US20020069462A1 - Bed foundation - Google Patents
Bed foundation Download PDFInfo
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- US20020069462A1 US20020069462A1 US09/900,685 US90068501A US2002069462A1 US 20020069462 A1 US20020069462 A1 US 20020069462A1 US 90068501 A US90068501 A US 90068501A US 2002069462 A1 US2002069462 A1 US 2002069462A1
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- rails
- rail
- bed foundation
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C19/00—Bedsteads
- A47C19/005—Bedsteads dismountable
Definitions
- the present invention relates generally to a bed foundation. More particularly, the present invention relates to a shippable foundation for use with a mattress.
- a few bed foundations have been conceived that may be reversibly assembled and are provided in components that can be conveniently stored and shipped prior to assembly at an end user's location.
- Several embodiments of such bed foundations are described in Walker, U.S. Pat. No. 5,144,706 and Shoenhair et al., U.S. Pat. No. 5,564,140, both of which are assigned to the assignee of the present application.
- Walker describes a bed foundation that is assembled from several interlocking sections.
- the Walker bed foundation has two center sections that are shorter than the end sections so that the center sections may be packed within the end sections.
- Shoenhair et al. discloses a bed foundation that is fabricated from a pair of side rails, a pair of end rails, at least one intermediate rail, and several top panels. When disassembled, the components of the Shoenhair et al. bed foundation are relatively flat to facilitate shipment of the bed foundation to customers.
- UPS United Parcel Service
- OS1 Oversized 1
- the packages' combined length and girth is equal or less than 108 inches.
- the package's actual weight is less than 30 pounds.
- Girth is defined as twice the width plus twice the depth of a package which has a length (or height when standing on end), a depth and a width where length is the greatest dimension. For each OS1 package, the billable weight is 30 pounds.
- the second surcharge called Additional Handling, is applied to packages which exceed 60 inches in length. These packages are assessed an additional handling surcharge of $5.00 per package.
- a bed foundation could be assembled without tools from components that can be packed into a standard sized container. Such a foundation would give a customer a good impression of the bed company once the customer gets the package home or has the package delivered and begins to assemble the bed. Assembly details are not easily shown in a retail setting. Bed foundations, or other products for that matter, requiring assembly, can often leave a bad impression with the customer if the assembly asked of the customer is excessive, complicated or poorly described in an instruction manual.
- a kit requiring assembly and tools quite often contains a large number of screws, possibly a hexagonal wrench, a plurality of metal angle irons and corner pieces, and a plurality of wooden boards having holes already drilled at predetermined locations. It is not unusual for there to be screws missing, tools missing, holes drilled in the wrong location, and missing angle irons. These discrepancies can often create significant discontent with the customer and may even result in the customer returning the entire package and purchasing a competitor's product.
- the present invention includes a bed foundation capable of supporting a variety of mattresses.
- the bed foundation is constructed entirely of blow-molded plastic components. These components interlock without the use of tools and can be quickly and easily assembled by a customer. When disassembled, the components compactly ship within a container having a length less than 60 inches and a girth less than 84 inches. When assembled, the bed foundation is inherently sturdy, attractive, and impressive.
- the bed foundation generally comprises a pair of side rails, a pair of end rails, a plurality of intermediate rails, and top portions that lie upon, and interlock with the rail members.
- the side rails consist of two portions that disassemble to give the side rails an overall length of less than 60 inches.
- FIG. 1 is a perspective view of a bed foundation according to the present invention
- FIG. 2 is a perspective view of the preferred bed foundation with the top plate removed;
- FIG. 3 is a perspective view of an embodiment of the side rail joint of the present invention in a disassembled state
- FIG. 4 is a side elevation view of the side rail joint of FIG. 3 in an assembled state
- FIG. 5 is a perspective view of the side rail joint of FIG. 3 further having a locking mechanism
- FIG. 6 is a perspective view of a preferred side rail joint of the present invention in a disassembled state
- FIG. 7 is a perspective view of the preferred side rail joint of FIG. 6 shown in an assembled state
- FIG. 8 is top view of the preferred side rail joint of FIG. 6 shown in a disassembled state
- FIG. 9 is a side elevation of the preferred side rail joint of FIG. 6 shown in an assembled state
- FIG. 10 is a perspective view of a preferred locking pin of the present invention.
- FIG. 11 is a perspective view of an intermediate rail of the present invention.
- FIG. 12 is a side elevation of the intermediate rail of FIG. 11;
- FIG. 13 is a top plan view of the intermediate rail of FIG. 11;
- FIG. 14 is a perspective view of an end rail of the present invention showing the inner side
- FIG. 15 is a side elevation of an end rail of the present invention showing the outer side
- FIG. 16 is a top plan view of the end rail of FIGS. 14 and 15;
- FIG. 17 is a perspective view of a top panel portion of the present invention which has been inverted to show the detail of the lower surface;
- FIG. 18 is a perspective view of a cover of the present invention.
- FIG. 19 is a perspective view of the bottom of a preferred embodiment having an overhanging top panel and a cover with filler foam.
- a bed foundation 20 which includes a pair of side rails 22 , a pair of end rails 24 , at least one intermediate rail 26 , and a top panel 28 .
- the side rails 22 , the end rails 24 , the intermediate rails 26 , and the top panel 28 are all preferably blow-molded from plastic.
- the components of the bed foundation 20 permit reversible assembly so that the bed foundation 20 may be shipped to the customer in packages that do not incur sized-based penalties when shipping.
- the bed foundation 20 is constructed and arranged to permit the customer to assemble and disassemble the bed foundation 20 so it may be later stored in a relatively small space when a customer is not using the foundation 20 .
- the components of the foundation 20 include interlocking joints that enable the foundation 20 to be assembled without the use of tools. These interlocking joints are integrally molded with the components so that no other parts are required. While not necessary, the interlocking joints may be further secured with lock pins or similar devices.
- the side rails 22 each include a first section 30 and a second section 32 .
- the first and second sections, 30 and 32 are removably attachable to each other. When attached, the first section 30 is aligned with the second section 32 to form a straight, linear side rail 22 .
