ES2869431T3 - Lightweight, integrally formable bed frame structure for articulated beds - Google Patents

Abstract

A frame for an adjustable bed comprising: an extruded beam (24) having an upper inner flange (26) and a lower inner flange (28) separated by a slot (30) opening into a support channel (32) formed therein and having an upper wall (33) and a lower wall (35) with an upper outer flange (34) closing the support channel (32), terminating an upper inner flange (26) lower edge and a lower inner flange upper edge (28) on an upper slider heel (46) and lower slider heel (48), respectively, delimiting the slot with said extruded beam cut to form side frame members and end members; and, a plurality of translation support blocks (60) having an upper notch (62) and a lower notch (64), received in and supported by the support channel and engaged and mounted on the upper and lower slider butts. with an inner portion (66) of each translational support block coupled within the support channel, the translational blocks translatable within the support channel and engaging a translatable carriage (22) supporting a seat section of an articulated structure .

Description

DESCRIPTION

Lightweight, integrally formable bed frame structure for articulated beds

This application claims the priority of US Provisional application no. serial 61993087 filed on 05/14/2014

Background

Countryside

This invention relates generally to the field of adjustable beds and more particularly to a frame structure for an articulated bed having an extruded support frame with integral elements for reinforcing joint and support coupling of articulated elements.

Description of Related Art

Articulated beds are becoming increasingly popular and are being produced in a number of sizes and styles. Assembled wood and / or metal frames are typically used to support the articulated elements of the bed. Variable frame sizes are required for separate twin, queen, king, super king and king beds and typically must be individually prepared for fabrication resulting in numerous part numbers. Welding or heavy mechanical fasteners are required for assembly and the weight of the assembled bed can be significant.

It is therefore desirable to provide a frame for an articulated bed that is easily manufactured with minimal tooling, use of simple fasteners, and reduction of separate part number assembly elements. Document KR 2011 0021152 A discloses a frame for an articulated bed according to the state of the art. Summary

The embodiments disclosed herein overcome the shortcomings of the prior art by providing an extruded metal frame conformation that is formed into any desired bed size by slicing cuts in the extrusion for side lengths with bending in the cuts around base members. sized to create the entire frame. The frame for an articulated bed employs an extruded beam having an inner flange and a support channel formed therein. The extruded beam is cut to form side frame members and end members and a plurality of support blocks are received in and supported by the support channel. The support blocks are coupled to a carriage that supports a seat section of an articulated structure.

Brief description of the drawings

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

Figure 1A is a top perspective view of the articulated bed employing the frame embodiments described herein;

Figure 1B is a bottom perspective view of the bed of Figure 1A;

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

Figure 2B is an end view of the first example structural frame extrusion;

Figure 2C is a perspective view of a second exemplary frame extrusion for a second exemplary frame as described herein;

Figure 2D is an end view of the second example structural frame extrusion;

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

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

Figure 4A is a partial top view of a corner of the folded frame;

Figure 4B is a partial perspective view of a corner of the folded frame;

Figure 5 is a perspective view of an example slide for mounting in the support channel in the frame; Figure 6A is an end view of the first structural frame extrusion showing the slide mounted in the support channel;

Figure 6B is an end view of the second structural frame extrusion showing a wheeled stand mounted in the support channel;

Figure 7A is a partial perspective detail view showing the slide in the support channel with example positioning of the seat board and upper body boards as relatively positioned on the carriage;

Fig. 7B is a partial perspective detail view showing a wheeled support for the carriage in the support channel with example positioning of the seat board and upper body boards as relatively positioned on the carriage;

Figure 8 is a sectional perspective view showing example slides in the support channel with relative positioning of the articulated elements of the mattress support;

Figure 9 is a side sectional view showing the carriage supporting the articulated structure;

Figure 10A is a perspective view of a support block locked in the support channel;

Figure 10B is an end sectional view of the structural frame extrusion with an angled support member for the hinged support boards inserted into the support channel;

FIG. 10C is a perspective view showing the angled support member in a further function as a frame extrusion assembler;

