Bed foundation having a structural foam perimeter utilizing mechanical interlocking

Abstract

A bed foundation includes, in an advantageous form, a sidewall frame, a box-spring array, at least one spring interconnect, and at least a first structural foam layer. The sidewall frame includes a plurality of interlocking frame members. The sidewall frame has a frame interior, a frame top, and a frame bottom. The box-spring array is received within the frame interior and includes a plurality of springs. The at least one spring interconnect extends from the sidewall frame and into the frame interior. At least one spring interconnect interacts with at least one spring to thereby aid in retaining that at least one spring in place relative to the sidewall frame. The first structural foam layer is attached to one of the frame top and the frame bottom and extends thereacross. Advantageously, this first structural foam layer forms a mechanical interlock with the sidewall frame at the given one of frame top and the frame bottom to which it is attached.

1 . A bed foundation, comprising: 
 a first bed frame member, said first frame member being composed of a structural foam, said first frame member having a pair of first frame member ends, at least one said first frame member end having a first mechanical interconnect portion associated therewith; and    a second bed frame member, said second frame member being composed of a structural foam, said second frame member having a pair of second frame member ends, at least one said second frame member end having a second mechanical interconnect portion associated therewith, said first mechanical interconnect portion and said second mechanical interconnect portion forming an interlocking connection.    
   
   
       2 . The bed foundation of  claim 1 , wherein said first bed frame member and said second bed frame member define a first side wall and a second side wall, respectively, of said bed foundation.  
   
   
       3 . The bed foundation of  claim 1 , wherein at least one of said first mechanical interconnect portion and said second mechanical interconnect portion is one of integral and co-formed with a respective one of said first bed frame member and said second bed frame member.  
   
   
       4 . The bed foundation of  claim 1 , wherein said first mechanical interconnect portion and said second mechanical interconnect portion together define a male/female interconnection.  
   
   
       5 . The bed foundation of  claim 4 , wherein said first mechanical interconnect portion and said second mechanical interconnect portion together define a notched interconnection.  
   
   
       6 . The bed foundation of  claim 1 , further comprising a third bed frame member and a fourth bed frame member, said third bed frame member being mechanically connected to said first bed frame member and said fourth bed frame member, said fourth bed frame member being further mechanically connected to said second bed frame member.  
   
   
       7 . The bed foundation of  claim 6 , wherein said third bed frame member is interlocked with said first bed frame member and said fourth bed frame member, said fourth bed frame member being further interlocked with said second bed frame member.  
   
   
       8 . The bed foundation of  claim 6 , wherein said first bed frame member, said second bed frame member, third bed frame member, and a fourth bed frame member together define a side wall frame of said bed foundation.  
   
   
       9 . The bed foundation of  claim 8 , wherein said side wall frame has a frame top, a frame bottom, and a frame interior, said bed foundation further including at least one of a box-spring array received within said frame interior; a foam topper mechanically interlocked with said frame top; and a foam bottom mechanically interlocked with said frame bottom.  
   
   
       10 . The bed foundation of  claim 8 , including said box-spring array received within said frame interior, said box-spring array including a plurality of perimeter springs, each said perimeter spring being adjacent said side wall frame, said side wall frame having at least one spring interconnect mechanism extending therefrom into said frame interior, at least one said spring interconnect mechanism interacting with at least one said perimeter spring to thereby aid in retaining said at least one said perimeter spring in place relative to said side wall frame.  
   
   
       11 . A bed foundation, comprising: 
 a side wall frame defining a frame interior;    a box-spring array received within said frame interior, said box-spring array including a plurality of perimeter springs, each said perimeter spring being adjacent said side wall frame; and    at least one spring interconnect extending from said side wall frame and into said frame interior, at least one said spring interconnect interacting with at least one said perimeter spring to thereby aid in retaining said at least one said perimeter spring in place relative to said side wall frame.    
   
   
       12 . The bed foundation of  claim 11 , including a plurality of spring interconnects, at least one pair of said spring interconnects being positioned adjacent one another in a manner so as to thereby define a spring receiving zone therebetween, at least one said perimeter spring being received within said spring receiving zone.  
   
