CN111904202B

CN111904202B - Method and structure for an integrally formable lightweight bed frame for an articulating bed

Info

Publication number: CN111904202B
Application number: CN202010833619.6A
Authority: CN
Inventors: 艾伦·克莱奈特; 乔伊·克鲁格
Original assignee: Ergomotion Inc
Current assignee: Ergomotion Inc
Priority date: 2014-05-14
Filing date: 2015-05-14
Publication date: 2022-06-24
Anticipated expiration: 2035-05-14
Also published as: JP2017515594A; NZ726908A; JP6713930B2; AU2015259008A1; CN107072402A; WO2015175816A2; EP3142517A2; ES2869431T3; WO2015175816A3; AU2015259008B2; CN107072402B; EP3142517B1; EP3142517A4; CN111904202A

Abstract

The present invention relates to a method and structure for an integrally formable lightweight bed frame for an articulating bed. An articulating bed frame (20) incorporates an extruded metal frame shape (24) formed into any desired bed size by cutting a cut out in the extrusion for a side length, bending at the cut out around a sized base plate element to create a complete frame. The frame employs an extruded beam having an inner flange and a support channel formed therein. The extruded beam is cut to form frame side elements and end elements, and support channels receive and support blocks (66). The support blocks engage with a carriage (22) supporting the seating section of the hinge structure.

Description

Method and structure for an integrally formable lightweight bed frame for an articulating bed

The application is a divisional application of an application with the application date of 2015, 5 and 14, the application number of 201580035247.X, and the name of the invention of a method and a structure of an integrally-formed light bed frame for an articulated bed.

Reference to related applications

This application claims priority to U.S. provisional application No. 61993087, filed on 5/14/2014, the disclosure of which is incorporated herein by reference.

Background

FIELD

The present invention relates generally to the field of adjustable beds and more particularly to a structure for a frame of an articulating bed having an extruded support frame with integrated elements for attachment of a mattress and support engagement of the articulated elements.

Description of the related Art

Articulating beds are becoming more and more popular and are being produced in a variety of sizes and styles. The articulated elements of the bed are typically supported by assembling wooden and/or metal frames. Pairs of single, double, big, super big and independent big beds require different frame sizes that must be individually tooled for manufacturing, resulting in many part numbers. Assembly requires welding or heavy mechanical fasteners and the weight of the assembled bed can be significant.

It is therefore desirable to provide a frame for an articulating bed that is easy to produce with minimal tooling, uses simple fasteners, and reduces the number of individual part number assembly elements.

Disclosure of Invention

Embodiments disclosed herein overcome the disadvantages of the prior art by providing an extruded metal frame shape that is formed into any desired bed size by cutting a cut out in the extrusion for the side length, bending at the cut out around a sized substrate element to create a complete frame. The frame for an articulating bed employs an extruded beam having an inner flange and a support channel formed therein. The extruded beam is cut to form frame side elements and end elements, and support channels receive and support blocks. The support blocks engage a carriage that supports a seating section of the hinge structure.

The present application provides the following:

1) a frame for an articulating bed, the frame comprising:

an extruded beam having an internal flange and a support channel formed therein, the extruded beam being cut to form a plurality of frame side elements and a plurality of end elements; and the number of the first and second groups,

a plurality of support elements received within and supported by the support channel, the support elements being engaged with a carriage that supports a seating section of the articulating structure.

2) The frame for an articulating bed of claim 1), wherein the support elements are translatable within the support channel.

3) The frame for an articulating bed of claim 1) wherein the extruded beam further comprises an accessory channel.

4) The frame for an articulating bed of claim 1) wherein the extruded beam further comprises a bottom flange and further comprises a head endplate and a foot endplate, the head and foot endplates joined to the bottom endplate.

5) The frame for an articulating bed of claim 4), wherein the extruded beam further comprises a touch flange extending from the bottom flange and engaging peripheral edges of the head and foot endplates.

6) The frame for an articulating bed of claim 1), wherein the extruded beam further comprises an upper and lower gripping flange, and further comprising a foam padding engaged between the upper and lower gripping flange.

7) The frame for an articulating bed as claimed in 6) wherein the foam padding is covered by fabric.

