E-SPRING FURNITURE PRODUCTS

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

[0001]Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57. This application is a U.S. Non-Provisional application and claims priority to U.S. Provisional Application No. 63/743,463, filed Jan. 9, 2025, titled E-SPRING FURNITURE PRODUCTS, and U.S. Provisional Application No. 63/743,648, filed Jan. 9, 2025, titled FOLDABLE/CONVERTIBLE FURNITURE PIECES WITH E-SPRINGS. The entire contents of each of the foregoing applications are hereby incorporated by reference herein and form a part of this specification for all purposes.

BACKGROUND

Field

[0002]The disclosure relates generally to furniture products, and more particularly to furniture products using sinuous springs or E-springs incorporated therein for resiliently supporting a person during use, such as within a furniture mattress.

Description

[0003]Many furniture pieces, such as foldaway or convertible beds, are built with foldable mattresses so they can serve as a sofa or other seating during the day and transform into a bed at night. However, the mattresses in these convertible designs are often quite thin. While this makes them easy to store, it usually comes at the expense of comfort, making it difficult for users to get a good night's sleep.

[0004]There is a need for an improved foldable mattress, particularly one that incorporates E-springs. Such a mattress should also be suitable for integration into various furniture pieces, enhancing adaptability for different uses.

SUMMARY

[0005]The disclosure herein presents various embodiments of E-spring systems that may be incorporated within various convertible furniture pieces, such as, for example, a cabinet bed, a sofa bed, a bed in a box, a reclining chair bed, a wall bed, and a wall bed with pocket coils on top.

[0006]In some examples disclosed herein, a foldable mattress may have an open position for supporting a user and a folded position for storage. The foldable mattress may include a spring assembly. The spring assembly may include an upper wire grid. The spring assembly may include a lower wire grid. The spring assembly may include a plurality of sinuous springs connected to the upper wire grid and the lower wire grid to space the upper wire grid from the lower wire grid. The plurality of sinuous springs may be pivotally connected to the upper wire grid at a first side of the plurality of sinuous springs and connected to the lower wire grid at a second side of the plurality of sinuous springs, the first side opposite the second side. The foldable mattress may include a transition section. The transition section may include an upper bar connected to the upper wire grid. The upper wire grid may be configured to pivot about the upper bar. The lower bar may be connected to the lower wire grid. The lower wire grid may pivot about the lower bar. The upper wire grid and the lower wire grid may pivot about the upper bar and the lower bar, respectively, between the open position and the folded position with the plurality of sinuous springs pivoting about the upper wire grid and the lower wire grid to cause the upper bar and the lower bar are to simultaneously pivot about the upper bar and the lower bar. The foldable mattress may include a furniture piece configured to store the foldable mattress within a storage compartment in the folded position. In the open position, a general extent of the plurality of sinuous springs extending between the upper wire grid and the lower wire grid may be perpendicular to a general extent of the upper wire grid and a general extent of the lower wire grid for the plurality of sinuous springs to space the upper wire grid from the lower wire grid a first distance. The plurality of sinuous springs may be configured to support the user on the foldable mattress in the open position. In the folded position, the general extent of the plurality of sinuous springs extending between the upper wire grid and the lower wire grid may be at an angle to the general extent of the upper wire grid and the general extent of the lower wire grid for the plurality of sinuous springs to space the upper wire grid from the lower wire grid a second distance. The second distance may be less than the first distance to allow for storage of the foldable mattress in the storage compartment.

[0007]In some examples, the plurality of sinuous springs may include E-springs. The E-springs may include two or more loops along a same plane.

[0008]In some examples, the upper wire grid may include a border wire extending along a perimeter of the upper wire grid. A plurality of wire runners may be configured to extend from the border wire to form a grid.

[0009]In some examples, a spiral connector may be configured to extend along a length of and spiral around the plurality of wire runners. The spiral connector may be configured to receive the first side of the plurality of sinuous springs.

[0010]In some examples, the first side of the plurality of sinuous springs may extend through the spiral connector and may be configured to pivot about the upper wire grid.

[0011]In some examples, a spiral connector may be configured to extend from a first end of the border wire to a second end of the border wire. The spiral connector may be configured to receive the first side of the plurality of sinuous springs.

[0012]In some examples, the plurality of sinuous springs may be formed from a continuous wire extending from the first side to the second side. The plurality of sinuous springs may be compressible along a height thereof.

[0013]In some examples, the foldable mattress may include a plurality of pocket coils positioned above the upper wire grid which may be configured to provide support for the user.

[0014]In some examples, the transition section may include a plurality of hinges pivotally connected to the upper wire grid and the lower wire grid.

[0015]In some examples, the plurality of hinges may be disposed along a length of the transition section. The plurality of hinges may extend from the transition section and to an end of the upper wire grid at a pivot point. The upper wire grid may rotate at the pivot point.

[0016]In some examples, the upper bar and the lower bar may be connected by a plurality of links. The plurality of links may be configured to fold when the upper wire grid and the lower wire grid are in the folded position. The plurality of links may be configured to extend when the upper wire grid and the lower wire grid are in the open position.

[0017]In some examples, the upper wire grid, the lower wire grid, and the plurality of sinuous springs may be configured to form a three-dimensional matrix in the open position. The three-dimensional matrix may be configured to support a weight of the user.