   
       13 . The bed foundation of  claim 12 , wherein said at least one pair of said spring interconnects is configured for at least one of slidably fitting around said at least one said perimeter spring and forming a snap-fit therewith.  
   
   
       14 . The bed foundation of  claim 13 , wherein each said spring interconnect is T-shaped, each said spring interconnect being separate from each adjacent said spring interconnect, said at least one pair of said spring interconnects being configured for snap fitting around at least one said perimeter spring.  
   
   
       15 . The bed foundation of  claim 11 , wherein each said spring interconnect is one of integral and co-formed with at least a portion of said side wall frame.  
   
   
       16 . The bed foundation of  claim 11 , wherein at least said spring interconnect has an arrow shape configured for easy insertion between two adjacent said perimeter springs and for subsequent difficult removal from therebetween.  
   
   
       17 . The bed foundation of  claim 11 , wherein each said spring interconnect is composed of a structural foam material.  
   
   
       18 . A bed foundation, comprising: 
 a side wall frame having a frame top and a frame bottom; and    a first structural foam layer mechanically interlocked with said side wall frame and extending across one of said frame top and said frame bottom.    
   
   
       19 . The bed foundation of  claim 18 , wherein said first structural foam layer mechanically interlocks with said side wall frame at at least one wall location on said one of said frame top and said frame bottom.  
   
   
       20 . The bed foundation of  claim 18 , wherein said first structural foam layer is attached to said frame top, said first structural foam layer thereby being a foam topper.  
   
   
       21 . The bed foundation of  claim 18 , wherein said first structural foam layer is attached to said frame bottom, said first structural foam layer thereby being a foam bottom.  
   
   
       22 . The bed foundation of  claim 21 , wherein said side wall frame and said foam bottom together define a foundation tub configured for selectably receiving one of a structural foam support insert, an air bladder, a water containment unit for a waterbed, and a box-spring set.  
   
   
       23 . The bed foundation of  claim 21 , further comprising a second structural foam layer attached to said frame top, said second structural layer being a foam topper, said side wall frame, said foam bottom, and said foam topper together defining a foundation box configured for selectably receiving one of a structural foam support insert, an air bladder, a water containment unit for a waterbed, and a box-spring set.  
   
   
       24 . A bed foundation, comprising: 
 a side wall frame comprised of a plurality of mechanically interlocking frame members, said side wall frame having a frame interior, a frame top, and a frame bottom;    a box-spring array received within said frame interior, said box-spring array including a plurality of springs;    at least one spring interconnect extending from said side wall frame and into said frame interior, at least one said spring interconnect interacting with at least one said spring to thereby aid in retaining said at least one said spring in place relative to said side wall frame; and    at least a first structural foam layer mechanically interlocked with said side wall frame at one of said frame top and said frame bottom and extending across said one thereof.    
   
   
       25 . A bed foundation, comprising: 
 a side wall frame comprised of a plurality of frame members, at least two said frame members mechanically interlocking at adjoining ends thereof.    
   
   
       26 . The bed foundation of  claim 25 , wherein said mechanical interlocking is in the form of one of a slide connection and a snap-fit.  
   
   
       27 . The bed foundation of  claim 25 , wherein said side wall frame defines a frame interior, said bed foundation further comprising: 
 a box-spring array received within said frame interior, said box-spring array including a plurality of springs; and    at least one spring interconnect extending from said side wall frame and into said frame interior, at least one said spring interconnect interacting with at least one said spring to thereby aid in retaining said at least one said spring in place relative to said side wall frame.    
   
   
       28 . The bed foundation of  claim 25 , wherein said side wall frame defines a frame top and a frame bottom, said bed foundation further comprising: 
 at least a first structural foam layer attached to said side wall frame at one of said frame top and said frame bottom and extending across said one thereof.    
   
   
       29 . The bed foundation of  claim 27 , wherein said first structural foam layer is mechanically interlocked with said side wall frame.