Figure 11A is an end sectional view showing the first structural frame extrusion with a foam reinforcing element inserted into the reinforcing flanges;

Figure 11B is an end section isometric view showing the first structural frame extrusion with a foam reinforcing member inserted into the reinforcing flanges;

Figures 11C and 11D are end sectional perspective views showing the second structural frame extrusion with a foam reinforcing member attached to the extrusion with and without the corner brace;

Figure 12A is a sectional perspective view of the stiffening element as inserted into the stiffening flanges and the hinged structure in a non-hinged position flush with the structural frame;

Figure 12B is a partial perspective view showing a corner of the finished bed frame with the upholstered reinforcement;

Figure 13A is an interior perspective view of an assembled frame employing extrusions as described with respect to Figures 2C and 2D;

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

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

Figure 14A is a perspective view of an assembly table for manufacturing a bed frame employing the cut structural frame extrusions;

Figure 14B is a perspective view of exemplary corner support members for the assembly table; Figure 15A is a top view of an example base member for the bed frame;

Figure 15B is a perspective view of the base member;

Figure 16A is a perspective view of the assembly table with base members installed and the cut structural frame extrusion positioned for assembly;

Figure 16B is a perspective view showing the structural frame extrusion bent to create the frame sides;

Figure 17 is a detailed partial view showing the frame extrusion 22 as folded and mounted to the end plate with the probe flange engaging the edges of the end plate;

Figure 18 is a partial perspective view of an exploded corner element for finishing the reinforcement; Figure 19 is a partial perspective view showing the joining of frames using mating flanges in the support channel of adjacent frames for a paired king bed assembly;

Figure 20 is an image view of the prior art assembly of two twin bed frames to form a king size bed;

Figure 21 is an image view of the actual frame assembly enabled by attachment with mating flanges as shown in Figure 19 with a continuous reinforcement assembly;

Figures 22A-C are image views of alternate embodiments of the extrusion for exterior finish;

and,

Figure 23 is an image view of a bracket that engages the support channel for mounting a header.

Detailed description

Embodiments shown in the drawings and described herein provide a structure and system for manufacturing an articulated bed frame structure that allows linear manufacturing processes with minimal labor and tooling. The frame elements are self-oscillating for assembly and are adaptable to a range of sizes.

With reference to the drawings, Figure 1A shows an articulated bed employing a structural frame as disclosed herein. The articulated structure 10 has a seat support 12, an upper body support member 14, a thigh support member 16, the upper body support member, and a thigh support member attached to the support member. seat hinge, and a lower leg support member 18 hingedly attached to the thigh support member. The support elements are shown to be substantially solid however, a rigid honeycomb or similar material may be employed that provides a rigid flat surface. A frame 20 supports the articulated structure 10. As shown in Figure 1B, a carriage 22 is coupled to the seat support 12 and carries the articulated frame 10 allowing a "wall-tight" effect with the upper body support element 14. The carriage 22 traverses longitudinally (from the foot to the head of the bed) when the upper body support element 14 is raised from a flat to a vertical position.

Frame 20 is formed from an extruded beam 24 shown in Figures 2A and 2B. The extruded beam 24, which can be made of metal or other structural material and, for the embodiments disclosed in this document is made of aluminum, incorporates an upper inner flange 26 and a lower inner flange 28 separated by a slot 30 that opens into a channel. Support 32 having a top wall 33 and a bottom wall 35. An upper outer flange 34 closes the support channel 32 and extends upwardly to an upper gripping flange 36. An accessory channel 38 is supported by the lower inner flange 28 and a lower outer flange 40 provides a partial closure of the exterior of the accessory channel 38. Cabling for articulation system actuators, integral massage systems, audio or lighting systems associated with the bed can be routed through the accessory channel. In alternative embodiments, the lower outer flange may provide a total outer closure of the accessory channel. A bottom gripping flange 42 extends from a bottom flange 44 which also forms a bottom wall of the accessory channel 38. Support channel bottom wall 35 provides the top termination of accessory channel 38 for the embodiment shown in the drawings. The lower inner flange edge 26 and upper inner flange edge 28 terminate in an upper slide butt 46 and lower slide butt 48, respectively, which delimits the slot 30 in the exemplary embodiment. A probe flange 50 is dependent on the bottom flange 44.

