JP6713930B2 - Method and structure of a lightweight, integrally formable bed frame for a refraction bed - Google Patents

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application claims priority to US Provisional Patent Application No. 61993087 filed May 14, 2014. The disclosure content of said provisional patent application is incorporated herein by reference.

FIELD OF THE INVENTION The present invention relates generally to the field of adjustable beds, and more particularly to the construction of a frame of a refraction bed having an extruded support frame with integral elements for bolster mounting and flex element support engagement.

Bending beds are becoming increasingly popular and continue to be manufactured in a variety of sizes and styles. An assembled wooden and/or metal frame is typically used to support the refractive elements of the bed. Different frame sizes are required for twin, queen, king, super king and separate king beds, which generally must be individually tooled, which results in a large number of parts. Welding or heavy mechanical fasteners are required for assembly and the assembled bed can be quite heavy.

Therefore, it would be desirable to provide a refraction bed frame that is easily made with a minimum of tools, the use of simple fasteners and a reduction in the number of separate parts of the assembly element.

The embodiments disclosed herein provide any desired by slicing a score in the extrudate with respect to the side length and bending the score around a base element dimensioned to form the finished frame. It overcomes the drawbacks of the prior art by providing an extruded metal frame shape that is also formed in bed size. Frames for refractive beds use extruded beam material with an inner flange and support channels formed therein. The extruded beam material is cut to form frame side elements and end elements and a plurality of support blocks are received within and supported by the support channels. The support block engages a carriage that supports the bearing surface portion of the refractive structure.

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

FIG. 1A is a top perspective view of a refractive bed using the frame embodiments described herein. 1B is a bottom perspective view of the bed of FIG. 1A. 2A is a perspective view of a first exemplary structural frame extrudate for the first exemplary frame embodiment described herein. FIG. 2B is an end view of the first exemplary structural frame extrudate. FIG. 2C is a perspective view of a second exemplary structural frame extrudate for the second exemplary frame embodiment described herein. FIG. 2D is an end view of a second exemplary structural frame extrudate. FIG. 3A is a perspective view of a first structural frame extrudate showing cuts that define the length and width of the side and end elements of the frame. FIG. 3B is an end view of a first structural frame extrudate showing saw blades that form a score for bending the frame. FIG. 4A is a partial top view of a corner of a bent frame. FIG. 4B is a partial perspective view of a corner of the bent frame. FIG. 5 is a perspective view of an exemplary slider for mounting within a support channel of a frame. FIG. 6A is an end view of a first structural frame extrudate showing a slider mounted in a support channel. FIG. 6B is an end view of a second structural frame extrudate showing a wheeled support mounted within a support channel. FIG. 7A is a partial perspective detail view showing a slider in a support channel for exemplary positioning of a bearing board and an upper body board positioned relative to each other on a transfer pedestal. FIG. 7B is a partial perspective detail view showing a wheeled support for a mobile pedestal in a support channel with respect to an exemplary positioning of a bearing board and an upper body board relative to each other on the mobile pedestal. FIG. 8 is a cross-sectional perspective view showing an exemplary slider within a support channel for relative positioning of refractive elements of a mattress support. FIG. 9 is a side sectional view showing a movable pedestal that supports the refraction structure. FIG. 10A is a perspective view of a fixed support block within a support channel. FIG. 10B is an end cross-sectional view showing the structural frame extrudate with slanted support members for the refraction support board inserted in the support channels. FIG. 10C is a perspective view showing a tilted support member that additionally functions as a frame extrudate coupling device. FIG. 11A is an end cross-sectional view showing a first structural frame extrudate with a foam bolster element inserted within the bolster flange. FIG. 11B is an end cross-sectional isometric view of the first structural frame extrudate with a foam bolster element inserted within the bolster flange. FIG. 11C is an end cross-sectional perspective view of the second structural frame extrudate with foam bolster elements attached to the extrudate with corner brackets. FIG. 11D is an end cross-sectional perspective view of a second structural frame extrudate with foam bolster elements attached to the extrudate without corner brackets. FIG. 12A is a sectional perspective view of a bolster element inserted in a bolster flange and a refraction structure in a non-refraction position on the same plane as the structural frame. FIG. 12B is a partial perspective view showing a corner portion of the completed bed frame having the upholstered bolster. FIG. 13A is a perspective inside view of an assembled frame using the extrudate described in connection with FIGS. 2C and 2D. 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 table for making a bed frame using a grained structural frame extrudate. FIG. 14B is a perspective view of an exemplary corner support element for an assembly table. FIG. 15A is a top view of an exemplary base element for a bed frame. FIG. 15B is a perspective view of the base element. 16A is a perspective view of the assembly table with the base element introduced and the scored structural frame extrudate positioned for assembly. FIG. 16B is a perspective view showing the structural frame extrudate bent to form the frame sides. FIG. 17 is a detailed partial view showing the frame extrudate 22 bent and attached to the end plate with a feeler flange engaging the edge of the end plate. FIG. 18 is a partial perspective view of an exploded corner element for finishing a bolster. FIG. 19 is a partial perspective view of a pair of king bed assemblies showing the joining of frames using engagement flanges within the support channels of adjacent frames. FIG. 20 is a pictorial view of a prior art assembly consisting of two twin bed frames forming a king size bed. FIG. 21 is a pictorial view of a current frame assembly for a continuous bolster assembly tolerated by coupling using the engagement flanges shown in FIG. FIG. 22A is a pictorial view of an alternative embodiment of an extrudate for exterior finishing. FIG. 22B is a pictorial view of an alternative embodiment of an extrudate for exterior finishing. FIG. 22C is a pictorial view of an alternative embodiment of an extrudate for exterior finishing. FIG. 23 is a pictorial view of a bracket engaging a support channel for mounting a headboard.