9) The frame for an articulating bed of claim 1), wherein the extruded beam comprises saw cuts extending as cuts through the beam to the inner flange to form the side elements and end elements, said inner flange being bent at the saw cuts.

10) The frame for an articulating bed of claim 1) further comprising a plurality of locked support blocks received in the support channel and engaged with structural elements of the actuation system for the articulating structure.

11) The frame for an articulating bed of claim 1), wherein the extruded beam further comprises a bottom flange, and further comprising a foam pad joined to the bottom flange, said foam pad being in combination with a mounting support fastened to the extruded beam, a resiliently flexible spacer extending over the support channel.

12) A method for manufacturing a frame of an articulating bed, the method comprising:

forming an extruded beam;

introducing a plurality of saw cuts in the extruded beam to form a plurality of side members and end members;

mounting a foot endplate and a head endplate on the tool;

causing the extrusion beam to engage the foot end plate against the end element;

bending the side elements at the first two saw cuts to engage the feet and head end plates to form a frame assembly;

removing the frame assembly from the tool;

inserting a plurality of translating support blocks into a plurality of support channels of the extrusion beam;

closing end elements at the head end plate by bending at two remaining saw cuts;

mounting a carriage on the translational support blocks; and the number of the first and second electrodes,

a hinge structure is mounted to the carriage.

13) The method of claim 12), further comprising:

inserting a plurality of fixed support blocks into the support channels;

fixing the fixed supporting blocks; and the number of the first and second electrodes,

actuating elements for the hinge assembly are mounted to the fixed support blocks.

14) The method of claim 12), further comprising:

mounting a center plate on the tool;

engaging the center plate with the side elements of the extruded beam during bending of the side elements; and also,

actuating elements for the hinge assembly are mounted on the center plate.

15) The method of claim 12), further comprising:

a liner is engaged in the extruded beam between a plurality of capture plates.

16) The method of claim 15), further comprising:

extruding the backing from a rigid foam; and the number of the first and second electrodes,

the foam was covered with a fabric outer layer.

17) The method of claim 12), further comprising:

engaging end and side surfaces of the end plates with touch flanges on the extruded beam; and the number of the first and second electrodes,

the extruded beam is secured to the end plates.

18) The method of claim 12), further comprising coupling two frames by inserting a plurality of coupling flange elements into the plurality of exposed support channels.

19) A method for manufacturing a frame of an articulating bed, the method comprising:

forming an extruded beam;

cutting the extruded beam to form a plurality of side elements and end elements;

mounting a foot endplate and a head endplate on a tool;

engaging the first end component against the foot endplate;

engaging a plurality of side elements to engage the foot endplate and the head endplate to form a frame assembly;

inserting a plurality of translating support elements into a plurality of support channels of the extrusion beam;

engaging a second end member at the head endplate;

a hinge structure is mounted to the carriage.

Drawings

These and other features and advantages of the present invention will be better understood by reference to the following detailed description of exemplary embodiments when considered in conjunction with the accompanying drawings, wherein:

FIG. 1A is a top perspective view of an articulating bed employing the frame embodiments described herein;

FIG. 1B is a lower perspective view of the bed of FIG. 1A;

FIG. 2A is a perspective view of a first exemplary structural frame extrusion for the first exemplary frame embodiment described herein;

FIG. 2B is an end view of a first exemplary structural frame extrusion;

FIG. 2C is a perspective view of a second example structural frame extrusion for the second example frame embodiment described herein;

FIG. 2D is an end view of a second exemplary structural frame extrusion;

FIG. 3A is a perspective view of a first structural frame extrusion showing cuts defining the length and width of the frame side and end members;

FIG. 3B is an end view of the first structural frame extrusion showing a saw blade creating a cut for the curved frame;

FIG. 4A is a partial top view of a corner of a curved frame;

FIG. 4B is a partial perspective view of a corner of the curved frame;

FIG. 5 is a perspective view of an exemplary slider for mounting in a support channel in a frame;

FIG. 6A is an end view of the first structural frame extrusion showing the slide block installed in the support channel;

FIG. 6B is an end view of the second structural frame extrusion showing the pulley supports installed in the support channels;

