 16 are connected to the internal members of the frame (such as the frame members 22) before or after the connection of the internal members of the frame with other members of the frame. The spring modules are secured to the frame members by inserting the key 37 through the key hole of the frame member and rotating 90 degrees to a locking position. The number of connection points for the spring module (e.g., holes for receiving the keys 37) will determine the maximum number of modules that a frame member can support. For example, a single member of the frame can include up to forty modules or more connection points, although only twenty or less can be connected evenly apart in the assembly process. The type of spring modules used can be selected by the shape and / or color (indicating the spring coefficient) so that they have uniform or different spring properties. By P1617 / 99MX example, modules with a higher spring coefficient can be placed in the hip and / or back regions of the base and those with a lower spring coefficient can be placed on the ends. Similarly, the stiffer spring modules can be located on the perimeter of the base to provide greater support to the edge of the mattress where people generally sit. The grid 14 is then secured with each of the grid connection attachments 36 of the grid of the modules 16 by means of an upper or lateral entry coupling at the intersections of the grid (of the elements 26 and 28) with the fingers of the grid. fastening 44 of the post, as described above. Then the padding and the cover are joined. Each of the assembly steps lends itself to the automation provided by the small size, light weight and simple geometry of the spring modules and the elimination of the need for dimension dictated by the multi-folds steel wire springs. Although the invention has been described in detail with respect to certain preferred and alternative embodiments, those skilled in the art will appreciate certain modifications and variations of the disclosed inventive principles. In particular, it can be recognized that composite spring modules with integrally formed connection fittings can be connected or used with P1617 / 99MX any other supporting structure or framework and elements or members of any overlay structure, such as a grid or structure design for transferring loads to the springs, such as, for example, frames and structures found in mattresses , furniture, seats, damping devices and any structure or assembly where a reflective weight or load bearing surface is required. Also, any form of connection attachments that are integrally formed with or attached to the spring body and configured for connection to a member that supports the spring module and for connection to a structure supported by the spring module are they are within the scope of the invention. All variations and modifications are within the scope and scope of the invention as defined by the appended claims and all equivalents thereof.

P1617 / 99MX

Claims (62)

1. NOVELTY OF THE INVENTION Having described the present invention, it is considered as a novelty and, therefore, the content of the following CLAIMS is claimed as property; 1. A composite spring module comprising: a composite spring body including a plastic and a fiber; and connection attachments integrally formed around the spring body.
2. 2. The composite spring module according to claim 1, wherein the plastic of the spring body is a vinyl ester and the fiber of the spring body is fiberglass.
3. 3. The composite spring module according to claim 1, wherein the fiber of the spring body is oriented to extend generally along the length of the spring body.
4. 4. The composite spring module according to claim 1, wherein the fiber of the spring body extends, in essence, over the entire length of the spring body. The composite spring module according to claim 1, wherein the fiber of the spring body includes a plurality of fiber strands. P1617 / 99MX 6. The composite spring module according to claim 1, wherein the fiber of the spring body includes a plurality of fibers of a length generally shorter than the length of the spring body. The composite spring module according to claim 6, wherein the fibers are arranged randomly within the plastic of the spring body. The composite spring module according to claim 1, wherein the connection fittings formed integrally are formed of a plastic different from the plastic of the spring body. 9. The composite spring module according to claim 1, wherein the plastic of the connection attachments is selected from the group consisting of polypropylene, polyethylene, nylon and ABS. The composite spring module according to claim 1, wherein the connection attachments consist of gripping elements configured for coupling with a structure including the spring module. The composite spring module according to claim 10, wherein the gripping elements of the connection fittings are configured to frictionally engage the P1617 / 99MX elements of a structure that includes the spring module. 12. The composite spring module according to claim 1, wherein the spring body is generally planar. The composite spring module according to claim 1, wherein the spring body is generally curvilinear. The composite spring module according to claim 10, wherein the gripping elements of the connection attachments are separated from the spring body by a post. 15. The composite spring module according to claim 10, wherein the gripping elements of the connection attachments are separated to define channels, wherein the elements of a structure supported by the spring modules are received. 16. The composite spring module according to claim 10, wherein the gripping elements consist of curved heads that engage frictionally with the elements to which the connection attachments are connected. 17. The composite spring module according to claim 1, wherein the connection attachments have upper openings through which elements can be inserted. P1617 / 99MX inside the connection attachments. 