Alternative extrusion configurations can be employed for other desired embodiments. Figures 2C and 2D show a first alternative for use with an embodiment to be described in greater detail subsequently wherein the extruded beam 24 terminates at the upper wall 33 of the support channel 32 and does not incorporate an upper gripping flange. The lower wall 35 extends from the upper outer flange 34 which closes the channel 32 support. The bottom wall 35 is supported by an inner flange 29. A lower outer flange 41 extends downwardly from the support channel 32 and terminates in a bottom flange 44. A bottom flange 43 is present extending from the bottom flange 44 and the probe flange 50 depends on the bottom flange 44 as in the previous embodiment. An accessory channel 39 is provided.

The configuration of extruded beam 24 described with respect to Figures 2A and 2B allows the creation of saw cuts 52 to define the length and width of side elements 70 and end elements 72 and 72a, 72b of frame 10 as shown in Figure 3A. As shown in Figure 3B, a saw blade 54 is employed to provide precision cuts of extruded beam 24 extending to line 56 through top grip flange 36, top outer flange 34, top wall 33 and lower wall 35 of support channel, lower outer flange 40, lower grip flange 42, wall 44 of lower part of accessory channel and probe flange 50 leaving only the web of the upper inner flange 26 and lower inner flange 28 intact as completion of cut 52. Extruded beam 24 can then be bent at each cut as shown in Figures 4A and 4B to form frame 10 as will be described in greater detail subsequently. As seen in Figure 4B, the bends in the cut position the support channel 32 on the inside of the frame 10 and the accessory channel 38 on the outside of the frame. The support channel 32 in each frame element is accessible from the open ends created in the cut for assembly operations as will be described in greater detail subsequently. Similarly, the accessory channel is open at the ends.

The carriage 22 that supports the articulated structure 10 as described with respect to Figure 1B, is coupled to support elements mounted in the support channel 32 such as translation support blocks 60 shown in detail in Figure 5. Each block The translation bracket 60 has an upper notch 62 and a lower notch 64 that are adapted to engage and mount on the upper and lower slide heels 46, 48 with an interior portion 66 of the translation block 60 engaged within the support channel 32 as shown in Figures 6a and 7A. A central hole 68 receives a shaft extending from carriage 22. Secondary holes 70 may be used for tie fasteners. The translation support block 60 is formed of naturally lubricated material such as nylon or Teflon® to allow easy translation along the slider beads and the support channel during translation of the carriage 22 during operation of the articulated structure 10. As shown in Figures 8 and 9, a pair of translation support blocks 60 mounted in the support channels 32 of the side members 70 are coupled to the carriage 22 in spaced relationship providing support for the articulated structure 10. In an illustrative example the translation blocks can be mounted on the bottom 35 of the support channel 32 or the support elements can be wheels 67 or similar structure with an axle 69 of the carriage 22 that can be received within the support channel 32 as shown in Figure 6B to engage and support the carriage to translate motion. The alternative configuration of extrusion 24 as described with respect to Figures 2C and 2D are shown for this alternative example. The resulting carriage arrangement is shown in Figure 7B.

Various mechanisms of articulation with the frame structure can be employed in the disclosed embodiments. A head end plate 76, foot end plate 78, and center plate 80 are employed as a portion of frame 20 for additional rigidity and for integrated manufacturing forms as will be described in greater detail subsequently. The peripheral edges of the end plates and the side edges of the center plate are engaged by the probe flange on the extruded beam. The actuators and tension or compression elements for the link mechanisms can be mounted on the plates or can be engaged by stationary or locked support blocks 82 received in the support channel 32 as shown in FIG. 10A. The locked support blocks incorporate coupling holes 84 to receive shafts for coupling the hinge elements and may include fixing holes 86. Locked support blocks 82 may be engaged to be secured at a predetermined location in the support channel by matching fasteners drilled through upper or lower inner flanges 26, 28, wide head fasteners inserted into attachment holes 86 to engaging one or both of the inner upper and lower flanges 26, 28 or set screws inserted through set holes 86 to dimple and engage the back surface of the support channel, or grainy dimples created in the channel flanges bracket to secure the locked support blocks.