[0018]In some examples disclosed herein, a mattress may have an open position for supporting a user and a closed position for storage. The mattress may include a spring assembly including. The spring assembly may include first wire grid. The spring assembly may include a second wire grid. The spring assembly may include a plurality of springs connected to the first wire grid and the second wire grid to space the first wire grid from the second wire grid. The plurality of springs may be pivotally connected to the first wire grid at a first side of the plurality of springs and connected to the second wire grid at a second side of the plurality of springs, the first side opposite the second side. The mattress may include a section. The section may include a first support connected to the first wire grid, the first wire grid configured to pivot about the first support. The section may include a second support connected to the second wire grid, the second wire grid configured to pivot about the second support. In the open position for supporting the user, the plurality of springs may extend between the first wire grid and the second wire grid and may be generally perpendicular to the first wire grid and the second wire grid and space the first wire grid and the second wire grid a first distance from each other. In the closed position for storage of the mattress, the plurality of springs may extend between the first wire grid and the second wire grid are at an angle to the first wire grid and the second wire grid and space the first wire grid and the second wire grid a second distance from each other. The second distance may be less than the first distance.

[0019]In some examples, the plurality of springs may include E-springs.

[0020]In some examples, the first wire grid may include a border wire extending along a perimeter of the first wire grid. A plurality of wire runners may be configured to extend from the border wire to form a grid.

[0021]In some examples, a spiral connector may be configured to extend along a length of and spiral around the plurality of wire runners. The spiral connector may be configured to receive the first side of the plurality of springs.

[0022]In some examples, the first wire grid is configured to pivot about the first side of the plurality of springs extending through the spiral connector.

[0023]In some examples, the spring assembly may be a plurality of spring assemblies. In a stored position, a first spring assembly and a second spring assembly of the plurality of spring assemblies may be rotated about the section. The first spring assembly and the second spring assembly may be positioned above each other along a vertical axis.

[0024]In some examples disclosed herein, a method may include folding a mattress into a convertible furniture unit. The method may include positioning a spring system in an open position. The spring system may include an upper wire grid, a lower wire grid, and a plurality of sinuous springs interconnecting the upper wire grid and the lower wire grid. The method may include pivoting the spring system relative to a transition section of the mattress, the upper wire grid and the lower wire grid connected to the transition section with a plurality of hinges. The method may include pivoting the plurality of sinuous springs from an upright position to a flat position. The method may include reducing a distance between the upper wire grid and the lower wire grid to position the spring system in a collapsed position. The method may include folding the spring system in the collapsed position into the convertible furniture unit for storage.

[0025]In some examples, the method may further include a second spring system. The spring system may be folded relative to the second spring system at the transition section.

[0026]In some examples, the transition section may move from an extended position to a folded position when the spring system is folded into the collapsed position.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027]Certain embodiments of the inventions will now be discussed in detail with reference to the following figures. These figures are provided for illustrative purposes only, and the inventions are not limited to the subject matter illustrated in the figures.

[0028]FIG. 1A illustrates a schematic view of a first example of a wire grid for use in a foldable furniture system, such as a foldable mattress.

[0029]FIG. 1B illustrates another view of a second example of a wire grid for use in a foldable furniture system, such as a foldable mattress.

[0030]FIG. 1C illustrates an example of connectors or hinges for attaching the wire grids of FIG. 1A and FIG. 1B to a transition support section.

[0031]FIG. 1D illustrates another example of connectors or hinges for attaching the wire grids of FIG. 1A and FIG. 1B to a transition support section.

[0032]FIG. 1E illustrates another example of connectors or hinges for attaching the wire grid of FIG. 1A and FIG. 1B to a transition support section.

[0033]FIG. 1F shows a sinuous spring coupled to the wire grids of FIG. 1A and FIG. 1B with a spiral connector.

[0034]FIG. 2A illustrates a front perspective view of a transition support structure for use in a foldable furniture system in a deployed position.

[0035]FIG. 2B illustrates a perspective view of the transition support structure of FIG. 2A in a collapsed position.

[0036]FIG. 2C illustrates a perspective view of another example of a transition support structure for use in a furniture system.

[0037]FIG. 3A illustrates a side view of a spring system formed using the wire runners, connectors, hinges, and the transition support section of FIGS. 1A-2C.

[0038]FIG. 3B illustrates a partial side view of the spring system of FIG. 3A having pocket coils arranged along a top surface of the spring system.

[0039]FIG. 3C illustrates a side view of the spring system of FIG. 3A rotated from an open, thicker position to a closed, thinner position.

[0040]FIG. 4 illustrates a convertible furniture piece for use with the spring system of FIG. 3A or 3B.

[0041]FIG. 5 illustrates the spring system of FIG. 3A or FIG. 3B positioned within a convertible furniture piece.

[0042]FIG. 6 illustrates the spring system of FIG. 3A or FIG. 3B positioned within a convertible furniture piece.

[0043]FIG. 7 illustrates the spring system of FIG. 3A, where the spring system has been folded into a clam structure in order to position the spring system into a collapsed position.

[0044]FIG. 8 illustrates the spring system of FIG. 3B, where the spring system has been folded into a clam structure in order to position the spring system and the pocket coils into a collapsed position.

[0045]FIG. 9 illustrates the spring system of FIG. 3A, where the spring system has been folded multiple times in order to position the spring system in a collapsed position.

[0046]FIG. 10 illustrates the spring system of FIG. 3B, where the spring system has been folded multiple times in order to position the spring system and the pocket coils into a collapsed position.

[0047]FIG. 11 illustrates the spring system of FIG. 3A or FIG. 3B positioned within a convertible furniture piece.

[0048]FIG. 12 illustrates the spring system of FIG. 3A or FIG. 3B positioned within a convertible furniture piece.

[0049]FIG. 13A illustrates a wall bed for use with the spring system of FIG. 3A or FIG. 3B positioned in a stored position.

[0050]FIG. 13B illustrates the wall bed for use with the spring system of FIG. 3A or FIG. 3B moving from the stored position to an open position.

[0051]FIG. 13C illustrates the wall bed for use with the spring system of FIG. 3A or FIG. 3B moving from the stored position to the open position.