The embodiments shown in the drawings and described herein provide a structure and system for making a refractive bed frame structure that allows for a linear fabrication process with minimal effort and tools. .. The frame element itself jigs for assembly and is adaptable to a wide range of dimensions.

Referring to the drawings, FIG. 1A shows a refractive bed using a structural frame as disclosed herein. The flexure structure 10 has a seat support 12, an upper body support element 14, and a thigh support element 16, the upper body support element and the thigh support element being attached to the seat support element using a hinge. The flexure structure further comprises a lower leg support element 18 hingedly attached to the thigh support element. Although the support elements are shown as substantially solid, a rigid honeycomb material or similar material that provides a rigid flat surface may be used. A frame 20 supports the refractive structure 10. As shown in FIG. 1B, a moving pedestal 22 is engaged with the seat support 12 to carry the refractive structure 10 and to enable a “wall hugging” effect with the upper body support element 14. The transfer pedestal 22 traverses longitudinally (from the foot to the head of the bed) when the upper body support element 14 is lifted from the flat position to the upright position.

The frame 20 is formed from the extruded beam 24 shown in FIGS. 2A and 2B. The extruded beam material 24, which may be metal or other structural material, is aluminum in the embodiments disclosed herein and incorporates an upper inner flange 26 and a lower inner flange 28, which are upper wall 33 and lower wall. They are separated by a slot 30 which opens into a support channel 32 having a wall 35. The upper outer flange 34 closes the support channel 32 and extends upward to the upper grip flange 36. The accessory channel 38 is lined by the lower inner flange 28 and the lower outer flange 40 provides partial outer closure of the accessory channel 38. Wiring for refractive system actuators, integrated massage systems, acoustic or lighting systems associated with the bed can be routed through accessory channels. In an alternative embodiment, the lower outer flange may provide a general closure outside the accessory channel. The lower grip flange 42 forms a bottom flange 44, which also forms the bottom wall of the accessory channel 38. The lower support channel wall 35 provides the upper end of the accessory channel 38 in the embodiment shown in the drawings. The lower edge of the upper inner flange 26 and the upper edge of the lower inner flange 28 terminate in an upper runnade 46 and a lower runnade 48, respectively, which delimit the slot 30 in this exemplary embodiment. .. The feeler flange 50 depends on the bottom flange 44.