Additional support elements such as angled support members 88, as seen in Figure 10B, can be received at predetermined positions in support channels 32. Angled support member 88 includes a body 90 received in support channel 32 and an angled extension 92 that projects through slot 30 to provide additional support for an articulated support member such as part support member 14. upper body in non-articulated position flush with frame 20.

The angled support member as shown in Figure 10C is of sufficient length to span a joint between adjoining extruded beam elements such as end closure elements 72a and 72b as previously described.

Frame 20 provides comprehensive finishing capability for a full upholstered bed frame. As shown in Figures 11A and 11B, a cushioned reinforcement 94 surrounding the frame is created by inserting blocks 96 of extruded foam, which may be covered with an outer fabric layer 98, between the upper grip flange 36 and flange 42 of the lower grip of the first embodiment of extrusion 24 as described with respect to Figures 2A and 2B. Upper grip flange 36 and lower grip flange 42 employ teeth 100 to engage foam block 96 upholstered. The fabric texture and color, as well as the shape of the reinforcement based on the extrusion shape of the foam block can be selected at the time of installation of the reinforcement in the frame thereby providing great flexibility in the appearance of the product.

In alternative embodiments, an adhesive or mechanical fasteners may be used to secure the reinforcement. As an example shown in Figures 11C and 11D employing extrusion 24 as described with respect to Figures 2C and 2D, a reinforcement 95 may employ an extruded foam block 97 in which a mounting bracket 99 is incorporated. The reinforcement rests on the lower flange 43. The mounting bracket 99 can then be attached to the extrusion 24 using mechanical fasteners such as screws 101 that extend 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 extension of the support channel 32, the reinforcement 95 provides a resiliently flexible spacer 103 that extends over the rigid elements of the extrusion ( best seen in Figure 11D) to provide pinch protection where the hinged frame can rest on top of the frame in the non-hinged position as disclosed in US Patent No. 8,990,983 entitled Bed Frame for an Adjustable Bed, which has a common Assignee with the present application.

As shown in Figures 12A and 12B, the complete frame 20 provides an attractive complete piece of bedroom furniture. Articulated structure 10 is supported by frame 10 and, for the embodiment shown, is carried with all elements lowered flush with the upper extension of the frame.

For frame embodiments where the frame side and end sections are cut as individual pieces, the frame is easily assembled using corner clamps as shown in Figures 13A-13C. An assembled frame employing extrusions as described with respect to Figures 2C and 2D is shown in Figure 13A. As shown, side members 70 are connected to end members 72 with a corner clamp 104 as shown in Figure 13B and seen in Figure 11D using fasteners 105 received through holes 107. For the embodiment shown, the corner bracket 104 has a threaded corner to accommodate a rounded corner on the stiffener 95. While the embodiment shown places the bracket 104 on the outer extrusion wall 24 at side members 70 and end members 72, the bracket can be received internally on channel 32.

A bottom bracket and leg bracket 106 shown in Figure 13C can be used to provide additional corner rigidity of the assembled side members 70 and end members 72 as seen in Figure 13A. The fasteners can be inserted through the bottom flange 43 or bottom flange 44 (as described with respect to Figures 2C and 2D) and holes 108 to couple the bottom bracket and leg support to the frame extrusions. Frame 20 can then be supported by legs attached to bottom bracket and leg support 106.

Embodiments for frame 22 as disclosed provide a highly simplified manufacturing process with minimal tooling, specialty part numbers, and skilled labor requirements. The extruded beam 24 can be received in long lengths or operated directly from the extruder with a beam length cut to a desired bed size as shown in Figure 3A. The saw cuts 52 are cut to predetermined lengths for the side and end members of the frame for the desired bed size. Each beam can then be powder coated and oven cured, or anodized or otherwise provided with a desired finish in a direct linear process.