[0052]FIG. 13D illustrates the wall bed for use with the spring system of FIG. 3A or FIG. 3B moving from the stored position to the open position.

[0053]FIG. 13E illustrates the wall bed for use with the spring system of FIG. 3A or FIG. 3B wall moving from the stored position to the open position.

[0054]FIG. 13F illustrates the wall bed for use with the spring system of FIG. 3A or FIG. 3B in the open position.

[0055]FIG. 14A illustrates a side view of another example of a spring system having sinuous springs joined together by wire grids, where two or more straps are attached to the wire grids.

[0056]FIG. 14B illustrates a top view of a first wire grid for use in the spring system of FIG. 14A.

[0057]FIG. 14C illustrates another top view of a second wire grid for use in the spring system of FIG. 14A.

[0058]FIG. 15A illustrates a side view of a spring system formed using the wire grids, and straps of FIGS. 14A-14C.

[0059]FIG. 15B illustrates a side view of the spring system of FIG. 15A having pocket coils arranged along a top surface of the spring system.

[0060]FIG. 16A illustrates a perspective view of cushions interposed along rows of the spring system.

[0061]FIG. 16B illustrates another example of the spring system of FIG. 16A having sinuous springs separating rows cushions within the spring system.

[0062]FIG. 17A illustrates a cross-sectional view of a furniture system having support provided by a plurality of E-springs.

[0063]FIG. 17B illustrates a cross-sectional view of a furniture system having support provided by a plurality of M-springs.

DETAILED DESCRIPTION

[0064]The following detailed description is directed to certain specific examples of embodiments of the disclosure. In this description, reference is made to the drawings wherein like parts are designated with like numerals throughout the description and the drawings. The inventions are not limited to the examples expressly illustrated or described in this specification. Any step, feature, and/or structure illustrated or described in any embodiment of this specification can be used with or used in place of any other step, function, and/or structure illustrated or described in this specification.

[0065]The present disclosure is generally related to furniture, particularly convertible and foldable furniture in which a body-supporting component, such as a mattress, is moved between a storage position and a use position. The disclosure includes a mattress having sinuous springs, such as E-springs, arranged in columns and joined by upper and lower wire grids to form mesh grids. These mesh grids are connected to border wires and can articulate about deflectable transition sections, allowing the mattress to hinge at one or more points. As the furniture folds, the upper wire grid translates relative to the lower wire grid, enabling the sinuous springs positioned between them to lay flat for compact storage. This hinging mechanism allows the mattress to transition from a thicker sleeping position to a thinner storable position, facilitating its use in a variety of furniture products, including cabinet beds, sofa beds, beds in a box, reclining chair beds, wall beds, and Murphy beds. The furniture solutions may also include a vertical sliding mechanism to further reduce the required storage space. In some embodiments, pocket coils (e.g., cushions, cushioned springs, or the like) are disposed on or above the upper wire grid. The pocket coils may provide additional comfort for a user resting on the furniture piece. The foldable furniture used herein may be used in items found in recreational vehicles, trailers, boats, and similar environments.

[0066]FIGS. 1A-1E illustrate components for forming a spring system, spring assembly, or support structure (such as a mattress or the spring system 300A in FIG. 3A) for use in a foldable furniture system. FIG. 1A shows a first wire grid 102 (or an upper wire grid). FIG. 1B shows a second wire grid 104 (or a lower wire grid). FIGS. 1C, 1D, and 1E show examples of connectors or hinges 124 for attaching the wire grids of FIGS. 1A and 1B to a transition section (such as the transition section 128 shown in FIG. 2A). FIG. 1F shows an example of the sinuous springs attached to spiral connectors (e.g., coils) of the wire grids of FIGS. 1A and 1B.

[0067]The first wire grid 102 and the second wire grid 104 may have a border wire 110. The border wire 110 may form a perimeter of the first wire grid 102 and/or the second wire grid 104. The border wire 110 may have a plurality of connectors or hog clips 116 arranged along the border wire 110. The hog clips 116 may be used to attach or couple one or more wire runners 114 to the border wire 110. For example, an end (e.g., a curved end) of the one or more wire runners 114 may extend through and couple to the hog clips 116. Therefore, when a force is exerted (e.g., a downward vertical force) on the first wire grid 102 or the second wire grid 104, the force is distributed about the entire first wire grid 102 or second wire grid 104. The one or more wire runners 114 may provide stability and support to the first wire grid 102. The one or more wire runners 114 may extend along a length L of the first wire grid 102 or the second wire grid 104. The one or more wire runners 114 (extending about the length L or width W) of the first wire grid 102 and/or the second wire grid 104 may form a grid.

[0068]The first wire grid 102 and the second wire grid 104 may also have one or more coils 109 (e.g., helical coils, spiral connector) extending along a width W (or a length L) of the first wire grid 102 and/or the second wire grid 104. In some examples, the one or more wire runners 114 may also extend along the width W. The one or more coils 109 may surround or coil about the one or more wire runners 114. The one or more coils 109 may be used to attach a plurality of sinuous springs 108 to the first wire grid 102 or the second wire grid 104. The plurality of sinuous springs 108 may be pivotally connected to the first wire grid 102 and the second wire grid 104. The plurality of sinuous springs 108 may pivot, fulcrum, or swivel about the first wire grid 102 and the second wire grid 104.