Alternative extrudate structures may be used for other desired embodiments. 2C and 2D show a first alternative for use in embodiments described in more detail below, where the extruded beam 24 terminates in the upper wall 33 of the support channel 32 and does not incorporate an upper gripping flange. .. The lower wall 35 extends from an upper outer flange 34 that closes the support channel 32. The lower wall 35 is supported by the inner flange 29. The lower outer flange 41 extends downwardly from the support channel 32 and terminates in a bottom flange 44. There is a lower flange 43 extending from the bottom flange 44 and the feeler flange 50 is dependent on the bottom flange 44 as in the previous embodiments. An accessory channel 39 is provided.

The structure of the extruded beam 24 described in connection with FIGS. 2A and 2B determines the length and width of the side elements 70 and end elements 72 and 72a, 72b of the frame 10 as shown in FIG. 3A. Allows the formation of saw kerfs 52 for. As shown in FIG. 3B, a saw blade 54 is used to upper grip flange 36, upper outer flange 34, support channel upper and lower walls 33 and 35, lower outer flange 40, lower grip flange 42, accessory channel bottom. Providing a precise cut in the extruded beam 24 that extends through the wall 44 and the feeler flange 50 to the line 56, with only the web of the inner upper flange 26 and the lower inner flange 28 terminating the score 52. It is left intact. Extruded beam 24 may then be folded at each score as shown in FIGS. 4A and 4B to form frame 10 as described in more detail below. As seen in FIG. 4B, the folds in the crease position the support channels 32 inside the frame 10 and the accessory channels 38 outside the frame. The support channel 32 of each element of the frame is accessible from the open end formed in the notch for assembly operations, as described in more detail below. Similarly, accessory channels open at the ends.

The transfer pedestal 22 supporting the refractive structure 10 as described in connection with FIG. 1B engages a support element moving within the support channel 32, such as the translating support block 60 shown in detail in FIG. Each translation support block 60 has an upper groove 62 and a lower groove 64 that are adapted to engage and move over the upper and lower runnades 46, 48, at which time the translation The inner portion 66 of the block 60 is engaged within the support channel 32 as shown in Figures 6A and 7A. The central bore 68 receives an axle extending from the pedestal 22. The auxiliary bore 70 may be used for mounting fasteners. The translation support block 60 is formed of an essentially lubricious material, such as nylon or Teflon®, thereby allowing the runnad and the translation pedestal 22 to translate during actuation of the refractive structure 10. Allows easy translation along the support channel. As shown in FIGS. 8 and 9, a pair of translating support blocks 60 that move within the support channels 32 of the lateral elements 70 move the pedestal 22 in a spaced relationship while providing support for the refractive structure 10. Engage with. In an alternative embodiment, the translation block may move over the bottom 35 of the support channel 32, or the support element may be a wheel 67 or a similar structure with an axle 69 from the moving pedestal 22, the wheel 67 or A similar structure can be received in the support channel 32 as shown in FIG. 6B to engage and support the transfer pedestal for translation. An alternative construction of extrudate 24 as described in connection with Figures 2C and 2D is shown for this alternative embodiment. The resulting transport structure is shown in Figure 7B.

Various bending mechanisms may be used with the frame structures of the disclosed embodiments. The head end plate 76, the foot end plate 78 and the center plate 80 are a part of the frame 20 for additional rigidity and for an integrated construction, as will be described in more detail below. Used as a part. The edges of the end plates and the side edges of the center plate are engaged by the feeler flanges of the extruded beam. The bending mechanism actuators and tensioning or compression elements may be attached to the plates or engaged by stationary or stationary support blocks 82 housed within the support channels 32 as shown in FIG. 10A. The fixed support block incorporates an engagement bore 84 that receives an axle for engaging a refractive element and may include a fixed bore 86. The fixed support block 82 includes a fixed bore 86 for engaging one or both of the upper and lower inner flanges 26, 28 by fasteners that are threaded in shape with the upper or lower inner flanges 26, 28. By a wide head fastener inserted into the fixed channel or by a set screw that is recessed in the back surface of the support channel and inserted into the fixed bore 86 to engage the back surface of the support channel, or the fixed support block. Can be fixedly engaged in position within the support channel by an impacted recessed dimple formed in the flange of the support channel to secure the.