Fabrication of frame 20 for embodiments employing the saw cut configuration described with respect to Figures 3A, 3B, 4A, and 4B can be accomplished in a single forming tool 110 as shown in Figure 14A. The end blocks 112, shown in detail in Figure 14B, are placed in the tool 110 in the corner position that corresponds to the corners of the entire frame 22. End blocks 112 incorporate positioning discs 114 which receive corresponding positioning holes 116 in head end plate 76 and foot end plate 78 which are shown in detail in Figures 15A and 15B. For an example embodiment, the end plates 76, 78 are made of plywood and can be precisely cut to length and width on a CNC saw or milling machine and the positioning holes 116 drilled to match the positioning discs in End Blocks 112 of Tool 110 As seen in Figures 14A and 14B, end blocks 112 are mounted on a top plate 118 on tool 110 with dowels 120 received in sizing holes 122. Various twin, double, queen or king bed widths can be accommodated by positioning the studs in the desired width sizing holes 122. A top surface 124 on the end blocks 112 provides stable horizontal support for the end plates 76, 78. Precision fastener holes 126 can be drilled as part of the CNC forming process for the end plates 76, 78.

With end plates 76, 78 mounted on tool 110 as shown in FIG. 16A, extrusion 22 is aligned with an end member 72 positioned with cutouts 52a and 52b at the corners of end plate 76. Stylus flange 50 is urged against an end edge 128 of end plate 76 (seen in Figure 15A) and fasteners are installed along that edge to engage bottom flange 44 with the end member. . Side members 70 are then created by bending extrusion 22 at cuts 52a and 52b to 90 ° as seen in figure 16B. The center plate 80 can be installed in center blocks 130 in the tool 110 prior to bending the side members 70. The feeler flange 50 of the side members 70 of the extrusion 22 are urged against side edges 132 of the end plate 76 (seen in Figure 15A), center plate 80 and end plate 78 and fasteners 127 are installed thereon. along those edges to couple the end plate to the bottom flange 44. The joint configuration is shown in figure 17 in detail.

A frame 20 can also be manufactured with side elements 70 and end elements 72 cut to the length of the extrusions 24 without leaving webs for bending the elements. Side elements 70 and end elements 72 are aligned at the corners with probe flanges 50 (as described with respect to Figures 2C and 2D) engaged against the end edges of end plates 76, 78 and center plate 80 for the installation of fasteners 127 and corner brackets 104 as described with respect to Figures 13A and 13B may be installed to complete the rigid frame 20.

Translation support blocks 60, locked support blocks 82, and angled support members 88 can then be inserted into support channels 32 in side frame members 70. The non-translating blocks or members can then be secured at predetermined locations. To finish the assembly with completely separate end and side elements, the second end element is then installed and secured. For extrusions that have bendable saw cuts, frame 20 can then be removed from tool 110 and extrusion 22 can then be bent into cuts 52c and 52d to close the frame with frame end elements 72a and 72b by engaging the frame. End plate 78 with the feeler flange 50 urged against the end edge 128 of the end plate 78 and fasteners are installed along that edge to engage the bottom flange 44 with the end member. As previously described and shown in FIG. 10C, an angled support block may be employed to provide additional rigidity by coupling through support channels 32 of adjacent frame end members 72a and 72b. The actuation elements for the articulated structure 10 and carriage 22 can then be installed in the blocks or on the center plate or end plates as appropriate and the articulated structure mounted on the carriage and actuation elements.