[0069]As shown in FIGS. 1A and 1B, only a top or bottom end of the plurality of sinuous springs 108 is shown. FIG. 1F shows a top or bottom end 107 of the plurality of sinuous springs 108 that may extend through the one or more coils 109 in order to secure the plurality of sinuous springs 108 to the first wire grid 102 and/or the second wire grid 104. The top or bottom end 107 may be opposite ends of the plurality of sinuous springs 108. The plurality of sinuous springs 108 may be formed from a continuous wire. In some embodiments, the plurality of sinuous springs 108 may be formed from separate wires. The plurality of sinuous springs 108 may be compressible (e.g., as shown in FIG. 1F). In some embodiments, a supporting structure, such as a tube, may be positioned in the one or more coils 109—for example, coaxially positioned for the tube to extend through the one or more coils 109 along a centrals axis of the one or more coils 109. The top or bottom end 107 may be attached to tube. The tube may have perforations or holes that accept the top or bottom end 107 to secure the plurality of sinuous springs 108.

[0070]The plurality of sinuous springs 108 may also be shown in FIGS. 3A and 3B, where the plurality of sinuous springs 108 extend from the first wire grid 102 and to the second wire grid 104. In some examples, the first wire grid 102 and the second wire grid 104 may have a plurality of loops 111. The plurality of loops 111 may be used to connect multiple coils of the one or more coils 109 to one another. For example, a first coil of the one or more coils 109 may connect to a second coil of the one or more coils 109 along the width W of the second wire grid 104 (or the first wire grid 102) via the plurality of loops 111 (see also, for example, FIG. 14B). The one or more coils 109 may also provide structural support for the first wire grid 102 and/or the second wire grid 104.

[0071]The first wire grid 102 and the second wire grid 104 may extend from a first region 106 (or first end) and to a second region 120 (or second end). The first region 106 may be formed by the border wire 110. The second region 120 may connect to the transition section 128. As shown in FIGS. 1C-1E, a connector 112 can extend from a support plate (such as an upper support 154) of the transition section 128 (described further herein with respect to FIGS. 2A-2C). The connector 112 can rotate about the support plate at a pivot point 112A.

[0072]FIGS. 2A-2C illustrate examples of the transition section 128. The transition section 128 may include a lower support 152 (or a lower bar) and an upper support 154 (or an upper bar) spaced vertically away from the lower support 152. The upper support 154 and the lower support 152 may have one or more connectors 112 extending away from the lower support 152 and the upper support 154. The connector 112 may extend to the second region 120 of the first wire grid 102 or the second wire grid 104.

[0073]The lower support 152 and the upper support 154 may be coupled to one or more links. For example, the lower support 152 may be connected to a lower link 156. The upper support 154 may be coupled to an upper link 158. The upper link 158 and the lower link 156 may be connected or coupled together at a pivot 160. The pivot 160 may allow for the upper link 158 to move relative to the lower link 156. FIG. 2A shows the transition section 128 in an expanded position, where the upper link 158 and the lower link 156 are extended and the upper support 154 and lower support 152 are spaced away from one another. FIG. 2B shows the transition section 128 in a collapsed position, where the upper link 158 and the lower link 156 are closer together (e.g., adjacent to one another, folded). The transition section 128 can have a reduced profile in order to be capable of storage in convertible furniture unit when in the collapsed position. The lower support 152 and the upper support 154 may have one or more retainers 162. The one or more retainers 162 may be used to support a set of the plurality of sinuous springs 108.

[0074]FIG. 2C shows another embodiment of a transition section 128A. The transition section 128A may have many or all of the same features as the transition section 128, therefore the same or similar reference numbers may be used when describing transition section 128A. The transition section 128A may have the lower support 152 and the upper support 154. The connectors 112 may extend from the lower support 152 and the upper support 154 and to the first wire grid 102 and/or second wire grid 104. The transition section 128A may extend or collapse via the upper link 158 and the lower link 156.

[0075]FIG. 3A shows a spring system 300A formed from the first wire grid 102, the second wire grid 104, the plurality of sinuous springs 108, and the transition section 128 of FIGS. 1A-2C. FIG. 3B shows a spring system 300B, similar to the spring system 300A, further including pocket coils 140 positioned above the first wire grid 102. The pocket coils 140 may provide additional comfort for a user (e.g., when the spring system 300B is used as a mattress). The pocket coils 140 may be attached to the first wire grid 102 via the hog clips 116. The first wire grid 102, the second wire grid 104, and the plurality of sinuous springs 108, may form a mesh grid 105. The plurality of sinuous springs 108 may be E-springs (e.g., a spring having at least two loops doubled on each in the same plane). The plurality of sinuous springs 108 may be M-springs. The spring system 300A may be a mattress, used in a mattress system, or used for a convertible furniture piece. The spring system 300A may be designed for use in cabinet beds, sofa beds, beds in a box, reclining chair beds, wall beds (including Murphy beds), ottomans, and chairs. The spring system 300A may move between a thick, supportive position (e.g., a sleeping position) and a thin, compact storable position (e.g., a stored position) when the mesh grid 105 is rotated relative to the transition section 128.

[0076]The spring system 300A may have the transition section 128 (e.g., a deflectable transition section) coupled to the mesh grid 105. For example, the first wire grid 102 and the second wire grid 104 may be coupled to the transition section 128 via the hinges 124 and connectors 112 (as described in herein with respect to FIGS. 1C-2C). For example, the upper support 154 of the transition section 128 may be pivotally coupled to the first wire grid 102. The first wire grid 102 may pivot, fulcrum, or swivel about the transition section 128. The lower support 152 of the transition section 128 may be pivotally coupled to the second wire grid 104. The second wire grid 104 may pivot, fulcrum, or swivel about the transition section 128. The plurality of sinuous springs 108 may extend vertically from the first wire grid 102 and to the second wire grid 104. The plurality of sinuous springs 108 may provide resiliency and flexibility for the mesh grid 105. For example, the plurality of sinuous springs 108 may allow the spring system 300A to be used as a mattress, and may provide comfort during use (e.g., sleeping).

