Bedding or seating foundation having metal spring modules

Abstract

A bedding or seating product comprising a base having a pair of end rails, a pair of side rails and a plurality of intermediate rails. A plurality of resilient C-shaped metal spring modules are secured to the base rails. A nestably stackable wire assembly including a wire grid and surrounding border wire are supported by the metal spring modules.

We claim:  
     
         1 . A bedding or seating foundation comprising: 
 a base comprising a pair of end rails, a pair of side rails and a plurality of intermediate rails,    a plurality of generally arcuate sheet metal spring modules secured to said intermediate rails of said base,    a plurality of transversely spaced, parallel and longitudinally extending support wires,    a wire grid spaced above said base,    each of said support wires being generally corrugated along its length having flattened peaks and flattened valleys, said flattened peaks being secured to said wire grid and said flattened valleys being secured to said sheet metal spring modules, and    an upholstered covering surrounding said base, sheet metal spring modules, support springs and wire grid.    
     
     
         2 . A bedding or seating foundation comprising: 
 a base comprising a pair of end rails, a pair of side rails and a plurality of intermediate rails,    a plurality of generally arcuate sheet metal spring modules secured to said intermediate rails of said base,    a plurality of transversely spaced, parallel and longitudinally extending support wires,    a wire grid spaced above said base,    each of said support wires being generally corrugated along its length having flattened peaks and flattened valleys, said flattened peaks being secured to said wire grid and said flattened valleys being secured to said sheet metal spring modules.    
     
     
         3 . The foundation of  claim 2  wherein each of said sheet metal spring modules is C-shaped.  
     
     
         4 . The foundation of  claim 3  wherein each of said sheet metal spring modules has a middle portion with holes therethrough to enable fasteners to secure said sheet metal module to one of said rails of said base.  
     
     
         5 . The foundation of  claim 3  wherein each of said sheet metal spring modules has end portions with receptacles therein adapted to receive said flattened valleys of said support wires.  
     
     
         6 . A bedding or seating foundation comprising: 
 a base comprising a pair of end rails, a pair of side rails and a plurality of intermediate rails,    a plurality of generally C-shaped sheet metal spring modules secured to said intermediate rails of said base, each of said sheet metal spring modules having a pair of end portions, each of said end portions having a receptacle therein,    a plurality of transversely spaced, parallel and longitudinally extending support wires, each of said support wires being generally corrugated along its length and having flattened peaks and flattened valleys, said flattened valleys being located in said receptacles of said sheet metal spring modules, and    a wire grid secured to said flattened peaks of said support wires.    
     
     
         7 . The foundation of  claim 6  wherein said wire grid has a border wire around the periphery thereof.  
     
     
         8 . The foundation of  claim 7  wherein each of said support wires has a pair of ends secured to said border wire.  
     
     
         9 . A bedding or seating foundation comprising: 
 a base comprising a pair of end rails, a pair of side rails and a plurality of intermediate rails,    a plurality of generally C-shaped sheet metal spring modules secured to said intermediate rails and said end rails of said base, each of said sheet metal modules having a pair of end portions raised from said intermediate and end rails of said base,    a nestably stackable wire assembly comprising 
 a plurality of transversely spaced, parallel and longitudinally extending support wires, each of said support wires being generally corrugated along its length and having flattened peaks and flattened valleys, and  
 a wire grid, said flattened peaks of said support wires being secured to said wire grid and said flattened valleys of said support wires being secured to said end portions of said sheet metal modules.  
   
     
     
         10 . The foundation of  claim 9  wherein said wire grid has a border wire around the periphery thereof.  
     
     
         11 . The foundation of  claim 10  wherein each of said support wires has a pair of ends secured to said border wire.  
     
     
         12 . A bedding or seating foundation comprising: 
 a base comprising a pair of end rails, a pair of side rails and a plurality of intermediate rails,    a plurality of generally C-shaped sheet metal spring modules secured to said rails of said base, each of said sheet metal spring modules having a pair of receptacles formed therein,    a nestably stackable wire assembly comprising    a plurality of transversely spaced, parallel and longitudinally extending support wires, each of said support wires being generally corrugated along its length and having flattened peaks and flattened valleys, and    a wire grid, said flattened peaks of said support wires being secured to said wire grid and said flattened valleys of said support wires being located in said receptacles of said sheet metal spring modules.    
     
     
         14 . The foundation of claim  13  wherein said pair of receptacles of said sheet metal spring module are raised above said rails of said base.  
     
     
         15 . The foundation of claim  13  wherein each of said sheet metal spring modules has holes therein for securing said sheet metal spring module to one of said rails of said base.  
     
     
         16 . The foundation of claim  13  wherein said rails of said base are made of wood.  
     
     
         17 . The foundation of claim  13  wherein each of said sheet metal spring modules is made of steel.  
     
     
         18 . The foundation of claim  13  wherein each of said sheet metal spring modules is made of Martinsite steel.  
     
     
         19 . The foundation of claim  13  wherein said wire grid has a border wire around the periphery thereof.  
     
     
         20 . The foundation of  claim 19  wherein each of said support wires has a pair of ends secured to said border wire.  
     
     
         21 . A bedding or seating foundation comprising: 
 a base comprising a pair of end rails, a pair of side rails and a plurality of intermediate rails,    a plurality of generally arcuate sheet metal spring modules secured to said intermediate rails of said base, and    a wire assembly supported by said arcuate sheet metal spring modules.    
     
     
         22 . The foundation of  claim 21  wherein said wire assembly is nestably stackable.  
     
     
         23 . The foundation of  claim 21  wherein said wire assembly comprises a plurality of transversely spaced, parallel and longitudinally extending support wires, each of said support wires being generally corrugated along its length having flattened peaks and flattened valleys, said flattened peaks being secured to said a wire grid and said flattened valleys being secured to said sheet metal spring modules.  
     
     
         24 . The foundation of  claim 21  wherein said wire assembly includes a wire grid having a border wire.  
     
     
         25 . The foundation of  claim 21  wherein each of said sheet metal spring modules is C-shaped.  
     
     
         26 . The foundation of  claim 25  wherein each of said C-shaped metal spring modules has a middle portion attached to said base, outer portions extending upwardly for opposite ends of said middle portion and U-shaped end portions at an outer end of each of said outer portions, said wire assembly being supported in said U-shaped end portions.  
     
     
         27 . The foundation of  claim 26  wherein an inserted U-shaped rib is formed in said C-shaped sheet metal modules and extends from one end of one end portion, thru said middle portion to the end of said other end portion.  
     
     
         28 . A flexible metal spring module for resiliently supporting a wire assembly on a base in a bedding or seating foundation, said spring module comprising: 
 a generally planar middle portion, and    a pair of outer portions extending upwardly and outwardly from said middle portion, each of said outer portions terminating in an end portion adapted to receive a wire of said wire assembly.    
     
     
         29 . The spring module of  claim 28  wherein said end portion comprises a generally U-shaped receptacle.  
     
     
         30 . The spring module of  claim 28  wherein said sheet metal spring module is made of Martinsite steel.  
     
     
         31 . The spring module of  claim 28  wherein said middle portion has holes therein adapted to receive fasteners.