FIG. 7A is a partial perspective detail view showing the slides in the support channels in an exemplary orientation of the seat plate and upper body plate as positioned relative to each other on a carriage (chariot);

FIG. 7B is a partial perspective detail view showing the pulley support for the carriage in the support channel with an exemplary positioning of the seat plate and upper body plate as positioned opposite on the carriage;

FIG. 8 is a fragmentary perspective view showing an exemplary slide block in a support channel with the hinge elements of the mattress support positioned relative to one another;

figure 9 is a side section view showing the carriage supporting the hinge structure;

FIG. 10A is a perspective view of the locking support block in the support channel;

FIG. 10B is an end cross-sectional view of a structural frame extrusion with angled support members for articulating the support plates inserted in the support channels;

FIG. 11A is a end section view showing a first structural frame extrusion with a foam cushion (bolster) element inserted in the frame flange;

FIG. 11B is an isometric view of the tip section showing the first structural frame extrusion with a foam cushioning element inserted in the frame flange;

11C and 11D are end section perspective views showing a second structural frame extrusion with foam underlayment elements attached to the extrusion with and without corner brackets;

FIG. 12A is a fragmentary perspective view of a gasket member inserted in a gasket flange and a hinge structure in an unhinged position flush with a structural frame;

fig. 12B is a partial perspective view showing a corner of the finished bed frame with an upholstery cushion;

FIG. 13A is a perspective interior view of the assembled frame described with respect to FIGS. 2C and 2D using an extrusion;

FIG. 13B is a perspective view of a corner bracket for the assembly shown in FIG. 13A;

FIG. 13C is a perspective view of a bottom bracket and leg support for the assembly shown in FIG. 13A;

FIG. 14A is a perspective view of an assembly station for making a bed frame using a structural frame extrusion with a cut-out;

FIG. 14B is a perspective view of an exemplary corner support member for the assembly station;

fig. 15A is a top view of an exemplary base member for a bed frame;

FIG. 15B is a perspective view of the base member;

FIG. 16A is a perspective view of an assembly station with installed base members and positioned notched structural frame extrusions for assembly;

FIG. 16B is a perspective view showing the structural frame extrusion being bent to create a frame side;

FIG. 17 is a detailed partial view showing the frame extrusion 22 bent and mounted on the end plate with the reach flange engaged with the end plate flange;

FIG. 18 is a partial perspective view of an exploded corner member for completing the dunnage;

FIG. 19 is a partial perspective view showing the use of engagement flanges in the support channels of adjacent frames for a group to join frames to a large bed assembly;

FIG. 20 is a prior art illustration of assembling two single bed frames to form a queen bed;

FIG. 21 is an illustration of the present frame assembly with a continuous dunnage assembly permitted by engagement with the engagement flanges as shown in FIG. 19;

22A-D are diagrams of alternative embodiments of extrusions for external surfaces; and the number of the first and second electrodes,

figure 23 is an illustration of a bracket engaged with the support channel for mounting the headboard.

Detailed Description

The various embodiments shown in the figures and described herein provide a structure and system for making an articulating bed frame structure that allows for a linear manufacturing process with minimal labor and tooling. The frame element is self-warping (self-aligning) for assembly and is adaptable for a range of sizes.

Referring to the drawings, FIG. 1A shows an articulating bed employing the structural frame disclosed herein. The articulating structure 10 has a seating support 12, an upper body support element 14, a thigh support element 16, the upper body support element and the thigh support element being attached to the seating support element by hinges, and a lower leg support element 18 being attached to the thigh support element by hinges. The support elements are shown as being substantially solid, however, a rigid honeycomb material or similar material providing a rigid planar surface may also be employed. The frame 20 supports the hinge structure 10. As shown in fig. 1B, the carriage 22 is engaged to the seating support 12 and carries the hinge structure 10, allowing for a "wall hugging" effect with the upper body support element 14. As the upper body support member 14 is raised from a flat position to a standing position, the carriage 22 travels longitudinally (from the foot to the head).