[0077]The mesh grid 105 may connect to the transition section 128 at the second region 120 of the first wire grid 102 and second wire grid 104. The mesh grid 105 may, when in an open state (or thick supportive position) support a user (e.g., the weight of a user). When the mesh grid 105 is in the open state, the plurality of sinuous springs 108 are arranged in a vertical orientation (e.g., along the vertical axis Z) to support the first wire grid 102 (e.g., the upper wire grid) in a horizontal orientation (e.g., perpendicular to the vertical axis Z). When the spring system 300A is in open, or thick supportive position, a user may lie on the first wire grid 102 of the spring system 300A. When in the open, or thick supportive position, a general extent (e.g., a height measured along the vertical axis Z) of the plurality of sinuous springs 108 extending between the first wire grid 102 and the second wire grid 104 may be perpendicular to general extent (e.g., the width W) of the first wire grid 102 and a general extent (e.g., the width W) of the second wire grid 104. The plurality of sinuous springs 108 may compress locally under the pressure of the user, allowing the spring system 300A to conform to the user. Since the plurality of sinuous springs 108 are connected to the first wire grid 102 and second wire grid 104 along rows and columns of the mesh grid 105, the load or pressure exerted by the user on the spring system 300A is distributed (e.g., evenly distributed). The plurality of sinuous springs 108 may provide a resilient support for a user in the open position.

[0078]The mesh grid 105 may also rotate relative to the transition section 128 at the second region 120. For example, when a user is seeking to fold or reduce the profile of the spring system 300A when the spring system 300A is not in use, a user can rotate the mesh grid 105 relative to the transition section 128 (e.g., via the hinges 124). As the mesh grid 105 rotates (e.g., to close and/or reduce the profile of the spring system 300A) the plurality of sinuous springs 108 can transition from an upright or vertical profile (e.g., as shown in FIGS. 3A and 3B) and to a flat profile (e.g., as shown in FIG. 3C and as shown schematically in FIGS. 7-10 as discussed further herein). The plurality of sinuous springs 108 may be articulating springs.

[0079]The mesh grid 105 may rotate relative to an adjacent mesh grid 105 (e.g., another mesh grid 105 positioned on an opposite end of the transition section 128). The mesh grid 105 may rotate from approximately 0 degrees to approximately 90 degrees. In some examples, the mesh grid 105 may rotate from approximately 0 degrees to approximately 180 degrees. In some cases, the mesh grid 105 may rotate relative to the transition section 128 (at the hinges 124) when a user lifts up the mesh grid 105 (e.g., without actuators or straps securing the mesh grid 105 in place). For example, the first wire grid 102 and the second wire grid 104 may pivot about the upper support 154 and the lower support 152 between the open and closed position. The first wire grid 102 and second wire grid 104 may rotate about the transition section 128 simultaneously (e.g., via the lower support 152 and upper support 154). In some examples, the mesh grid 105 may only rotate relative to the transition section 128 after a user disengages any actuators or removes any straps along the mesh grid 105 so that the mesh grid 105 may rotate when a user lifts the mesh grid 105 in the open position.

[0080]As shown in FIG. 3C, as the mesh grid 105 rotates relative to the transition section 128 the first wire grid 102 and/or the second wire grid 104 may rotate (e.g., twist, articulate) relative to plurality of sinuous springs 108 in order to reduce an overall profile of the mesh grid 105 (e.g., by laying flat). The ends of the plurality of sinuous springs 108 coupled to the one or more coils 109 may rotate within the coils in order to allow the plurality of sinuous springs 108 to lay flat. The rotation of the mesh grid 105, causing the plurality of sinuous springs 108 to move from an upright or extended position to a flat or overlapping position, moves the first wire grid 102 closer to (e.g., adjacent to, reducing the distance between) the second wire grid 104.

[0081]When in the folded position, a general extent (e.g., a height) of the plurality of sinuous springs 108 extending between the first wire grid 102 and the second wire grid 104 is at an angle to the general extent (e.g., a width) of the first wire grid 102 and the second wire grid 104. Rotating the mesh grid 105 relative to the transition section 128 reduces the overall profile of the mesh grid 105 (e.g., making the mesh grid 105 thinner). Reducing the overall profile of the mesh grid 105 can allow the spring system 300A to be easily stored (e.g., in a convertible furniture unit, as described further herein). When in the open position, the first wire grid 102 and the second wire grid 104 may be spaced apart a first distance (e.g., a height of the plurality of sinuous springs 108 along the vertical axis Z, the vertical distance V).

[0082]When in the closed position, the first wire grid 102 and the second wire grid 104 may be spaced apart a second distance (e.g., as shown in FIG. 3C where the mesh grid 105 is rotated) which is shorter than the first distance (e.g., as shown in FIG. 3A). When in the closed position, the plurality of sinuous springs 108 may overlap one another while laying flat. As the mesh grid 105 rotates, the plurality of sinuous springs 108 may remain substantially vertical as the first wire grid 102 and the second wire grid 104 become angled (e.g., from a horizontal state to a vertical state). In some examples, the first wire grid 102 may also translate relative to the second wire grid 104 when the mesh grid 105 is rotated in order to close or collapse the spring system 300A.

[0083]As the mesh grid 105 rotates relative to the transition section 128, the transition section 128 may also compress or collapse (e.g., as shown in FIG. 2B). The transition section 128 may collapse in order to reduce the overall vertical profile of the transition section 128 such that the spring system 300A may fit into a convertible furniture unit.