Additional support elements, such as sloping support members 88, may be housed in place within support channel 32, as seen in FIG. 10B. The sloping support member 88 includes a body 90 housed within the support channel 32 and a sloping extension 92 projecting through the slot 30 and in a non-refractive position coplanar with the frame 20, the upper body support element 14 is shown. Provide additional support for refractive support elements such as.

The tilted support member as shown in FIG. 10C is of sufficient length to span the joint between the abutting extruded beam material elements, such as end closure elements 72a and 72b as previously described.

The frame 20 provides integral finishing performance for a fully upholstered bed frame. A padded bolster 94 surrounding a frame, as shown in FIGS. 11A and 11B, includes an extruded foam block 96, which may be covered with a fabric outer layer 98, as described in connection with FIGS. 2A and 2B. The extrudate 24 is formed by inserting it between the upper gripping flange 36 and the lower gripping flange 42 of the first embodiment. The upper gripping flange 36 and the lower gripping flange 42 use teeth 100 to engage the upholstered foam block 96. The shape of the bolster based on the texture and color of the fabric and the extruded shape of the foam block can be selected when mounting the bolster to the frame, which provides excellent flexibility in product appearance.

In alternative embodiments, adhesives or mechanical fasteners may be used to secure the bolster. As in the example shown in FIGS. 11C and 11D using extrudate 24 as described in connection with FIGS. 2C and 2D, bolster 95 uses an extruded foam block 97 incorporating mounting support 99. obtain. The bolster is arranged on the lower flange 43. The mounting support 99 may then be attached to the extrudate 24 using a mechanical fastener such as a screw 101 extending through the outer flange 34 of the support channel 32. In the second embodiment of the extrudate 24 where the outer flange 34 terminates in the upper extension of the support channel 32, the bolster 95 provides a resilient flexible spacer 103 that extends over the rigid elements of the extrudate (best seen in FIG. 11D. (See), the refractive structure of the frame in the non-refractive position as disclosed in U.S. Pat. No. 8,990,983 (titled "Bed Frame for an Adjustable Bed") having common assignee with the present application. It provides pinch protection if it can be mounted on top.

As shown in FIGS. 12A and 12B, the completed frame 20 provides an attractive finished piece of bedroom furniture. The refraction structure 10 is supported by the frame 10 and, in the embodiment shown, is supported with all elements recessed flush with the upper limit of the frame.

In embodiments where the frame side and end sections are cut as separate pieces, the frame is simply assembled using the corner brackets as shown in Figures 13A-13C. A frame assembled using an extrudate as described in connection with Figures 2C and 2D is shown in Figure 13A. As shown, the side element 70 uses the corner brackets 104 as shown in FIG. 13B and seen in FIG. 11D, and the fasteners 105 received in the holes 107 to provide the end elements. Connected to 72. In the embodiment shown, the corner bracket 104 has a chamfered corner to accommodate the rounded corner of the bolster 95. Although the embodiment shown places the bracket 104 on the outer wall of the extrudate 24 of the side elements 70 and end elements 72, the bracket may be housed inside the channel 32.

The bottom bracket and leg support 106 shown in FIG. 13C is used to provide additional rigidity in the corners of the assembled side elements 70 and end elements 72, as seen in FIG. 13A. obtain. Fasteners are inserted through bottom flange 43 or bottom flange 44 (as described in connection with FIGS. 2C and 2D) and holes 108 to engage the bottom bracket and leg supports with the frame extrudate. The frame 20 may then be supported by legs attached to the bottom bracket and leg support 106.

Embodiments of the frame 22 as disclosed provide a very simplified fabrication process with minimal tools, specific parts count and skilled labor requirements. Extruded beam 24 can be received in long lengths, or work can be done directly from the extruder with beam lengths cut for the desired bed size as shown in FIG. 3A. The perforations 52 are cut into the sides of the frame and at predetermined lengths of the end elements for the desired bed size. Each beam may then be powder coated and oven cured, or anodized, or may be given the desired finish in a direct linear process.