The frame 20 is formed from extruded beams 24 shown in fig. 2A and 2B. The extruded beam 24, which may be metal or other structural material, and for the embodiments disclosed herein aluminum, incorporates an inner upper flange 26 and an inner lower flange 28 separated by a slot 30 that opens into a support channel 32 having an upper wall 33 and a lower wall 35. The outer upper flange 34 closes the support channel 32 and extends upwardly to an upper catch flange 36. The accessory channel 38 is backed by the inner lower flange 28 and the outer lower flange 40 provides a partial closure of the exterior of the accessory channel 38. Cables for an articulation system actuator, an integrated massage system, a sound or lighting system associated with the bed may be routed through the accessory channel. In an alternative embodiment, the outer lower flange may provide a complete closure of the accessory channel. Lower gripping flange 42 extends from a bottom flange 44 which also forms the bottom wall of accessory channel 38. The support channel lower wall 35 provides an upper limit for the accessory channel 38 for the embodiment shown in the drawings. The lower edges of the inner upper flange 26 and the upper edges of the inner lower flange 28 terminate in upper and

lower chute beads

46, 48, respectively, which in the exemplary embodiment define the slot 30. Depending from the bottom flange 44 is a touch flange 50.

Other desired embodiments may employ alternative configurations of the extrusion. Fig. 2C and 2D show a first alternative for use with embodiments that will be described in more detail later, in which extruded beam 24 terminates with an upper wall 33 of support channel 32 and does not incorporate an upper gripping flange. The lower wall 35 extends from an outer upper flange 34 which closes the support channel 32. The lower wall 35 is supported by the inner flange 29. An outer lower flange 41 extends downwardly from the support channel 32 and terminates at a bottom flange 44. There is a lower flange 43 that extends from the bottom flange 44 and a touch flange 50 that overhangs the bottom flange 44 as in the previous embodiment. An accessory channel 39 is provided.

The configuration of extrusion beam 24 set forth with respect to fig. 2A and 2B allows for the creation of saw cuts 52 as shown in fig. 3A for defining the length and width of side members 70 and end members 72 and 72A, 72B of frame 10. As shown in fig. 3B, a saw blade 54 is employed to provide a precision cut to the extrusion beam 24 extending to a line 56 through the upper gripping flange 36, the outer upper flange 34, the support channel upper and

lower walls

33, 35, the outer lower flange 40, the lower gripping flange 42, the attachment channel bottom wall 44, and the touch extension flange 50, leaving only the webs of the inner upper and

lower flanges

26, 28 intact as the termination of the cut 52. As shown in fig. 4A and 4B, extruded beam 24 may then be bent at each cut to form frame 10, as will be described in more detail below. As can be seen in fig. 4B, the support channel 32 at the interior of the frame 10 is curved with the cut-out location at the attachment channel 38 at the exterior of the frame. The support channels 32 in each element of the frame are accessible from an open end created at a cut for assembly operations, as will be described in more detail below. Similarly, the end of the accessory channel is open.

The carriage 22 supporting the hinge structure 10 described with respect to fig. 1B engages a support element (such as a translational support block 60 shown in detail in fig. 5) guided in the support channel 32. As shown in fig. 6A and 7A, each translational support block 60 has an upper slot 62 and a lower slot 64 adapted to engage and guide on the upper and

lower runner beads

46, 48, with an interior portion 66 of the translational support block 60 engaged within the support channel 32. The central aperture 68 receives a shaft extending from the carriage 22. Auxiliary holes 70 may be employed for attachment fasteners. The translating support block 60 is formed of a natural lubricating material such as nylon or teflon to allow easy translation along the runner bead and support channel during operation of the hinge structure 10, during translation of the carriage 22. As shown in fig. 8 and 9, a pair of translating support blocks 60 guided in the support channels 32 of the side members 70 engage the carriage 22 in spaced relation to provide support for the hinge structure 10. In alternative embodiments, the translation blocks may be guided on the bottom 35 of the support channel 32 or the support elements may be wheels 67 or similar structures with shafts 69 from the carriage 22, which may be received within the support channel 32 as shown in fig. 6B to engage and support the carriage for translational movement. An alternative configuration of the extrusion 24 described with respect to fig. 2C and 2D is shown for this alternative embodiment. Fig. 7B shows the resulting support arrangement.