[0084]FIG. 4 illustrates a cabinet bed system 400. The cabinet bed system 400 may include a mattress or any of the spring systems (such as spring systems 300A or 300B). The cabinet bed system 400 may be coupled to a wall or a wall support structure 404. The support portion 402 (e.g., the bed or mattress or support system, such as spring system 300A), may include a slider 406. The slider 406 may connect the support portion 402 to the wall support structure 404 at an attachment zone 408. The support portion 402 may rotate and slide at the attachment zone 408 via the slider 406. For example, the support portion 402 may be deployed for sleeping or sitting. Although not shown, a fully open spring system, such as spring systems 300A or 300B, or any foldable mattress, may extend out of the support portion 402. To transition to a storage state, a user may grab an end of the mesh grid 105 (e.g., first region 106) and fold the mesh grid 105 via the transition section 128. The folded mesh grid 105 may have a reduced profile due to the first wire grid 102 moving closer to (e.g., translating towards) the second wire grid 104. The folded mesh grid 105 (e.g., folded and compacted spring system 300A) may fit within the support portion 402. The user may then lift, rotate, and translate the support portion 402 into the wall support structure 404. The support portion 402 may rotate at the attachment zone 408 and the support portion 402 may slide along the slider 406 in order to position the support portion 402 within the wall support structure 404.

[0085]FIG. 5 illustrates a convertible bed system 500 in a fully open position. The convertible bed system 500 may include the spring system 300B, the spring system 300A, or any spring system or mattress disclosed herein. The convertible bed system 500 includes an ottoman 170. The ottoman 170 has a space 172 or a storage compartment for storing the spring system 300B when in the folded or collapsed state (e.g., each of the mesh grids 105 are folded over one another, each of the mesh grids 105 are rotated 180 degrees). A covering may be positioned over the space 172 of the ottoman 170.

[0086]The convertible bed system 500 may include a plurality of legs 142. The convertible bed system 500 may include a plurality of linkages 143. The plurality of legs 142 may extend from and underneath the second wire grid 104. The plurality of legs 142 may support the 300B in the upright position. The plurality of legs 142 may be interconnected by the plurality of linkages 143. The plurality of linkages 143 may allow the plurality of legs 142 to rotate to the fully extended, supported state and to a collapsed state (e.g., where the plurality of legs 142 fold relative to one another). The convertible bed system 500 may have three mesh grids 105 (e.g., a first mesh grid 105A, a second mesh grid 105B, and a third mesh grid 105C). The convertible bed system 500 may have two transition sections 128 (e.g., first transition section 128A, second transition section 128B). The first mesh grid 105A at a first end 502 of the convertible bed system 500 may first fold relative to the first transition section 128A (e.g., by rotating 180 degrees). The legs 142 positioned underneath the first mesh grid 105A may fold into a flat state. Next, the second mesh grid 105B located at the middle region 506 may fold relative to the first transition section 128A and/or the second transition section 128B. The legs 142 positioned underneath the second mesh grid 105B may also fold flat via the plurality of linkages 143. The first mesh grid 105A and the second mesh grid 105B may rotate relative to one another (e.g., they may each rotate 180 degrees about a rotational axis). The third mesh grid 105C located at the second end 504 may also rotate relative to the second transition section 128B and the second mesh grid 105B. Each of the mesh grids 105A, 105B, 105C may lay over one another in a folded state. When in the folded state, the spring system 300B may fit into the space 172 of the ottoman 170. Each of the legs 142 may also be folded flat in order to fit into the space 172.

[0087]FIG. 6 illustrates another example convertible bed system 600 in a fully open position. The convertible bed system 600 may include the spring system 300B, the spring system 300A, or any spring system or mattress disclosed herein. The convertible bed system 600 includes a chair 180. The chair has a space 182 for storing the spring system 300B when in the folded or collapsed state (e.g., each of the mesh grids 105 are folded over one another, each of the mesh grids 105 are rotated 180 degrees). The spring system 300B may be folded into the space 182 of the chair 180 similar to or the same as the described with respect to the convertible bed system 500 and the ottoman 170.

[0088]FIG. 7 shows a clam bed 700 having the spring system 300A (e.g., without the pocket coils 140) in a folded state. FIG. 8 shows a clam bed 800 having the spring system 300B having pocket coils 140 and in the folded state. The first mesh grid 105A may fold relative to the second mesh grid 105B. The first mesh grid 105A and the second mesh grid 105B may rotate 180 degrees relative to each other at the transition section 128. As shown in FIGS. 7 and 8, schematically, the plurality of sinuous springs 108, in the folded position, lay flat and are collapsed relative to the expanded position (e.g., as shown in FIGS. 3A and 3B). The first mesh grid 105A and second mesh grid 105B have a thin profile in the folded position. The clam bed 700 and clam bed 800 may be stored in a desired position (e.g., vertically, within a furniture cavity, a trunk, against a wall, etc.). The clam bed 700 may have an open space 138 between the folded first mesh grid 105A and second mesh grid 105B. The clam bed 800 may have pocket coils 140 positioned between the first mesh grid 105A and the second mesh grid 105B.

[0089]The first mesh grid 105A and the second mesh grid 105B may hinge in opposite directions at the transition section 128 in order to fold into a storable configuration. The first mesh grid 105A and the second mesh grid 105B may fold relative to one another like a clam, or similarly to a person closing a book (e.g., where the transition section 128 may form the spine of the book). As the first mesh grid 105A and the second mesh grid 105B hinge at the transition section 128, they become thinner, as disclosed herein. The first mesh grid 105A and the second mesh grid 105B may form a thin, rectangular unit designed for storage in a convertible furniture system. The first mesh grid 105 and the second mesh grid 105B may be a three-dimensional matrix.

[0090]FIG. 9 shows a trunk bed 900 having a spring system, similar to that of spring system 300A (e.g., without the pocket coils 140) in a folded state. FIG. 10 shows a trunk bed 1000 having the spring system, similar to that of the spring system 300B, having pocket coils 140 and in the folded state.