- the first section 30 and the second section 32 are preferably of different lengths. The different lengths of the first section 30 and the second section 32 allow the resulting union 33 between the first section 30 and the second section 32 of each of the side rails 22 to be offset from the center of the bed foundation 20 .
- the union 33 of one side rail 22 is closer to a head end of the side rail 22 whereas the union 33 of the other side rail 22 is closer to the foot end of that side rail 22 .
- This is advantageous because when both side rails 22 are assembled and facing each other, the union 33 of one side rail 22 may be longitudinally displaced from the union 33 of the other side rail 22 , thereby increasing the rigidity of the overall foundation 20 . If the unions 33 of either side rail 22 directly faced each other, a line of instability in the bed foundation 20 would be created.
- sections 30 and 32 are asymmetric such that errors cannot be made in arranging the side rails 22 , thereby ensuring that unions 33 do not face each other. This arrangement prevents the occurrence of a natural creasing point in the bed foundation 20 .
- one of ordinary skill in the art will appreciate it that is possible to form the first section 30 and the second section 32 with approximately equal lengths without going beyond the concepts of the present invention.
- the T-joint 40 has an approximate T-shape and includes a male portion 42 extending from the first section 30 and a female portion 44 formed in the second section 32 .
- the male portion 42 has a shape that is substantially complementary to the female portion 44 so that the male portion 42 and the female portion 44 form a snug, interlocking fit.
- One skilled in the art will understand that it is not important whether the female portion 44 be formed in the first section 30 or in the second section 32 , only that one male portion 42 and one female portion 44 are provided and have complementary shapes.
- the interlocking fit between the male portion 42 and the female portion 44 prevents the first section 30 from being pulled away from the second section 32 , as indicated by arrow 46 .
- the interlocking fit between the male portion 42 and the female portion 44 also prevents the first section 30 from moving up or down with respect to the second section 32 as indicated by arrow 48 .
- the interlocking fit between the male portion 42 and the female portion 44 also resists lateral movement of the first section 30 with respect to the second section 32 , as indicated by arrow 49 of FIG. 3. However, the resistance to this lateral movement, shown by arrow 49 , results only from the friction between the first section 30 and the second section 32 .
- the joint 40 preferably includes a reinforcing mechanism 50 , shown in FIGS. 5.
- the reinforcing mechanism 50 maintains the first section 30 and the second section 32 in an assembled configuration, and preferably includes a slot 52 formed in a side surface 54 of the first section 30 and in the second section 32 .
- the slot 52 preferably extends from a top surface 56 of the side rail 22 substantially to a bottom surface 58 of the side rail 22 .
- the slot 52 is adapted to receive a pin 53 .
- the pin 53 has a profile that substantially conforms to a cross-section of the slot 52 such that the pin 53 fits snugly within the slot 52 .
- the pin 53 is retained in the slot 52 by a pair of lips 55 that extend partially over the slot 52 .
- the pin 53 is preferably fabricated from a metallic or plastic material.
- Assembly is achieved by positioning the male portion 42 adjacent the female portion 44 .
- the male portion 42 is then pressed into the female portion 44 until the male portion 42 engages the female portion 44 .
- the pin 53 is then placed into the slot 52 locking the first section 30 and the second section 32 together. It may be preferable to provide more than one slot 52 and pin 53 to further enhance rigidity.
- a more preferred mechanism for reversibly joining the first section 30 and the second section 32 is an L-hook joint 70 as seen in FIGS. 6 - 9 .
- the L-hook has a male portion 72 and a female portion 74 .
- the male portion 72 has at least one extension 76 .
- the male portion has two extensions 76 .
- at least one of the extensions 76 has a vertical catch 78 , the function of which will be explained below.
- the female portion 74 comprises a cavity 82 constructed and arranged to receive the male portion 72 .
- the cavity 82 preferably does not pass through the side rail 22 . Rather, the cavity 82 has a rear surface 84 and a plurality of complementary raised surfaces 86 .
- the male portion 72 and the female portion 74 fit together in a snug, interlocking manner when the extensions 76 are inserted into the cavity 82 .
- the vertical catches 78 of the extensions 76 act on vertical surfaces 80 of the cavity 82 .
- the relationship between the catches 78 and the vertical surfaces 80 prevent the first section 30 from being pulled away from the second section 32 in a longitudinal direction. This relationship also helps to prevent the first section 30 from being angled upwardly or downwardly in relation to the second section 32 .
- the joint 70 preferably includes a reinforcing mechanism 90 , as seen in FIGS. 7 - 10 .
- the reinforcing mechanism 90 preferably includes a slot 92 formed in a side surface 94 of the first section 30 and the second section 32 .
- the slot 92 extends from the top surface 56 of second section 32 to the bottom surface 98 of the cavity 82 formed in the second section 32 .
- FIG. 7 shows how the slot 92 is completed when the first section 30 and the second section 32 are assembled.
- the reinforcing mechanism 90 includes the aforementioned pin 53 .
- the pin 53 is shaped to be received by the slot 92 , and is preferably fabricated from a metallic or plastic material.
- the pin 53 is retained in the slot 92 by a pair of lips 102 that partially extend over the slot 92 , as is most clearly illustrated in FIG. 8.
- FIGS. 7 and 10 show a preferred embodiment of the pin 53 used to retain the first section 30 and the second section 32 in an engaged relationship. It can be seen that the pin 53 includes a horizontal surface 100 on which to press when inserting the pin 53 into the slot 92 . Integral with the horizontal surface 100 , is a pin portion 101 .
- the pin 53 also preferably provides a downward facing surface 103 under which a user's fingers may be placed in order to pull the pin 53 in an upward direction when disassembling the bed foundation 20 .
- the bed foundation 20 includes at least one, preferably four, intermediate rails 26 constructed and arranged to extend from one side rail 22 to the opposite side rail 22 , between the end rails 24 (as seen in FIG. 2).
- the intermediate rails 26 thereby enhance the structural rigidity of the bed foundation 20 .
