Box spring assemblies employing foam cushioning grids, and related components, mattress assemblies, and methods

Abstract

Box spring assemblies employing foam cushioning grids, and related components, mattress assemblies, and methods are disclosed. Foam cushioning grids are comprised of a plurality of foam grid members that are interconnected to form the foam cushioning grid. By interconnecting the foam grid members, a plurality of voids may be disposed between the interconnecting foam grid members as part of the foam cushioning grid. In this manner, as a non-limiting example, the foam cushioning grid can be disposed on a wire grid, such as in box springs, to provide cushioning support for the wire grid, as one non-limiting example. A load placed on the wire grid will be cushioned by the foam cushioning grid disposed therebetween. Further, as a non-limiting example, voids in the foam cushioning grid allow air to easily flow between the interconnected foam grid members.

We claim: 
     
         1 . A box springs assembly for supporting a mattress, comprising:
 a frame having a first elongated end and a second elongated end opposite the first elongated end;   a plurality of elongated support members extending from the first elongated end of the frame to the second elongated end of the frame;   a wire support structure, comprising:
 a plurality of wire springs each having a first end supported by the plurality of elongated support members, the plurality of wire springs configured to support a mattress; and 
 a planar-shaped wire grid interconnecting the plurality of wire springs on a second end of the plurality of wire springs opposite the first end of the plurality of wire springs; 
   a foam cushioning grid disposed on the planar-shaped wire grid to provide cushioning between the planar-shaped wire grid and a mattress disposed on top of the planar-shaped wire grid.   
     
     
         2 . The box springs assembly of  claim 1 , wherein the foam cushioning grid is comprised of an interconnected plurality of foam grid members. 
     
     
         3 . The box springs assembly of  claim 2 , wherein the wire grid is comprised of an interconnected plurality of wire members. 
     
     
         4 . The box springs assembly of  claim 3 , wherein the interconnected plurality of foam grid members are each disposed on at least a portion of a wire member among the interconnected plurality of wire members. 
     
     
         5 . The box springs assembly of  claim 3 , wherein the interconnected plurality of foam grid members disposed on the planar-shaped wire grid completely cover each of the interconnected plurality of wire members. 
     
     
         6 . The box springs assembly of  claim 3 , wherein the interconnected plurality of foam grid members disposed on the planar-shaped wire grid do not completely cover each of the interconnected plurality of wire members. 
     
     
         7 . The box springs assembly of  claim 3 , wherein at least a portion of at least one of the interconnected plurality of foam grid members is not disposed directly over any interconnected plurality of wire members. 
     
     
         8 . The box springs assembly of  claim 2 , wherein the interconnected plurality of foam grid members are only disposed in parallel and orthogonal to the first elongated end of the frame and the second elongated end of the frame. 
     
     
         9 . The box springs assembly of  claim 2 , wherein the interconnected plurality of foam grid members are up to 0.5 inches in thickness. 
     
     
         10 . The box springs assembly of  claim 2 , wherein the interconnected plurality of foam grid members are up to (6) inches in width. 
     
     
         11 . The box springs assembly of  claim 2 , wherein the interconnected plurality of foam grid members are wider than a width of any portion of the interconnected plurality of wire members. 
     
     
         12 . The box springs assembly of  claim 2 , comprising a plurality of voids disposed between the interconnected plurality of foam grid members. 
     
     
         13 . The box springs assembly of  claim 12 , wherein a surface area of the interconnected plurality of foam grid members is greater than an area of the plurality of voids. 
     
     
         14 . The box springs assembly of  claim 12 , wherein the plurality of voids comprise a plurality of rectangular-shaped voids and a plurality of triangular-shaped voids. 
     
     
         15 . The box springs assembly of  claim 12 , wherein the plurality of voids comprise a plurality of arc-shaped voids. 
     
     
         16 . The box springs assembly of  claim 12 , wherein the interconnected plurality of foam grid members comprise a plurality of arc-shaped foam grid members. 
     
     
         17 . The box springs assembly of  claim 1 , wherein the foam cushioning grid is symmetrical about a center longitudinal axis of the foam cushioning grid and a center latitudinal axis of the foam cushioning grid. 
     
     
         18 . The box springs assembly of  claim 2 , wherein the interconnected plurality of foam grid members comprises a plurality of foam grid members disposed parallel to the first elongated end and the second elongated end, and a plurality of foam grid members disposed orthogonal to the first elongated end and the second elongated end. 
     
     
         19 . The box springs assembly of  claim 18 , wherein the interconnected plurality of foam grid members further comprises a plurality of foam grid members angularly disposed to the first elongated end and the second elongated end. 
     
     
         20 . A method of assembling a box springs assembly for supporting a mattress, comprising:
 providing a frame having a first elongated end and a second elongated end opposite the first elongated end;   providing a plurality of elongated support members extending from the first end of the frame to the second end of the frame;   providing a wire support structure on the frame, comprising:
 providing a plurality of wire springs each having a first end supported by the plurality of elongated support members, the plurality of wire springs configured to support a mattress; and 
 interconnecting the plurality of wire springs on a second end of the plurality of wire springs opposite the first end of the plurality of wire springs to provide a planar-shaped wire grid; and 
   disposing a foam cushioning grid on the planar-shaped wire grid to provide cushioning between the planar-shaped wire grid and a mattress disposed on top of the planar-shaped wire grid.