[0091]The trunk beds 900, 1000 may have multiple mesh grids (e.g., a first mesh grid 105A, a second mesh grid 105B, a third mesh grid 105C, and a fourth mesh grid 105D). The first mesh grid 105A may be a foot portion or first end region of a mattress. The fourth mesh grid 105D may be a head portion or a second end region of a mattress. The second mesh grid 105B and the third mesh grid 105C may be body portion or middle portions of a mattress. The trunk beds 900, 1000 may also have multiple transition sections (e.g., a first transition section 128A, a second transition section 128B, and a third transition section 128C). The trunk beds 900, 1000 may have the first transition section 128A between the first mesh grid 105A and the second mesh grid 105B. The trunk beds 900, 1000 may have the second transition section 128B between the second mesh grid 105B and the third mesh grid 105C. The trunk beds 900, 1000 may have the third transition section 128C between the third mesh grid 105C and the fourth mesh grid 105D.

[0092]The first mesh grid 105A may hinge or rotate relative to the second mesh grid 105B (e.g., rotate 180 degrees in opposite directions) via the transition section 128A. As the first mesh grid 105A and the second mesh grid 105B rotate, the respective plurality of sinuous springs 108 move from an extended position to a flat position (schematically shown in FIGS. 9 and 10) in order to create a thinner profile. The third mesh grid 105C and the fourth mesh grid 105D may hinge or rotate relative to one another via the third transition section 128C (e.g., rotate 180 degrees in opposite directions). As the third mesh grid 105C or the fourth mesh grid 105D rotate relative to one another, the plurality of sinuous springs 108 may move from the extended position (e.g., as shown in FIG. 3A or 3B) and to a flat position (e.g., as shown schematically in FIGS. 9 and 10). The folded first mesh grid 105A and second mesh grid 105B may form a first folded region 129A. The folded third mesh grid 105C and fourth mesh grid 105D may form a second folded region 129B. The first folded region 129A and the second folded region 129B may hinge or rotate about the second transition section 128B. Each of the mesh grids may hinge via a respective transition section similarly to an accordion. When each of the mesh grids 105A, 105B, 105C, 105D are fully rotated into a closed position, the trunk beds 900 are formed in a single box-shaped unit (e.g., rectangular unit, three-dimensional unit) which can be stored in a dedicated furniture cavity or storage compartment (e.g., a trunk, a wall, etc.) as described herein.

[0093]FIGS. 11 and 12 show a spring system, such as the spring system 300A or spring system 300B positioned within reclining chairs 1100 or 1200. The spring system 300A or spring system 300B may be able to fold about the transition section 128 as described herein. For example, the reclining chairs 1100, 1200 may have a first mesh grid 105A, a second mesh grid 105B, and a third mesh grid 105C. The first mesh grid 105A may be able to fold relative to the second mesh grid 105B via the transition section 128. The third mesh grid 105C may be able to fold relative to the second mesh grid 105B at the transition section 128.

[0094]The reclining chairs 1100, 1200 may be designed such that as the third mesh grid 105C moves relative to a ground surface, the third mesh grid 105C and the second mesh grid 105B may hinge (e.g., rotate 180 degrees about the second transition section 128B) until the third mesh grid 105C and the second mesh grid 105B meet and are parallel to one another. The folded mesh grid (e.g., the fold of the third mesh grid 105C and the second mesh grid 105B) may then fold again at the first transition section 128A. The second mesh grid 105B and the third mesh grid 105C may move from a thicker profile to a thinner profile (e.g., by moving the first wire grid 102 closer to the second wire grid 104 when the plurality of sinuous springs 108 rotate) to the seated position (e.g., as shown in FIG. 11 or 12). When all of the mesh grids 105A, 105B, 105C, are folded relative to one another, the reclining chairs 1100, 1200 can be stored. For example, in the folded state, the mesh grids 105A, 105B, 105C can be positioned within the space 192 of the chair 190. The chair 190 may have a plurality of legs 194 extending from a bottom surface thereof and to the ground G.

[0095]FIGS. 13A-13F show a foldaway bed 1300 using the spring system 300A or spring system 300B disclosed herein for positioning on a wall. The foldaway bed 1300 is designed such that the spring system 300A or the spring system 300B is in the thin, folded state when in a vertical stored position (as shown in FIG. 13A). The spring system 300A or spring system 300B is in the thicker or extended position when in a horizontal (e.g., sleeping) position (as shown in FIG. 13F). Although not shown, the foldaway bed 1300 may include a slider that is attached to the point where the unit connects to the wall/vertical support structure (e.g., at point 1311). The slider may allows the head section to lower as the foot section raises so the entire unit can hinge in a smaller area. The foldaway bed 1300 may include the pocket coils 140 on the spring system 300A or the spring system 300B above the first wire grid 102 of the mesh grid 105.

[0096]The foldaway bed 1300 may include a lower panel 1302 provided underneath the platform 1301. The lower panel 1302 may be pivotable (e.g., in an outward direction) to expose a lower compartment 1303. As shown in FIGS. 13C-13D, base cabinets 1304 may be positioned in front of the folded bed 1306. The folded bed 1306 may have a set of cushions placed on the base cabinets 1304 to serve as a couch or seating area. Each cabinet is operable to receive the cushions therein, or to store additional items. The cushions may be placed in front of the base cabinets 1304 as shown in FIG. 5. When the bed is unfolded, as shown in FIG. 13F, the cabinets and the cushions are accommodated underneath the platform 1301. The spring system 300A may be unfolded (e.g., from the wall 1318), similar to and as described herein in connection with FIGS. 3A-12.