- the spacing between the intermediate rails 26 may be approximately equal, the intermediate rails 26 are preferably spaced so that all four intermediate rails are located in approximately a middle half of the bed foundation 20 .
- Such a configuration provides additional support and helps to prevent deflection in a central region of the bed foundation 20 where a high concentration of a person's weight will be located while that person is lying on the bed.
- the side rails include grooves 132 (FIGS. 6 - 9 ) defined therein.
- the grooves 132 are constructed and arranged to receive dovetails 134 which are integral with and extend from the ends of the intermediate rails 26 .
- the grooves 132 preferably extend from the top surface 56 of the side rail 22 to a stop 136 which is provided just above a lower surface 138 of the side rails 22 .
- the stop 136 provides a positive indication that the dovetail 134 is completely inserted in the groove 132 and prevents the dovetail 134 from extending too far into the groove 132 , resulting in the top surfaces of the intermediate rails 26 and the side rails 22 from being uneven.
- the end rails 24 connect to the side rails 22 in the same manner as the intermediate rails 26 .
- the only difference between the end rails 24 and the intermediate rails 26 is the appearance of an outside surface 141 .
- the outside surface 141 is ornamentally similar to the outside surfaces 143 (FIG. 1) of the side rails 22 such that when the bed foundation 20 is fully assembled, an attractive, completed appearance results.
- the bed foundation 20 further includes a top panel 28 constructed and arranged to extend over the side rails 22 , the end rails 24 , and the intermediate rail 26 when placed thereon.
- the top panel 28 substantially covers an area defined by these components.
- An alternate embodiment provides a top panel 28 , which extends a predetermined distance past the side rails 22 .
- Such an embodiment allows a larger mattress to be placed on a smaller bed foundation 20 . This is especially useful with the recent introduction of the deluxe queen, a new size being introduced by mattress manufacturers to provide a queen sized bed which is three inches wider than a convention queen sized bed.
- This larger top panel 28 obviates the need for a consumer to buy a new bed foundation or box spring and, more importantly, obviates the need for a new bed frame.
- the top panel 28 is preferably formed of multiple top panel portions 140 .
- Each of the top panel portions 140 preferably has a common shape. It is envisioned that queen and king sized foundations 20 will have four top panel portions 140 while twin sized and double sized foundations 20 will have two top panel portions 140 .
- the top panel portions 140 each include at least one tab 142 extending from a side of the top panel portion 140 and a recess 144 formed in the side of top panel portion 140 , as most clearly illustrated in FIG. 17.
- the tabs 142 preferably have a shape that substantially conforms with a shape of the recess 144 . It is envisioned that the top panel portions 140 include two tabs 142 and two recesses 144 , which permit all of the top panel portions 140 to have a substantially uniform configuration.
- the top panel portions 140 further include a mounting mechanism, which secures the top panel portions 140 to the side rails 22 , the end rails 24 , and the intermediate rails 26 .
- the mounting mechanism preferably includes a locking extension 152 formed on the top surfaces 56 of the side rails 22 , the top surfaces 96 of the intermediate rails 26 (FIGS. 6 - 9 and 11 - 16 ), and the top surfaces 154 of the end rails. It is understood that the number and size of the locking extensions 152 are selected based upon the size of the foundation 20 . A person of ordinary skill of the art will appreciate that a greater number of locking extensions 152 would be beneficial on a king-sized foundation than would be on a twin sized foundation.
- a receiving portion 156 is formed into a lower surface 158 of the top panel portions 140 , as seen in FIG. 19 and 20 .
- a recess 160 is preferably formed in the lower surface 158 of the top panel portions 140 adjacent the receiving portions 156 .
- the side rails 22 , the end rails 24 , the intermediate rails 26 , and the top panel 28 are each preferably fabricated from plastic, more preferably injected-molded plastic, even more preferably blow-molded plastic.
- blow-molded plastic is advantageous, not only because it allows complete recyclability, but also because it minimizes material costs. Also, once tooling is established, blow molding minimizes production costs and allows parts to be produced having complicated geometries. A person of ordinary skill in the art will appreciate that it is possible to fabricate the preceding components from a variety of materials, such as steel or wood, using the concepts of the present invention. However, doing so would result in increased production costs.
- tack-offs 110 are incorporated into the shape of the top panel portions 140 , the side rails 22 , the end rails 24 , and the intermediate rails 26 .
- the tack-offs 110 are simply indentations formed in a surface or two surfaces of a component. Tack-offs 110 are well known in the art and commonly used with blow-molded plastic components in order to increase rigidity.
- the tack-offs 110 may be created with a wide variety of dimensions and may range from deep to shallow and from long to short.
- the tack-offs 110 may be formed in either a vertical orientation, or a horizontal orientation.
- the intermediate rails 26 have tack-offs 110 running horizontally substantially the entire length of the intermediate rail 26 .
- the tack-offs 110 formed in the side rails 22 are preferably positioned so as not to interfere with the grooves 132 , or the slots 92 .
- the bed foundation 20 further includes a substantially decorative cover 170 shown in FIG. 18.
- the cover 170 extends over the entire outer surface of the bed foundation 20 .
- the cover is preferably fabricated from a cloth material and enhances the aesthetic appeal of the bed foundation by providing the bed foundation 20 with an appearance that is similar to the appearance of box springs used with conventional mattresses.
- a cover 170 may be provided with filler foam 172 which fills in the resulting space formed between the sides of the overhanging cover and the side rails 22 of the foundation 20 . This will give a rectangular, box-like appearance to the foundation 20 , as opposed to a ledged appearance created by the overhanging top panel 28 .
- the bed foundation 20 of the present invention therefore provides an alternative to a conventional bed foundation.
- the bed foundation 20 may be disassembled so that its components may be packaged into standard sized shipping containers, e.g., shipping containers having a length of less than 60 inches and a girth of less than 84 inches.
- standard sized shipping containers enables the bed foundation 20 to be readily transported using common carriers without incurring additional charges associated with oversized packages.