Various hinge mechanisms may be employed with the frame structure in the disclosed embodiments. For additional rigidity and in the form of integrated manufacturing, a head endplate 76, a foot endplate 78, and a central panel 80 are employed as part of the frame 20, as will be described in more detail below. The contact flanges of the extruded beams engage the peripheral edges of the end plates and the side edges of the center plate. As shown in fig. 10A, the actuator and tension or compression elements for the hinge mechanism may be mounted on the plates or may be engaged by a fixed or locking support block 82 that is received in the support channel 32. These lock support blocks incorporate engagement holes 84 to receive shafts to engage the hinge elements and may include securing holes 86. The locking support blocks 82 may be engaged to be secured in predetermined positions in the support channel by cooperatively drilling fasteners through the upper or lower

internal flanges

26, 28, wide-head fasteners inserted into the securing holes 86 to engage one or both of the upper and lower

internal flanges

26, 28, or by dimpling the back surface of the support channel with a set screw inserted through the securing holes 86, or by creating a hammered dimple in the flange of the support channel to secure the locked support blocks.

As seen in fig. 10B, additional support elements, such as angled support members 88, may be received at predetermined locations in the support channel 32. The angled support member 88 includes a body 90 that is received in the support channel 32 and an angled extension 92 that projects from the slot 30 to provide additional support for a hinged support element, such as the upper body support element 14 in an unhinged position that is flush with the frame 20.

The angled support members are of sufficient length to bridge the coupling between the abutted extruded beam elements, such as the aforementioned

end closure elements

72a and 72 b.

Frame 20 provides a conformable appearance capability for a fully cushioned bed frame. As shown in fig. 11A and 11B, padding-filled padding 94 surrounding the frame is created by inserting an extruded foam block 96, which may be covered with a fabric outer layer 98 between the upper and lower

gripping flanges

36, 42 of the first embodiment of the extrusion 24 described with respect to fig. 2A and 2B. The upper and lower

gripping flanges

36, 42 employ teeth 100 to engage the cushion foam bun 96. The fabric texture and color, as well as the shape of the cushion based on the extruded shape of the foam bun, can be selected when mounting the cushion on the frame, thereby providing great flexibility in product appearance.

In alternative embodiments, adhesives or mechanical fasteners may be employed to secure the backing. As an example of the use of the extrusion 24 described with respect to fig. 2C and 2D, shown in fig. 11C and 11D, the cushion 95 may employ an extruded foam block 97 having a mounting support 99 incorporated therein. The gasket rests on the lower flange 43. The mounting support 99 may then be attached to the extrusion 24 using mechanical fasteners, such as screws 101 extending through the outer flange 34 of the support channel 32. With the second embodiment of the extrusion 24 in which the outer flange 34 terminates at the upper extent of the support channel 32, the padding 95 provides resiliently flexible partitions 103 (best seen in fig. 11D) that extend above the rigid elements of the extrusion to provide anti-pinch protection in the event that the hinge structure can rest on top of the frame in an unhinged position, such as those disclosed in U.S. patent 8,990,983 entitled "bed frame for an adjustment bed" (having the same assignee as the present application).

As shown in fig. 12A and 12B, the completed frame 20 provides an attractive integral component of bedroom furniture. The hinge structure 10 is supported by the frame 20 and, for the embodiment shown, carries all elements that are flush with the frame upper extension recess.

For frame embodiments in which the frame side and end sections are cut as separate components, the frame is easily assembled using corner brackets, as shown in fig. 13A-13C. Fig. 13A shows an assembled frame using the extrusion described with respect to fig. 2C and 2D. As shown, the side member 70 is connected to the end member 72 by a corner bracket 104 as shown in fig. 13B and seen in fig. 11D using fasteners 105 received through holes 107. For the illustrated embodiment, the corner bracket 104 has rounded corners to accommodate the rounded corners on the pad 95. Although the illustrated embodiment places the bracket 104 on the outer wall of the extrusion 24 in the side member 70 and the end member 72, the bracket may be internally received in the channel 32.