[0097]FIG. 14A shows another embodiment of a mesh grid 1400A for a spring system, such as the spring system 300A. The mesh grid 1400A has many or all of the same or similar features as the mesh grid 105. The mesh grid 1400A has one or more straps 118 (e.g., two straps) extending from the first wire grid 102 and to the second wire grid 104. The one or more straps 118 may form an X-shape from the first wire grid 1400B to the second wire grid 1400C. The plurality of sinuous springs 108 may extend from the first wire grid 102 to the plurality of sinuous springs 108 in order to provide structural support (e.g., comfort/structure for a user sleeping on the mesh grid 1400A). The straps 118 may provide additional stabilization for the mesh grid 1400A so that the mesh grid 1400A is secure/stable when a user is atop the first wire grid 1400B.

[0098]FIG. 14B shows another embodiment of the first wire grid 1400B for a spring system, such as the spring system 300A. The first wire grid 1400B has many or all of the same or similar features as the first wire grid 102. FIG. 14C illustrates another embodiment of the second wire grid 1400C for use in a spring system, such as the spring system 300A. The second wire grid 1400C has many or all of the same or similar features as the first wire grid 102. The first wire grid 1400B and the second wire grid 1400C may have second straps or metal banding 119 extending along a width thereof. The metal banding 119 may be steel, aluminum, copper, or the like. The metal banding 119 may be used to provide edge support for first wire grid 1400B and/or second wire grid 1400C (e.g., along the border wire 110). The metal banding 119 may be used to stabilize the system.

[0099]FIG. 15A shows a spring system 1500A having the same or similar features as the spring system 300A disclosed herein. FIG. 15B shows a spring system 1500B having the same or similar features as the spring system 300B. The spring system 1500A and the spring system 1500B may not have a transition section or a transition region (e.g., transition section 128).

[0100]FIG. 16A shows a spring system 1600A having the same or similar features as the spring system 300A. FIG. 16B shows a spring system 1600B having the same or similar features as the spring system 300A. The spring system 1600A and the spring system 1600B have cushions 147 positioned within. The cushions 147 are arranged in rows. The cushions 147 may be separated by the plurality of sinuous springs 108 positioned along a midsection of the spring system 1600B (as shown in FIG. 16B). The plurality of sinuous springs 108 along the border wire 110 extending from the first wire grid 102 to the second wire grid 104 may also maintain the cushions 147 within the spring system 1600A and/or the spring system 1600B.

[0101]FIG. 17A shows a bed system 1700A having a mattress 144 positioned above a first wire grid 102. FIG. 17B shows another embodiment of a bed system 1700B having mattress 144 positioned above a first wire grid 102. The bed system 1700A and the bed system 1700B may have the same or similar features as any system disclosed herein with respect to FIGS. 1A-16B. The bed system 1700A may be supported by a plurality of sinuous springs 108. The plurality of sinuous springs 108 may be E-springs (e.g., spring having one or more loops along a height thereof). The plurality of sinuous springs 108 may provide support for the mattress 144 along the edges thereof. The bed system 1700B may be supported by a plurality of M-springs 108A. The M-springs 108A may be wrapped around a coil 108B.

[0102]Conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or states are in any way required for one or more embodiments or that one or more embodiments necessarily include these features, elements and/or states.

[0103]The ranges disclosed herein also encompass any and all overlap, sub-ranges, and combinations thereof. Language such as “up to,” “at least,” “greater than,” “less than,” “between,” and the like includes the number recited. Numbers preceded by a term such as “about” or “approximately” include the recited numbers and should be interpreted based on the circumstances (e.g., as accurate as reasonably possible under the circumstances, for example ±5%, ±10%, ±15%, etc.). For example, “about 1 mm” includes “1 mm.” Phrases preceded by a term such as “substantially” include the recited phrase and should be interpreted based on the circumstances (e.g., as much as reasonably possible under the circumstances). For example, “substantially parallel” includes “parallel.” Unless stated otherwise, all measurements are at standard conditions including temperature and pressure. The phrase “at least one of” is intended to require at least one item from the subsequent listing, not one type of each item in the subsequent listing. For example, “at least one of A, B, and C” can include A, B, C, A and B, A and C, B and C, or A, B, and C.

[0104]While the above detailed description may have shown, described, and pointed out novel features as applied to various embodiments, it may be understood that various omissions, substitutions, and/or changes in the form and details of any particular embodiment may be made without departing from the spirit of the disclosure. As may be recognized, certain embodiments may be embodied within a form that does not provide all of the features and benefits set forth herein, as some features may be used or practiced separately from others.

[0105]The methods which are described and illustrated herein are not limited to the sequence of acts described, nor are they necessarily limited to the practice of all of the acts set forth. Other sequences of acts, or less than all of the acts, or simultaneous occurrence of the acts, may be utilized in practicing embodiments of the embodiment(s).

[0106]It is to be understood that any range of values disclosed, taught, or suggested herein comprises all values and sub-ranges therebetween. For example, a range from 5 to 10 will comprise all numerical values between 5 and 10 and all sub-ranges between 5 and 10.

[0107]From the foregoing description, it will be appreciated that a novel approach for reducing energy in a scrap conveying system has been disclosed. While the components, techniques, and aspects of embodiments of the disclosure have been described with a certain degree of particularity, it is manifest that many changes may be made in the specific designs, constructions, and methodology herein above described without departing from the spirit and scope of this disclosure.

[0108]While a number of preferred embodiments of the disclosure and variations thereof have been described in detail, other modifications and methods for the same will be apparent to those of skill in the art. Accordingly, it should be understood that various applications, modifications, and substitutions may be made of equivalents without departing from the spirit of embodiments of the disclosure or the scope of the claims.

[0109]Various modifications and applications of the embodiments of the disclosure may occur to those who are skilled in the art, without departing from the true spirit or scope of the embodiments of the disclosure. It should be understood that the disclosure is not limited to the embodiments set forth herein for purposes of exemplification but is to be defined only by a fair reading of the appended claims, including the full range of equivalency to which each element thereof is entitled.