- standard sized shipping containers also facilitate easy handling by customers.
- the side rails 22 are assembled first by joining the first sections 30 to the second sections 32 .
- the first section 30 and the second section 32 are joined by placing the male portion 72 into the female portion 74 . This is most easily accomplished by laying the second portion 32 on its side on the floor, such that the female portion 74 faces upward.
- the extension 76 of the male portion 72 is then pressed into the cavity 82 and may be stepped on to ensure a snug fit.
- a pin 53 is then placed into the groove 92 by pushing on the upper surface 100 .
- the side rails 22 are then positioned such that they form a relative parallel relationship and such that pins 53 are facing each other, though longitudinally off-set.
- the end rails 24 are then placed between the side rails 22 and their dovetails 144 are positioned in the grooves 132 .
- the two end rails 24 and side rails 22 should now form a rectangular shape.
- the intermediate rails 26 are placed in a similar fashion between the end rails 24 so that they span across the side rails 22 . Their dovetails 134 are pressed into the corresponding grooves of the side rails 22 .
- top panel portions 140 are then attached to the assembly by placing the locking extensions 152 , which extend from the side rails 22 , the end rails 24 , and intermediate rails 26 into the receiving portions 156 formed in the lower surface 158 of the top panel portions 140 . This is most clearly seen in FIGS. 19 and 20.
- the cover 170 is simply placed over the top of the now assembled bed foundation 20 .
- the bed foundation 20 may be positioned to support virtually any type of mattress, e.g., a standard coil spring mattress, a fluid filled mattress, a futon, etc. Additionally, the bed foundation 20 may be placed atop, and supported by, a standard metal bed frame or may be placed atop and supported by a slat bed frame. Similarly, if desired, the bed foundation 20 may be placed atop and supported by a platform bed frame.
- a standard coil spring mattress e.g., a standard coil spring mattress, a fluid filled mattress, a futon, etc.
- the bed foundation 20 may be placed atop, and supported by, a standard metal bed frame or may be placed atop and supported by a slat bed frame. Similarly, if desired, the bed foundation 20 may be placed atop and supported by a platform bed frame.
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Abstract
Description
- This application claims the priority of U.S. Provisional Serial No. 60/216,908, filed on Jul. 7, 2000.
- The present invention relates generally to a bed foundation. More particularly, the present invention relates to a shippable foundation for use with a mattress.
- Despite the remarkable advances made in manufacturing processes over the last several decades, conventional bed foundations have, for the most part, dated designs and are assembled using old techniques. These foundations, commonly known as box springs, consist of a plurality of wood members combined with rigid metal springs constructed and arranged to form a rectangular box which provides a relatively rigid platform on which to place a mattress. The bottom of the box spring or bed foundation, having rigid members, is capable of being supported by a bed frame having two side rails and one or two cross members.
- Because these conventional bed foundations are assembled at the factory and covered with attractive ticking, they cannot be disassembled for shipping. If the manufacturer were to ship the parts of the box spring along with the cover and leave assembly up to the consumer, the consumer would likely not have the skill to properly construct the box spring. Therefore, box springs are shipped fully assembled despite the extra shipping costs charged for large packages, described in more detail below. These fully assembled box springs not only incur shipping penalties, they are difficult to handle, both during delivery to the consumer and by the consumer once in the consumer's home. For example, it is not uncommon, in the case of larger sized beds such as queen beds that a box spring is unable to fit up a stairwell or around certain corners. Thus, the bulky size of the box spring limits the number of rooms in which a homeowner can place a larger sized bed.
- A few bed foundations have been conceived that may be reversibly assembled and are provided in components that can be conveniently stored and shipped prior to assembly at an end user's location. Several embodiments of such bed foundations are described in Walker, U.S. Pat. No. 5,144,706 and Shoenhair et al., U.S. Pat. No. 5,564,140, both of which are assigned to the assignee of the present application.
- Walker describes a bed foundation that is assembled from several interlocking sections. The Walker bed foundation has two center sections that are shorter than the end sections so that the center sections may be packed within the end sections.
- Shoenhair et al. discloses a bed foundation that is fabricated from a pair of side rails, a pair of end rails, at least one intermediate rail, and several top panels. When disassembled, the components of the Shoenhair et al. bed foundation are relatively flat to facilitate shipment of the bed foundation to customers.
- United Parcel Service (hereinafter “UPS”) has standards that provide a shipping surcharge if a container is too large in various dimensions. Shipping charges are based primarily on the weight but, in the case of large packages, also on the dimensions of the packages being shipped. UPS penalizes the shipper for containers that are large but relatively light in weight.
- The first surcharge called Oversized 1 (OS1) is defined as:
- 1. The package's combined length and girth exceeds 84 inches.
- 2. The packages' combined length and girth is equal or less than 108 inches.
- 3. The package's actual weight is less than 30 pounds.
- Girth is defined as twice the width plus twice the depth of a package which has a length (or height when standing on end), a depth and a width where length is the greatest dimension. For each OS1 package, the billable weight is 30 pounds.
- The second surcharge called Additional Handling, is applied to packages which exceed 60 inches in length. These packages are assessed an additional handling surcharge of $5.00 per package.
- While these bed foundations provide a solution to the problem a conventional bed foundation poses pertaining to shipping a large, fully assembled box spring, these designs do require a significant amount of assembly by the consumer. Ideally, a bed foundation could be assembled without tools from components that can be packed into a standard sized container. Such a foundation would give a customer a good impression of the bed company once the customer gets the package home or has the package delivered and begins to assemble the bed. Assembly details are not easily shown in a retail setting. Bed foundations, or other products for that matter, requiring assembly, can often leave a bad impression with the customer if the assembly asked of the customer is excessive, complicated or poorly described in an instruction manual. Moreover, a kit requiring assembly and tools quite often contains a large number of screws, possibly a hexagonal wrench, a plurality of metal angle irons and corner pieces, and a plurality of wooden boards having holes already drilled at predetermined locations. It is not unusual for there to be screws missing, tools missing, holes drilled in the wrong location, and missing angle irons. These discrepancies can often create significant discontent with the customer and may even result in the customer returning the entire package and purchasing a competitor's product.