The bottom bracket and leg support 106 shown in fig. 13C may be employed to provide additional rigidity to the corners of the assembled side and

end members

70, 72 as seen in fig. 13A. Fasteners may be inserted through the lower flange 43 or the bottom flange 44 (as described with respect to fig. 2C and 2D) and the apertures 108 to join the bottom bracket and leg support to the frame extrusion. The frame 20 may then be supported by legs attached to the bottom bracket and leg supports 106.

The embodiment of frame 22 as disclosed provides a highly simplified manufacturing process with minimal tooling, minimal number of specialty parts, and minimal skilled labor requirements. The extruded beam 24 may be received in long lengths or operated directly from the extruder as shown in fig. 3A with beam lengths cut for the desired bed size. The saw cuts 52 are cut for a predetermined length for the side and end members of the frame for the desired bed size. Each beam may then be powder coated and oven cured, or anodized, or otherwise provided with a desired surface treatment in a direct linear process.

The fabrication of frame 20 for the embodiment described with respect to fig. 3A, 3B, 4A and 4B using the saw cut configuration may be accomplished on a single forming tool 110 as shown in fig. 14A. The end block 112, shown in detail in fig. 14B, is placed in a corner position of the tool 110 corresponding to a corner of the finished frame 22. The end block 112 cooperates with a locating plate 114, which is shown in detail in fig. 15A and 15B to receive corresponding locating holes 116 in the head endplate 76 and foot endplate 78. For the exemplary embodiment, the

end plates

76, 78 are fabricated from laminate sheets and can be precisely cut to length and width on a CNC saw or mill and the locating holes 116 drilled to mate with locating discs on the end block 112 of the tool 110. As can be seen in fig. 14A and 14B, the end block 112 is mounted to the top plate 118 of the tool 110, and the dowel pin 120 is received in the sizing hole 122. Different bed widths (single, double or large) can be accommodated by positioning the dowels in the sizing holes 122 of the desired width. The upper surface 124 of the end block 112 provides a stable horizontal support for the

end plates

76, 78. The precision fastener holes 126 may be drilled as part of the CNC molding process for the

end plates

76, 78.

The

end plates

76, 78 are mounted on the tool 110 as shown in fig. 16A such that the extrusion 22 is aligned to position the end element 72 with the

cutouts

52a and 52b at the corners of the end plate 76. The reach flange 50 presses against the end edge 128 (visible in fig. 15A) of the end plate 76 and fasteners are installed along that edge to engage the bottom flange 44 with the end member. Then, as seen in fig. 16B, the side element 70 may be produced by bending the extrusion 22 by 90 ° at the cuts 52a and 52B. The center plate 80 may be mounted on the center block 130 of the tool 110 prior to bending the side members 70. The touch flanges 50 of the side elements 70 of the extrusion 22 press against the side flanges 132 (visible in fig. 15A) of the end plate 76, of the central plate 80, and of the end plate 78, and fasteners 127 are installed along these edges to engage the end plate to the bottom flange 44. This attachment configuration is shown in detail in fig. 17.

The frame 20 may also be made by cutting the side and

end members

70, 72 from the extrusion 24 to length without leaving a web for the bending of the members. The side elements 70 are aligned with the end elements 72 at the corners, the reach flanges 50 (described with respect to fig. 2C and 2D) engage against the end edges of the

end plates

76, 78 and the center plate 80 for mounting fasteners 127, and the corner brackets 104 described with respect to fig. 13A and 13B may be mounted to complete the rigid frame 20.

The translating support block 60, the locking support block 82, and the angled support member 88 may then be inserted into the support channel 32 in the frame side element 70. The non-translating block or component may then be fixed at a predetermined position. To complete the assembly with the end or side elements completely separated, the second end element is then mounted and secured. For extrusions having deflectable saw cuts, the frame 20 may then be removed from the tool 110 and the extrusion 22 may then be bent at the cuts 52c and 52d to close the frame, engage the

end members

72a and 72b with the end plates 78, press the reach flanges 50 against the end edges 128 of the end plates 78, and install fasteners along the edges to engage the bottom flanges 44 with the bottom members. As previously described, angled support blocks may be employed to provide additional rigidity by engaging across the support channels 32 of the abutted

frame end elements

72a and 72 b. The hinge structures 10 and the actuating elements of the carriages 22 can then be mounted in these blocks or on a central or end plate, as appropriate, and the hinge structures are mounted on the carriages and on the actuating elements.