The reinforcement for the bed can be manufactured in a linear process similar to frame extrusion with the extruded foam which can be expanded polyethylene (EPE) or a similar material can be provided in long lengths or operated directly from the extruder. A full length can be cut for the reinforcement and cuts created to bend the reinforcement at the frame corners. The geometry for the cuts to provide bent bends at the corners may be employed as described in previously referenced copending application no. Serial 12 / 942,916 entitled Bed Frame for an Adjustable Bed, which has a common Assignee with the present invention. The fabric can be applied to the EPE foam in an adhesive roll process or alternative spray finishes can be applied to the foam. The cut foam is then inserted into gripping flanges 36 and 42 at extrusion 22. Alternatively, the covered foam can be cut into lengths corresponding to side frame members 70 and end members 72 and installed separately at each element. The corner finishers 136 that may include the legs for the bed can then be secured at the corners by inserting catch flanges 138 into the exposed fixture channel or support channel 32 as shown in Figure 18. The item The corner finish may be a top cap 137 that simply provides continuity to the support channel flange around the corner as shown in Figure 11C.

Similarly, the bed frames 10 can be physically joined using a tie joint 139 having flange elements 140 engaged in the exposed support channels 30 of the end elements 72 in adjacent frames as shown in Figure 19. This allows the joining of frames with separate hinged frames into a single bed, for example in a king size bed that has two hinged assemblies and twin size frames. The prior art requirement for multiple legs as shown in figure 20 is now removed by allowing king to be created from paired twins as shown in figure 21.

Extrusion 22 may further include elements formed to provide a finished surface on a portion or all of the outer surface of the frame. As shown in Figures 22A and 22B, the upper gripping flange 36 'may extend from an intermediate point in the outer flange 40 and a finished box member 102a or 102b may be included in the extrusion providing a substantially finished surface for the extrusion. minus a portion of the frame. The relative height of the finished box member and fabric padding 94 may be adjusted by positioning the upper grip flange 36 'as desired as shown in FIG. 22C or FIG. 22D.

The attachment for a headboard in the bed is also easily accommodated as shown in Figure 23. A mating angle 142 is inserted into the open head end of the support channels 32 in the side frame members 70 and secured using dimple screws or similar means as previously described for fixtures. A mounting plate 144 extends perpendicular to the header mounting insert flange 146.

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

Claims (8)

1. A frame for an articulated bed comprising: an extruded beam (24) having an upper inner flange (26) and a lower inner flange (28) separated by a slot (30) that opens to a support channel (32) formed therein and that has a wall (33) upper and a lower wall (35) with an upper outer flange (34) that closes the support channel (32), terminating a lower inner flange edge (26) and an upper inner flange edge (28) bottom in an upper slide butt (46) and lower slide butt (48), respectively, delimiting the slot with said extruded beam cut to form side frame members and end members; and, a plurality of translation support blocks (60) having an upper notch (62) and a lower notch (64), received in and supported by the support channel and engaged and mounted on the upper and lower slide heels with a inner portion (66) of each translational support block coupled within the support channel, the translatable translation blocks within the support channel and engaging a translatable carriage (22) that supports a seat section of an articulated structure. The frame for an articulated bed as defined in claim 1 wherein the extruded beam further includes an accessory channel (38). The frame for an articulated bed as defined in claim 1 wherein the extruded beam further includes a bottom flange (44) and further comprises a head end plate (78) and a head end plate (76) foot end, said head end plate and foot end plate coupled to the bottom flange. The frame for an articulated bed as defined in claim 3 wherein the extruded beam further includes a feeler flange (50) extending from the bottom flange and engaging peripheral edges of the end plate of head and foot end plate. The frame for an articulated bed as defined in claim 1 wherein the extruded beam further includes an upper grip flange (36) extending from the upper outer flange (34) and a lower grip flange (42) extending from a lower part flange (44) and further comprising a foam reinforcement (94) coupled between the upper grip flange and lower grip flange. 6. The frame for an articulated bed as defined in claim 5 wherein the foam backing is covered with fabric. The frame for an articulated bed as defined in claim 1 further comprising a plurality of locked support blocks (82) received in the support channel and engaging structural elements of the drive system for the articulated structure. 8. The frame for an articulated bed as defined in claim 1 wherein the extruded beam further includes a lower part flange (44) and further comprises a foam reinforcement coupled to the bottom flange, said reinforcement of foam a mounting bracket attached to the extruded beam with a resilient flexible spacer (103) that extends above the support channel.