- The present invention includes a bed foundation capable of supporting a variety of mattresses. Preferably, the bed foundation is constructed entirely of blow-molded plastic components. These components interlock without the use of tools and can be quickly and easily assembled by a customer. When disassembled, the components compactly ship within a container having a length less than 60 inches and a girth less than 84 inches. When assembled, the bed foundation is inherently sturdy, attractive, and impressive.
- The bed foundation generally comprises a pair of side rails, a pair of end rails, a plurality of intermediate rails, and top portions that lie upon, and interlock with the rail members. The side rails consist of two portions that disassemble to give the side rails an overall length of less than 60 inches.
- FIG. 1 is a perspective view of a bed foundation according to the present invention;
- FIG. 2 is a perspective view of the preferred bed foundation with the top plate removed;
- FIG. 3 is a perspective view of an embodiment of the side rail joint of the present invention in a disassembled state;
- FIG. 4 is a side elevation view of the side rail joint of FIG. 3 in an assembled state;
- FIG. 5 is a perspective view of the side rail joint of FIG. 3 further having a locking mechanism;
- FIG. 6 is a perspective view of a preferred side rail joint of the present invention in a disassembled state;
- FIG. 7 is a perspective view of the preferred side rail joint of FIG. 6 shown in an assembled state;
- FIG. 8 is top view of the preferred side rail joint of FIG. 6 shown in a disassembled state;
- FIG. 9 is a side elevation of the preferred side rail joint of FIG. 6 shown in an assembled state;
- FIG. 10 is a perspective view of a preferred locking pin of the present invention;
- FIG. 11 is a perspective view of an intermediate rail of the present invention;
- FIG. 12 is a side elevation of the intermediate rail of FIG. 11;
- FIG. 13 is a top plan view of the intermediate rail of FIG. 11;
- FIG. 14 is a perspective view of an end rail of the present invention showing the inner side;
- FIG. 15 is a side elevation of an end rail of the present invention showing the outer side;
- FIG. 16 is a top plan view of the end rail of FIGS. 14 and 15;
- FIG. 17 is a perspective view of a top panel portion of the present invention which has been inverted to show the detail of the lower surface;
- FIG. 18 is a perspective view of a cover of the present invention; and,
- FIG. 19 is a perspective view of the bottom of a preferred embodiment having an overhanging top panel and a cover with filler foam.
- Referring now to the drawings in first to FIGS. 1 and 2, a
bed foundation 20 is provided which includes a pair of side rails 22, a pair of end rails 24, at least oneintermediate rail 26, and atop panel 28. The side rails 22, the end rails 24, theintermediate rails 26, and thetop panel 28 are all preferably blow-molded from plastic. - The components of the
bed foundation 20 permit reversible assembly so that thebed foundation 20 may be shipped to the customer in packages that do not incur sized-based penalties when shipping. Thebed foundation 20 is constructed and arranged to permit the customer to assemble and disassemble thebed foundation 20 so it may be later stored in a relatively small space when a customer is not using thefoundation 20. - The components of the
foundation 20 include interlocking joints that enable thefoundation 20 to be assembled without the use of tools. These interlocking joints are integrally molded with the components so that no other parts are required. While not necessary, the interlocking joints may be further secured with lock pins or similar devices. - The side rails22, each include a
first section 30 and asecond section 32. The first and second sections, 30 and 32, are removably attachable to each other. When attached, thefirst section 30 is aligned with thesecond section 32 to form a straight,linear side rail 22. Notably, thefirst section 30 and thesecond section 32 are preferably of different lengths. The different lengths of thefirst section 30 and thesecond section 32 allow the resultingunion 33 between thefirst section 30 and thesecond section 32 of each of the side rails 22 to be offset from the center of thebed foundation 20. In other words, theunion 33 of oneside rail 22 is closer to a head end of theside rail 22 whereas theunion 33 of theother side rail 22 is closer to the foot end of thatside rail 22. This is advantageous because when both side rails 22 are assembled and facing each other, theunion 33 of oneside rail 22 may be longitudinally displaced from theunion 33 of theother side rail 22, thereby increasing the rigidity of theoverall foundation 20. If theunions 33 of eitherside rail 22 directly faced each other, a line of instability in thebed foundation 20 would be created. It will be seen thatsections unions 33 do not face each other. This arrangement prevents the occurrence of a natural creasing point in thebed foundation 20. However, one of ordinary skill in the art will appreciate it that is possible to form thefirst section 30 and thesecond section 32 with approximately equal lengths without going beyond the concepts of the present invention. - Referring now to FIGS.3-5, a mechanism is provided for reversibly joining the
first section 30 and thesecond section 32. It can be seen that the T-joint 40 has an approximate T-shape and includes amale portion 42 extending from thefirst section 30 and afemale portion 44 formed in thesecond section 32. Themale portion 42 has a shape that is substantially complementary to thefemale portion 44 so that themale portion 42 and thefemale portion 44 form a snug, interlocking fit. One skilled in the art will understand that it is not important whether thefemale portion 44 be formed in thefirst section 30 or in thesecond section 32, only that onemale portion 42 and onefemale portion 44 are provided and have complementary shapes. - The interlocking fit between the
male portion 42 and thefemale portion 44 prevents thefirst section 30 from being pulled away from thesecond section 32, as indicated byarrow 46. The interlocking fit between themale portion 42 and thefemale portion 44 also prevents thefirst section 30 from moving up or down with respect to thesecond section 32 as indicated byarrow 48. The interlocking fit between themale portion 42 and thefemale portion 44 also resists lateral movement of thefirst section 30 with respect to thesecond section 32, as indicated byarrow 49 of FIG. 3. However, the resistance to this lateral movement, shown byarrow 49, results only from the friction between thefirst section 30 and thesecond section 32. - To further enhance the structural rigidity of the joint40, and to prevent the lateral movement indicated by
arrow 49, the joint 40 preferably includes a reinforcingmechanism 50, shown in FIGS. 5. The reinforcingmechanism 50 maintains thefirst section 30 and thesecond section 32 in an assembled configuration, and preferably includes aslot 52 formed in aside surface 54 of thefirst section 30 and in thesecond section 32. Theslot 52 preferably extends from atop surface 56 of theside rail 22 substantially to abottom surface 58 of theside rail 22. - The