18. The composite spring module according to claim 1, wherein the connection fittings have side openings through which elements can be inserted into the connection attachments. 19. A composite spring module for use in a mattress base with a frame and a grid, the spring module is configured for connection to the frame and the grid is superimposed on the frame, the spring module consists of : a spring body made of composite material, the composite material consists of a plastic and a fiber; and connection fittings molded around the spring body, the connection fittings include at least one frame connection fitting configured for connection to the frame of the mattress base and at least one grid connection attachment configured for the connection with the mattress base grille. 20. The composite spring module of claim 19, wherein the spring body is generally linear and oriented generally parallel to the frame and grid when it is connected to the frame and grid. 21. The composite spring module of the P1617 / 99MX claim 19, wherein the frame connection fitting is formed on one side of the spring body and the grid connection attachment is formed on an opposite side of the spring body. 22. The composite spring module of claim 19, wherein the connection attachments are molded from a plastic other than the plastic of the spring body. 23. The composite spring module of claim 19, wherein the connection attachments are configured for a locking engagement with the frame and the mattress base grid. 24. The composite spring module of claim 19, wherein the connection attachments are flexible relative to the spring body. 25. The composite spring module of claim 19, wherein the spring body consists of multiple fibers extending essentially over the entire length of the spring body. 26. The composite spring module of claim 19, wherein the spring body consists of multiple fibers generally oriented randomly within the spring body. 27. The composite spring module of claim 19, wherein the at least one connection fitting consists of a flexible joint 28. The composite spring module of claim 19, wherein the connection attachment P1617 / 99MX frame consists of a collar and key configured for a lock coupling with a frame element of the mattress base. 29. The composite spring module of claim 19, wherein the grid connection attachment consists of gripping fingers configured for a lock engagement with the grille of the mattress base. 30. The composite spring module of claim 25, wherein the clamping fingers have curved heads. 31. A mattress base of composite material consisting of: a base frame with transverse members, longitudinal members and interconnected perimeter members; a grid parallel to the frame of the base and separated from it; a plurality of composite spring modules, each spring module consists of a fiber reinforced plastic body and a frame connection fitting and a grid connection fitting integrally formed around the spring body, each spring module being connected to the frame of the base by means of a frame connection attachment and connected to the grid by means of a grid connection attachment. 32. A mattress base for material P1617 / 99MX compound according to claim 31, wherein the perimeter members and the cross members of the base frame are oriented in a generally planar position. 33. A mattress base of composite material according to claim 26, wherein the greater width of the transverse members is orthogonal to the greater width of the perimeter members. 34. A mattress base of composite material according to claim 31, wherein the frame consists of a band board connected to the ends of the perimeter members, with a greater width of the band board oriented vertically and orthogonally with respect to a greater width of the perimeter members. 35. A mattress base of composite material according to claim 31, wherein the longitudinal members are steel members connected to the transverse members. 36. A composite mattress base according to claim 33, wherein the longitudinal members extend from a band board connected to the ends of the perimeter members to another band board connected to the opposite ends of the perimeter members. 37. A mattress base of composite material according to claim 31, wherein the transverse members are oriented in a vertical position. P1617 / 99MX 38. A mattress base of composite material according to claim 31, further comprising a longitudinal central member. 39. A mattress base of composite material according to claim 30, wherein the longitudinal members consist of connecting points configured for the connection of the composite spring modules. 40. A mattress base of composite material according to claim 30, wherein each of the spring modules consists of essentially continuous fibers extending, essentially, over the entire length of the body of the spring module. 41. A mattress base of composite material according to claim 30, wherein each of the spring modules consists of an array of fibers in the body of the spring. 42. A mattress base of composite material according to claim 30, wherein the connection attachments of the spring modules are formed with a plastic material different from the plastic of the spring body. 43. A mattress base of composite material according to claim 30, wherein the connection fitting of the frame of the spring modules comprises a key and a neck extending from the body of the spring. P1617 / 99MX 44. A mattress base made of a composite material according to claim 30, wherein the connection device of the grille of the spring modules consists of gripping fingers configured to grip the grille. 45. A mattress base of composite material according to claim 30, wherein the connection attachments of the spring modules consist of a flexible joint. 46. A mattress base of composite material according to claim 30, wherein the plastic forming the connection attachments of the spring modules essentially covers the entire body of the spring. 