Fabrication of the frame 20 for embodiments using the eyelet configuration described in connection with FIGS. 3A, 3B, 4A and 4B may be accomplished with a unitary forming tool 110 as shown in FIG. 14A. An end block 112, shown in detail in FIG. 14B, is placed on the tool 110 at a corner position corresponding to the corner of the finished frame 22. End block 112 incorporates a locating disc 114, which receives corresponding locating holes 116 in the head end plate 76 and foot end plate 78 shown in detail in FIGS. 15A and 15B. In the exemplary embodiment, the end plates 76, 78 are made from plywood and can be precisely cut to length and width with a CNC saw or milling machine, and the locating holes 116 are the locating discs of the end block 112 of the tool 110. It is drilled to fit exactly with. As seen in FIGS. 14A and 14B, the end block 112 is attached to the top plate 118 of the tool 110 with the dowel 120 housed in the sizing hole 122. A wide variety of bed widths, twin, double, queen or king can be accommodated by positioning the dowel within the desired width sizing hole 122. The upper surface 124 of the end block 112 provides a stable horizontal support for the end plates 76,78. Precise fastener holes 126 can be drilled as part of the CNC forming process for the end plates 76,78.

The extrudate 22 is aligned with the end plates 76, 78 attached to the tool 110 as shown in FIG. 16A, with the end elements 72 now having the crevices 52a and 52b at the corners of the end plate 76. It is arranged in the state where it is in the section. The feeler flange 50 is pressed against the edge 128 (seen in FIG. 15A) of the end plate 76 and fasteners are introduced along said edge to engage the bottom flange 44 with the end element. Lateral element 70 is then formed by bending extrudate 22 at 90° at perforations 52a and 52b as seen in FIG. 16B. The central plate 80 may be introduced into the central block 130 of the tool 110 before bending the side elements 70. The feeler flanges 50 of the side elements 70 of the extrudate 22 are pressed against the end plates 76 (seen in FIG. 15A), the center plate 80 and the side edges 132 of the end plates 78, with fasteners 127 at these edges. Is introduced along and engages the end plate with the bottom flange 44. The mounting structure is shown in detail in FIG.

The frame 20 may also be made with the side elements 70 and end elements 72 cut from the extrudate 24 to length without leaving a web to bend the elements. The lateral elements 70 and the end elements 72 are aligned at the corners, with the feeler flange 50 (as described in connection with FIGS. 2C and 2D) now having an end plate for introducing fasteners 127. Corner brackets 104, such as those described in connection with FIGS. 13A and 13B, may be introduced to complete the rigid frame 20, engaging the edges of 76, 78 and the central plate 80.

The translating support block 60, the fixed support block 82, and the slanted support member 88 can then be inserted into the support channels 32 of the frame lateral elements 70. The non-translating block or member can then be locked in place. The second end element is then introduced and secured in order to complete the assembly with completely separated end elements and side elements. For extrudates having bendable creases, the frame 20 may then be removed from the tool 110 and the extrudate 22 may then be bent at the creases 52c and 52d to close the frame, with frame end elements. 72a and 72b engage the end plate 78, the feeler flange 50 is pressed against the end edge 128 of the end plate 78, fasteners are introduced along that edge, and the bottom flange 44 is attached to the end element. Engage with. As previously described and shown in FIG. 10C, angled support blocks may be used to provide additional rigidity by engagement across the support channels 32 of abutting frame end elements 72a and 72b. The actuating element of the refracting structure 10 and the moving pedestal 22 may then be suitably introduced into the block or into the central plate or end plate, and the refracting structure is attached to the moving pedestal and the actuating element.

Bed bolsters can be made in a linear process similar to frame extrudates and have extruded foam, which can be expanded polyethylene (EPE) or similar material, can be provided in long lengths or directly from the extruder. Work can be done. The entire length of the bolster can be cut and a score can be formed to bend the bolster at the frame corners. The previously referenced co-pending US patent application Ser. No. 12/942,916, in which the shape of the perforations that provide curved folds at the corners has common assignee with the present invention (title “Bed Frame for an Adjustable Bed”). The fabric can be applied to the EPE foam with an adhesive roll process, or an alternative spray finish can be applied to the foam. The scored foam is then inserted into the grip flanges 36 and 42 of the extrudate 22. Alternatively, the coated foam may be cut to length corresponding to the frame side elements 70 and end elements 72 and introduced to each element separately. Corner finishing elements 136, which may include bed legs, may then be secured to the corners by inserting capture flanges 138 into the exposed accessory or support channels 32, as shown in FIG. The corner finishing element may be the top cap 137 and may simply provide the flange continuity of the support channel around the corner as shown in FIG. 11C.