slot 52 is adapted to receive apin 53. Thepin 53 has a profile that substantially conforms to a cross-section of theslot 52 such that thepin 53 fits snugly within theslot 52. Thepin 53 is retained in theslot 52 by a pair oflips 55 that extend partially over theslot 52. Thepin 53 is preferably fabricated from a metallic or plastic material. - Assembly is achieved by positioning the
male portion 42 adjacent thefemale portion 44. Themale portion 42 is then pressed into thefemale portion 44 until themale portion 42 engages thefemale portion 44. Thepin 53 is then placed into theslot 52 locking thefirst section 30 and thesecond section 32 together. It may be preferable to provide more than oneslot 52 andpin 53 to further enhance rigidity. - A more preferred mechanism for reversibly joining the
first section 30 and thesecond section 32 is an L-hook joint 70 as seen in FIGS. 6-9. The L-hook has amale portion 72 and afemale portion 74. Themale portion 72 has at least oneextension 76. Preferably, the male portion has twoextensions 76. Preferably, at least one of theextensions 76 has avertical catch 78, the function of which will be explained below. - The
female portion 74 comprises acavity 82 constructed and arranged to receive themale portion 72. Thecavity 82 preferably does not pass through theside rail 22. Rather, thecavity 82 has arear surface 84 and a plurality of complementary raised surfaces 86. - The
male portion 72 and thefemale portion 74 fit together in a snug, interlocking manner when theextensions 76 are inserted into thecavity 82. The vertical catches 78 of theextensions 76 act on vertical surfaces 80 of thecavity 82. The relationship between thecatches 78 and the vertical surfaces 80 prevent thefirst section 30 from being pulled away from thesecond section 32 in a longitudinal direction. This relationship also helps to prevent thefirst section 30 from being angled upwardly or downwardly in relation to thesecond section 32. - To further enhance the structural rigidity of the
joints 70, and to retain thefirst section 30 and thesecond section 32 in an assembled configuration, the joint 70 preferably includes a reinforcingmechanism 90, as seen in FIGS. 7- 10. The reinforcingmechanism 90 preferably includes aslot 92 formed in aside surface 94 of thefirst section 30 and thesecond section 32. Theslot 92 extends from thetop surface 56 ofsecond section 32 to thebottom surface 98 of thecavity 82 formed in thesecond section 32. FIG. 7 shows how theslot 92 is completed when thefirst section 30 and thesecond section 32 are assembled. - The reinforcing
mechanism 90 includes theaforementioned pin 53. Thepin 53 is shaped to be received by theslot 92, and is preferably fabricated from a metallic or plastic material. Thepin 53 is retained in theslot 92 by a pair oflips 102 that partially extend over theslot 92, as is most clearly illustrated in FIG. 8. FIGS. 7 and 10 show a preferred embodiment of thepin 53 used to retain thefirst section 30 and thesecond section 32 in an engaged relationship. It can be seen that thepin 53 includes ahorizontal surface 100 on which to press when inserting thepin 53 into theslot 92. Integral with thehorizontal surface 100, is apin portion 101. Thepin 53 also preferably provides a downward facingsurface 103 under which a user's fingers may be placed in order to pull thepin 53 in an upward direction when disassembling thebed foundation 20. - Referring now to FIGS.11-13, the
bed foundation 20 includes at least one, preferably four,intermediate rails 26 constructed and arranged to extend from oneside rail 22 to theopposite side rail 22, between the end rails 24 (as seen in FIG. 2). Theintermediate rails 26 thereby enhance the structural rigidity of thebed foundation 20. While the spacing between theintermediate rails 26 may be approximately equal, theintermediate rails 26 are preferably spaced so that all four intermediate rails are located in approximately a middle half of thebed foundation 20. Such a configuration provides additional support and helps to prevent deflection in a central region of thebed foundation 20 where a high concentration of a person's weight will be located while that person is lying on the bed. - To facilitate ease of assembly and disassembly of the
bed foundation 20, without tools, the side rails include grooves 132 (FIGS. 6-9) defined therein. Thegrooves 132 are constructed and arranged to receive dovetails 134 which are integral with and extend from the ends of the intermediate rails 26. As seen in FIG. 9, thegrooves 132 preferably extend from thetop surface 56 of theside rail 22 to astop 136 which is provided just above a lower surface 138 of the side rails 22. Thestop 136 provides a positive indication that thedovetail 134 is completely inserted in thegroove 132 and prevents thedovetail 134 from extending too far into thegroove 132, resulting in the top surfaces of theintermediate rails 26 and the side rails 22 from being uneven. - As seen in FIGS.13-15, the end rails 24 connect to the side rails 22 in the same manner as the intermediate rails 26. Structurally, the only difference between the end rails 24 and the
intermediate rails 26 is the appearance of anoutside surface 141. Preferably, theoutside surface 141 is ornamentally similar to the outside surfaces 143 (FIG. 1) of the side rails 22 such that when thebed foundation 20 is fully assembled, an attractive, completed appearance results. - As shown in FIGS. 1 and 17, the
bed foundation 20 further includes atop panel 28 constructed and arranged to extend over the side rails 22, the end rails 24, and theintermediate rail 26 when placed thereon. Thetop panel 28 substantially covers an area defined by these components. An alternate embodiment provides atop panel 28, which extends a predetermined distance past the side rails 22. Such an embodiment allows a larger mattress to be placed on asmaller bed foundation 20. This is especially useful with the recent introduction of the deluxe queen, a new size being introduced by mattress manufacturers to provide a queen sized bed which is three inches wider than a convention queen sized bed. This largertop panel 28 obviates the need for a consumer to buy a new bed foundation or box spring and, more importantly, obviates the need for a new bed frame. - To facilitate storing and shipping the
bed foundation 20, thetop panel 28 is preferably formed of multipletop panel portions 140. Each of thetop panel portions 140 preferably has a common shape. It is envisioned that queen and kingsized foundations 20 will have fourtop panel portions 140 while twin sized and doublesized foundations 20 will have twotop panel portions 140. - To facilitate mounting the
top panel portions 140 in a desired position with respect to each other, thetop panel portions 140, each include at least onetab 142 extending from a side of thetop panel portion 140 and arecess 144 formed in the side oftop panel portion 140, as most clearly illustrated in FIG. 17. Thetabs 142 preferably have a shape that substantially conforms with a shape of therecess 144. It is envisioned that thetop panel portions 140 include twotabs 142 and tworecesses 144, which permit all of thetop panel portions 140 to have a substantially uniform configuration. - The