47. A mattress base of composite material according to claim 30, wherein the plastic forming the connection attachments of the spring modules surrounds only a portion of the body of the spring. 48. A mattress base of composite material according to claim 30, wherein the grid is formed of a composite material. 49. A low profile mattress base frame for supporting a plurality of spring modules, the base frame consists of: two perimetral, longitudinal and parallel members, and a longitudinal, central, parallel frame member placed between the legs. members P1617 / 99MX longitudinal perimeter; a plurality of transverse members connected to a perimeter member and extending on and perpendicular thereto to the other, a greater width of the transverse members of the frame is orthogonal to the greater width of the perimeter members of the frame; and upper members connected perpendicularly to the upper edges of the transverse members and are parallel to the perimetral members. 50. The frame for a low profile mattress base according to claim 49, wherein the upper members provide connection points for the spring modules of the base. 51. The frame for a low profile mattress base according to claim 49, which also comprises a band board extending between the ends of the perimeter members, a greater width of the orthogonal band board to a greater width of the perimetral members and wherein a narrow lower edge of the band board is essentially flush with the lower surface of the perimeter members. 52. The frame for a low profile mattress base according to claim 49, wherein the upper members are made of steel. 53. The frame for a mattress base of P1617 / 99MX low profile according to claim 49, wherein a greater width of the band board is less than a greater width of the transverse members. 54. The framework for a low profile mattress base to support a plurality of spring modules, the base frame consists of: two longitudinal and parallel perimeter members and a longitudinal central parallel member placed between the longitudinal perimeter members; transverse perimeter members and intermediate members connected to the longitudinal central and perimeter members and extending orthogonally thereon and connected thereto, a greater width of the transverse end members and intermediate members is parallel to the greater widths of the transverse members. the longitudinal perimeter members and the central member; a band board extending between the ends of the perimeter, longitudinal members, a greater width of the band board is perpendicular to a greater width of the transverse members and a narrow lower edge of the band board is flush with the lower surfaces of the longitudinal members. 55. A method for manufacturing composite spring modules with hardware attachments P1617 / 99MX integrally formed connection comprising the steps of: encapsulating a plurality of fibers within a plastic material to form a composite spring module with encapsulated fibers; inserting the composite spring module into a mold with mold cavities in the form of connection attachments configured to connect the spring body to a support structure; and integrally forming the connection attachments around the spring body by injecting the mold cavity with a mouldable material. 56. The method of claim 55, comprising the step of encapsulating fibers within a plastic material by extrusion by stretching. 57. A method for assembling a mattress base with a frame supporting a plurality of composite spring modules with integrally formed connection attachments and a grid supported by the spring modules, the method comprising the steps of: assembling the frame; connecting the spring modules to the frame by securing the connection attachments to a frame member; and connect the spring modules to the grid when inserting the grid members inside P1617 / 99MX of the connection devices of the spring modules. 58. The method according to claim 57, wherein the spring modules are connected to the frame by inserting a key of the connecting fitting into a hole in the frame member and rotating the spring module ninety degrees relative to the length of the frame member to connect the connection attachment with the frame member. 59. The method according to claim 57, wherein the spring modules are connected to the grid by inserting the grid members in connection with the gripping fingers of the connecting fixtures. 60. The method according to claim 57, further comprising the steps of selecting the composite spring modules in accordance with the springing coefficient and selectively arranging the spring modules relative to the frame to provide the desired spring characteristics. in different areas of the mattress base, as a result of the springing coefficients of the selected spring modules. 61. A grid for use as an element of the mattress base grid supported by springs which in turn are supported by a base frame; The reticle consists of: P1617 / 99MX a generally linear extension of sufficient length to extend transversely from one side of the frame of the mattress base to the opposite side; generally vertical support elements extending downwards from the ends of the linear extension and ending at the mounting feet configured for connection with a frame support member of a mattress base; and recesses in the linear extension that extend in a horizontal plane when the grid is supported by the mounting feet, the recesses are located along the linear limit to be placed on the opposite sides of a section of a spring when it is connected with the reticle. 62. A composite edge support rod spring for use as a flexible support for an edge rod of a mattress base, the support spring comprises: a spring body with fibers encapsulated in the body; a mounting base configured for connection with a frame member for the base of the mattress; a vertical portion that extends generally vertically on the mounting base; a connection attachment at one end P1617 / 99MX distal superior vertical position, the connection attachment forms a channel in which frictionally engages a cross section of the edge rod. P1617 / 99MX