The mattress for the bed may be made from extruded, possibly Expanded Polyethylene (EPE) using a linear process similar to that of a frame extrusion, or similar materials may be provided in long lengths or may be provided in lengths or operated directly from the extruder, operating on beam lengths cut directly from the extruder. The overall length of the gasket may be cut and a cut made to bend the gasket at the frame gasket. As described in the previously cited co-pending application No. 12/942,916 entitled "bed frame for an adjustable bed" of the common assignee hereof, the geometry of the cutouts providing curved curves at the corners may be employed. The fabric may be applied to the EPE foam during the bonding roll or an alternative spray surface treatment may be applied to the foam. The cut foam is then inserted into the

gripping flanges

36 and 42 on the extrusion 22. Alternatively, the covered foam may be cut to a length corresponding to the frame side and

end members

70, 72 and separately mounted on each member. As shown in fig. 18, the corner completion element 136, which may include a leg of the bed, may then be secured in the corner by inserting the catch flange 138 into the exposed accessory channel or support channel 32. As shown in fig. 11C, the corner finishing element may be a top cap 137 that provides only flange continuity of the support channel around the corner.

Similarly, as shown in fig. 19, a plurality of bed frames 10 may be physically coupled by employing a coupling splice 139 having flange elements 140 that are engaged into the exposed support channels 30 of the end elements 72 of adjacent frames. This allows multiple frames with separate hinge structures to be coupled into a single bed, for example, a large bed with two single bed-sized hinge assemblies and frames. The prior art need for multiple legs as shown in fig. 20 is now eliminated, allowing a large bed to be created by a paired single bed as shown in fig. 21.

The extrusion 22 may additionally include a profiled element to provide a finished surface on a portion or the entire outer surface of the frame. As shown in fig. 22A and 22B, the upper gripping flange 36' may extend from an intermediate point on the outer flange 40, and the completed cassette element 102A or 102B may be included in the extrusion to provide a substantially finished surface for at least a portion of the frame. As shown in fig. 22C or 22D, the relative height of the finished box element and the fabric padded bolster 94 can be adjusted by positioning the upper gripping flange 36' as desired.

As shown in fig. 23, the attachment of a headboard to the bed can also be easily accommodated. The engagement corners 142 are inserted into the open head ends of the support channels 32 in the frame side members 70 and secured using recessed screws or similar means as previously described for the securing members. The mounting plate 144 extends perpendicular to the insertion flange 146 for mounting a headboard.

Having now described in detail various embodiments of the present invention as required by the patent statutes, those skilled in the art will recognize modifications and substitutions to the specific embodiments disclosed herein. Such changes are within the scope and intent of the present invention as defined in the appended claims.

Claims

1. A method for manufacturing a frame for an articulating bed, the method comprising:

forming an extruded beam;

mounting a foot endplate and a head endplate on a tool;

bending the side elements at the first two saw cuts to engage the foot end plates and the head end plates to form a frame assembly;

removing the frame assembly from the tool;

a hinge structure is mounted to the carriage.

2. The method of claim 1, further comprising:

inserting a plurality of fixed support blocks into the support channels;

fixing the fixed supporting blocks; and also,

actuating elements for the hinge structure are mounted to the fixed support blocks.

3. The method of claim 1, further comprising:

mounting a center plate on the tool;

engaging the center plate with the side elements of the extruded beam during bending of the side elements; and the number of the first and second electrodes,

actuating elements for the hinge structure are mounted on the central plate.

4. The method of claim 1, further comprising:

a liner is engaged in the extruded beam between a plurality of capture plates.

5. The method of claim 4, further comprising:

the foam was covered with an outer layer of fabric.

6. The method of claim 1, further comprising:

engaging end and side surfaces of the head and foot endplates with contact flanges on the extruded beam; and the number of the first and second electrodes,

the extruded beam is secured to the head and foot endplates.

7. The method of claim 1, further comprising coupling two frames by inserting a plurality of coupling flange elements into the plurality of exposed support channels.