top panel portions 140 further include a mounting mechanism, which secures thetop panel portions 140 to the side rails 22, the end rails 24, and the intermediate rails 26. The mounting mechanism preferably includes alocking extension 152 formed on thetop surfaces 56 of the side rails 22, thetop surfaces 96 of the intermediate rails 26 (FIGS. 6-9 and 11-16), and thetop surfaces 154 of the end rails. It is understood that the number and size of the lockingextensions 152 are selected based upon the size of thefoundation 20. A person of ordinary skill of the art will appreciate that a greater number of lockingextensions 152 would be beneficial on a king-sized foundation than would be on a twin sized foundation. - A receiving
portion 156 is formed into alower surface 158 of thetop panel portions 140, as seen in FIG. 19 and 20. To facilitate insertion of thelocking extension 152 into the receivingportion 156, arecess 160 is preferably formed in thelower surface 158 of thetop panel portions 140 adjacent the receivingportions 156. - The side rails22, the end rails 24, the
intermediate rails 26, and thetop panel 28 are each preferably fabricated from plastic, more preferably injected-molded plastic, even more preferably blow-molded plastic. Using blow-molded plastic is advantageous, not only because it allows complete recyclability, but also because it minimizes material costs. Also, once tooling is established, blow molding minimizes production costs and allows parts to be produced having complicated geometries. A person of ordinary skill in the art will appreciate that it is possible to fabricate the preceding components from a variety of materials, such as steel or wood, using the concepts of the present invention. However, doing so would result in increased production costs. - To further enhance the structural rigidity of the blow-molded plastic components, tack-
offs 110 are incorporated into the shape of thetop panel portions 140, the side rails 22, the end rails 24, and the intermediate rails 26. The tack-offs 110 are simply indentations formed in a surface or two surfaces of a component. Tack-offs 110 are well known in the art and commonly used with blow-molded plastic components in order to increase rigidity. The tack-offs 110 may be created with a wide variety of dimensions and may range from deep to shallow and from long to short. The tack-offs 110 may be formed in either a vertical orientation, or a horizontal orientation. Preferably, theintermediate rails 26, have tack-offs 110 running horizontally substantially the entire length of theintermediate rail 26. The tack-offs 110 formed in the side rails 22 are preferably positioned so as not to interfere with thegrooves 132, or theslots 92. - The
bed foundation 20 further includes a substantiallydecorative cover 170 shown in FIG. 18. Thecover 170 extends over the entire outer surface of thebed foundation 20. The cover is preferably fabricated from a cloth material and enhances the aesthetic appeal of the bed foundation by providing thebed foundation 20 with an appearance that is similar to the appearance of box springs used with conventional mattresses. For the embodiment providing atop panel 28 that extends over the side rails 22 to provide support for an oversized mattress, shown in FIG. 19, acover 170 may be provided withfiller foam 172 which fills in the resulting space formed between the sides of the overhanging cover and the side rails 22 of thefoundation 20. This will give a rectangular, box-like appearance to thefoundation 20, as opposed to a ledged appearance created by the overhangingtop panel 28. - The
bed foundation 20 of the present invention therefore provides an alternative to a conventional bed foundation. Thebed foundation 20 may be disassembled so that its components may be packaged into standard sized shipping containers, e.g., shipping containers having a length of less than 60 inches and a girth of less than 84 inches. Using standard sized shipping containers enables thebed foundation 20 to be readily transported using common carriers without incurring additional charges associated with oversized packages. Furthermore, standard sized shipping containers also facilitate easy handling by customers. - Once the
bed foundation 20 has been shipped to a customer in standard sized containers, the customer may easily assemble thebed foundation 20 without the use of any tools. The assembly process is straightforward. The side rails 22 are assembled first by joining thefirst sections 30 to thesecond sections 32. Thefirst section 30 and thesecond section 32 are joined by placing themale portion 72 into thefemale portion 74. This is most easily accomplished by laying thesecond portion 32 on its side on the floor, such that thefemale portion 74 faces upward. Theextension 76 of themale portion 72 is then pressed into thecavity 82 and may be stepped on to ensure a snug fit. Apin 53 is then placed into thegroove 92 by pushing on theupper surface 100. Having assembled twoside rails 22, the side rails 22 are then positioned such that they form a relative parallel relationship and such that pins 53 are facing each other, though longitudinally off-set. The end rails 24 are then placed between the side rails 22 and their dovetails 144 are positioned in thegrooves 132. The twoend rails 24 andside rails 22 should now form a rectangular shape. Theintermediate rails 26 are placed in a similar fashion between the end rails 24 so that they span across the side rails 22. Their dovetails 134 are pressed into the corresponding grooves of the side rails 22. Thetop panel portions 140 are then attached to the assembly by placing the lockingextensions 152, which extend from the side rails 22, the end rails 24, andintermediate rails 26 into the receivingportions 156 formed in thelower surface 158 of thetop panel portions 140. This is most clearly seen in FIGS. 19 and 20. Once thetop panel portions 140 are attached to the assembly, thecover 170 is simply placed over the top of the now assembledbed foundation 20. - With the assembly of the
bed foundation 20 complete, thebed foundation 20 may be positioned to support virtually any type of mattress, e.g., a standard coil spring mattress, a fluid filled mattress, a futon, etc. Additionally, thebed foundation 20 may be placed atop, and supported by, a standard metal bed frame or may be placed atop and supported by a slat bed frame. Similarly, if desired, thebed foundation 20 may be placed atop and supported by a platform bed frame. - It is contemplated that features disclosed in this application, as well as those described in the above applications, incorporated by reference, can be mixed and matched to suit particular circumstances. Various other modifications and changes will be apparent to those of ordinary skill in the art without departing from the spirit and scope of the present invention. Accordingly, reference should be made to the claims to determine the scope of the present invention.