Similarly, the bed frame 10 may be physically joined by using a coupling fitting 139, with the flange element 140 then exposing the exposed support channel 30 of the end element 72 of the adjacent frame as shown in FIG. Is engaged with. This allows combining frames with separate refractive structures into a single bed, for example a king bed size with two twin size refractive assemblies and frames. The prior art requirement for multiple legs as shown in FIG. 20 is now removed, allowing the king size to be formed from a pair of twin sizes as shown in FIG.

Extrudate 22 may further include molding elements to provide a finished surface on some or all of the outer surface of the frame. As shown in FIGS. 22A and 22B, an upper gripping flange 36 ′ may extend from a midpoint of the outer flange 40, and a finished box-like element 102 a or 102 b is included in the extrudate and includes at least one of the frames. The part may be provided with a substantially finished surface. The relative heights of the finished box-like element and the cloth padded bolster 94 can be adjusted by positioning the upper gripping flange 36' as desired, as shown in Figures 22C or 22D.

Similarly, mounting the headboard to the bed can be easily handled as shown in FIG. An engagement angle 142 is inserted into the open head end of the support channel 32 of the frame side element 70 and secured using a dipping screw as previously described for the securing element. A mounting plate 144 extends perpendicular to the insert flange 146 for mounting the headboard.

While various embodiments of the invention have been described in detail herein as required by patent law, one of ordinary skill in the art would appreciate that modifications and substitutions to the specific embodiments disclosed herein. You will recognize. Such modifications are within the scope and spirit of the invention as defined in the following claims.

Claims (7)

In the frame for the refractive bed,
A top inner flange (26), a bottom inner flange (28), a bottom flange (44), a feeler flange (50) extending from the bottom flange (44), the top inner flange (26) and the bottom inner. An extruded beam (24) having a support channel (32) formed in a flange, wherein a lower edge of the upper inner flange (26) terminates in an upper runnade (46). (28) an extruded beam material (24) terminated at the upper edge of the lower runnabide (48) to form frame lateral and end elements;
A head end plate and a foot end plate, engaged and fixed to the bottom surface of the bottom flange, extending between the frame lateral elements, wherein the feeler flange is the head end plate. And a head end plate and a foot end plate engaging with side edges and end edges of the foot end plate,
A plurality of support elements (60, 67) housed in and supported by the support channels, the support elements (60, 67) engaging a moving pedestal (22) supporting a bearing surface portion of a refractive structure. 67) and
The extruded beam includes a score line extending through the extruded beam to leave the upper inner flange and the lower inner flange , the side beam and the lateral element being bent at a predetermined angle at the score. Frame for a refraction bed, characterized in that end elements are formed. The frame for a refraction bed according to claim 1, wherein the support element is translatable within the support channel. A frame for a refraction bed according to claim 1, characterized in that the extruded beam material further comprises accessory channels (38, 39). The frame for a refraction bed according to claim 1, wherein the extruded beam material further comprises an upper gripping flange (36) and a lower gripping flange (42), wherein the frame for the refraction bed further comprises the upper gripper. Frame for a refraction bed, comprising a foam bolster (94) engaged between the flange and the lower grip flange. The frame for a refraction bed according to claim 4, wherein the foam bolster is covered with a cloth. The frame for a refraction bed according to claim 1, further comprising a plurality of fixed support blocks (82) housed in the support channels and engaging structural elements of an actuation system for the refraction structure. A frame for a refraction bed. The frame for a refraction bed according to claim 1, wherein the extruded beam material further comprises a bottom flange (44), and the frame for the refraction bed further comprises a foam bolster engaging on the bottom flange. A frame for a refraction bed, characterized in that the foam bolster incorporates a mounting support that is fastened to the extruded beam material with elastic flexible spacers (103) extending above the support channels. ..

Images