Claims (45)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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US09/900,685 US20020069462A1 (en) | 2000-07-07 | 2001-07-06 | Bed foundation |
US10/284,634 US6883191B2 (en) | 2000-07-07 | 2002-10-31 | Leg and bracket assembly for a bed foundation |
US10/742,173 US6832397B2 (en) | 2000-07-07 | 2003-12-19 | Bed foundation |
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US21690800P | 2000-07-07 | 2000-07-07 | |
US09/900,685 US20020069462A1 (en) | 2000-07-07 | 2001-07-06 | Bed foundation |
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US10/742,173 Continuation US6832397B2 (en) | 2000-07-07 | 2003-12-19 | Bed foundation |
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US5144706A (en) * | 1990-12-03 | 1992-09-08 | Walker Robert A | Bed foundation |
US5564140A (en) * | 1994-07-22 | 1996-10-15 | Select Comfort Corporation | Frame assembly for supporting a mattress |
US6338172B1 (en) * | 1997-10-15 | 2002-01-15 | Harry A. Taylor, et al. | Polymeric length and width adjustable bed frame system |
-
2001
- 2001-07-06 US US09/900,685 patent/US20020069462A1/en not_active Abandoned
-
2003
- 2003-12-19 US US10/742,173 patent/US6832397B2/en not_active Expired - Lifetime
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US20040078897A1 (en) * | 2002-07-11 | 2004-04-29 | Gladney Richard F. | Plastic mattress foundation |
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US7017205B2 (en) * | 2002-07-11 | 2006-03-28 | Dreamwell, Ltd. | Plastic mattress foundation |
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US20050028274A1 (en) * | 2003-08-07 | 2005-02-10 | Hooper William W. | Bed foundation |
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US20080208709A1 (en) * | 2006-08-08 | 2008-08-28 | Larry James Craver | Ready-to-assemble bed foundation |
US9538851B2 (en) | 2006-08-08 | 2017-01-10 | Larry James Craver | Ready-to-assemble bed foundation |
US8434178B2 (en) | 2008-06-24 | 2013-05-07 | Nomaco Inc. | Mattress side/edge support system |
US8561236B2 (en) | 2009-06-22 | 2013-10-22 | Nomaco Inc. | Stepped-edge and side-support members, assemblies, systems, and related methods, particularly for bedding and seating |
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US20140338125A1 (en) * | 2011-10-14 | 2014-11-20 | Finger Lakes Intellectual Property, Llc | Wrap around bed frame |
US9247825B2 (en) * | 2011-10-14 | 2016-02-02 | Finger Lakes Intellectual Property Llc | Wrap around bed frame |
US9333135B2 (en) * | 2013-01-24 | 2016-05-10 | Ergomotion, Inc. | Bolster attachment system for an adjustable bed |
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US11857076B2 (en) | 2013-03-11 | 2024-01-02 | Sleep Number Corporation | Adjustable bed system with foundations having first and second configurations |
USD737074S1 (en) | 2013-07-03 | 2015-08-25 | Nomaco Inc. | Foam cushion base |
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US10226132B2 (en) * | 2013-09-20 | 2019-03-12 | Integrated Furniture Technologies Limited | Adjustable bed |
US8990979B1 (en) | 2014-03-25 | 2015-03-31 | Larry J. Craver | Ready-to-assemble bed foundation |
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US20040128761A1 (en) | 2004-07-08 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: MEDALLION CAPITAL, INC., MINNESOTA Free format text: SECURITY AGREEMENT;ASSIGNORS:SELECT COMFORT CORPORATION;SELECT COMFORT RETAIL CORPORATION;SELECT COMFORT DIRECT CORPORATION;AND OTHERS;REEL/FRAME:012066/0633 Effective date: 20010928 |
|
AS | Assignment |
Owner name: SELECT COMFORT CORPORATION, MINNESOTA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:GABOURY, JAMES D.;MECHACHE, SUSAN R.;GIFT, JAMES E.;AND OTHERS;REEL/FRAME:012603/0661;SIGNING DATES FROM 20010925 TO 20011126 |
|
STCB | Information on status: application discontinuation |
Free format text: EXPRESSLY ABANDONED -- DURING EXAMINATION |
|
AS | Assignment |
Owner name: SELECT COMFORT SC CORPORATION, MINNESOTA Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:MEDALLION CAPITAL, INC.;REEL/FRAME:021006/0079 Effective date: 20080522 Owner name: SELECT COMFORT RETAIL CORPORATION, MINNESOTA Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:MEDALLION CAPITAL, INC.;REEL/FRAME:021006/0079 Effective date: 20080522 Owner name: SELECTCOMFORT.COM CORPORATION, MINNESOTA Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:MEDALLION CAPITAL, INC.;REEL/FRAME:021006/0079 Effective date: 20080522 Owner name: SELECT COMFORT DIRECT CORPORATION, MINNESOTA Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:MEDALLION CAPITAL, INC.;REEL/FRAME:021006/0079 Effective date: 20080522 Owner name: SELECT COMFORT CORPORATION, MINNESOTA Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:MEDALLION CAPITAL, INC.;REEL/FRAME:021006/0079 Effective date: 20080522 Owner name: DIRECT CALL CENTERS, INC., MINNESOTA Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:MEDALLION CAPITAL, INC.;REEL/FRAME:021006/0079 Effective date: 20080522 |