Abstract:
A unitary headboard comprises a single piece of laminated plywood that has two posts and at least one cross piece cut out of it. A bed frame comprising side rails and cross supports has each side rail formed of a single piece of material. Each side rail has a support ledge and a lip where the foundation extending between the side rails can be selected from springs or boards at the user&#39;s option.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
   This application claims the benefit of U.S. Application Ser. No. 60/481,329 filed Sep. 4, 2003. 

   FIELD OF THE INVENTION 
   The invention relates to beds and more particularly to the structure and fabrication of headboards and bed frames. 
   DESCRIPTION OF THE RELATED ART 
   Case goods sold to institutions such as schools and colleges often include beds comprising wooden headboards and metal bed frames. The term “headboards” typically includes both headboards and footboards, since they are usually identical at least in dimension. Consequently, beds can optionally be stacked atop one another to form bunk beds and save space. Also, in colleges especially, it is common to mount the headboards on extenders so that the bed will be elevated, providing space beneath the bed for desks, chairs and the like. 
   Wooden headboards are typically fabricated from two posts and at least one crosspiece extending between the posts. The crosspiece is joined to the posts by doweling and gluing or by mortise and tenon joints. Under normal use, this ancient construction serves adequately, but with heavy institutional use and with changes in climate (e.g., temperature and humidity), it is not uncommon for the joints to loosen. This will typically increase maintenance costs and possibly diminish the durability of the bed. 
   Bed frames are commonly fabricated from angle iron side rails and end rails, welded together in a square with one or more reinforcing pieces extending between the side rails. Springs or wires are strung between the rails to support a mattress. A mounting bracket adapted to hang on pins in each post of a headboard is riveted to a side rail at each corner of the bed frame. Frequently the joints between the mounting brackets and the side rails loosen under heavy use, leading to early failure of the bed frame. 
   This problem was solved by the development of a unitary side rail by Norse Furniture Company where the mounting brackets are integrally formed with the side rail. The unitary rail is typically formed first by stamping and then by rolling selected edges to stiffen the rail and provide mounting surfaces for springs and the like. It is known to mount plywood boards in place of the springs in the bed frame. The boards are typically bolted to the side rails. While the unitary side rail solves the problem of loosening joints found in earlier side rails, the assembly of the bed remains labor-intensive. Moreover, manufacturers have to stock two different types of bed frames, one for springs and another for boards. As well, problems with fabricated headboards remain. 
   SUMMARY OF THE INVENTION 
   These and other problems are solved by the present invention of a unitary headboard comprising two posts and at least one cross support extending between the posts. The posts and the cross support are integrally formed from a single piece of material and are capable of supporting a bed frame. Preferably, the posts and the cross support are integrally formed from a single piece of plywood. 
   The headboard can further have a stacking projection extending from an upper end of each post. Preferably, the stacking projection is integrally formed from the same piece of material as the posts and the cross support. In like manner, the headboard can have a stacking recess in a lower end of each post. The stacking recess is preferably complementary in shape to the stacking projection. 
   In one aspect, the cross support can be a stylized shape. Also, a bedpost unit can be mounted to each post. Likewise, a tab insert channel can be disposed in each post. 
   Another aspect of the invention is found in an improvement in a bed frame comprising side rails and cross supports. Each side rail is formed of a single piece of material and comprises an upwardly extending lip and a support ledge extending generally horizontally from the lip. 
   Each side rail further has a reinforcement flange. Preferably, the support ledge comprises holes adapted to receive springs. Thus, the bed frame is adapted to handle both springs and foundations such as wood. Preferably, the lip extends above the support ledge less than 50% of the height of the side rail. As well, a gusset at each end of the side rail extends above the support ledge. 
   In yet another aspect of the invention, an improvement is provided in a bed comprising two headboards spaced from each other and a bed frame mounted to and extending between the headboards. One of the headboards is a unitary headboard comprising two posts and at least one cross support extending between the posts. The posts and the cross support are integrally formed from a single piece of material and are capable of supporting the bed frame. 
   Preferably, the posts and the cross support of the unitary headboard are integrally formed from a single piece of plywood. Also, the cross support of the unitary headboard can be a stylized shape. 
   Further, the bed frame has side rails where each side rail has an upwardly extending lip and a support ledge extending generally horizontally from the lip. Each side rail can also have a reinforcement flange. The support ledge includes holes adapted to receive springs. Preferably, the lip extends above the support ledge less than 50% of the height of the side rail. And the side rail can have a gusset at each end of the side rail, wherein the gusset extends above the support ledge. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings: 
       FIG. 1  is an exploded view of a headboard according to the invention. 
       FIG. 2  is a perspective view of an alternative embodiment of a headboard according to the invention. 
       FIG. 3  is a side view of a portion of a side rail for a bed frame according to the invention. 
       FIG. 4  is a cross sectional view of the side rail taken along lines  4 — 4  of  FIG. 3 . 
       FIG. 5  is a perspective view of a bed frame according to the invention. 
       FIG. 6  is a perspective view of an alternative embodiment of a bed frame according to the invention. 
       FIG. 7  is an exploded fragmentary view of two headboards according to the invention. 
       FIG. 8  is a fragmentary view of the two headboards of  FIG. 7  joined together. 
   

   DETAILED DESCRIPTION 
   Looking now at the drawings, the invention is embodied in a bed made up of a pair of unitary or single piece headboards  10  and a unitary bed frame comprising a pair of single piece side rails  36 . The single piece headboard  10  includes any structure that forms the head or foot of the bed, and which is crafted as a single unit, i.e., one without joints. The single unit can be blocked out of a larger piece of material using any number of cutting or material removal methods, including but not limited to, blanking out the material using a press or other blanking device or cutting the material using an automatic programmed machine such as a computer numerical control (CNC) machine or manual cutting. Cutting tools employed could include, but are not limited to, wire electrical discharge machining (EDM), mechanical blades, lasers, ultrasonic or water jet streams, a lathe, a mill, or other cutting devices. The single unit can also be created from a collection of smaller units forming a single mass including, but not limited to, any molding, sintering, or material deposition operation. 
   Preferably, a sheet of high-grade plywood of a common thickness such as three-fourth inch could serve as the single piece headboard  10  material as could any other suitable material including, but not limited to, any wood, plastic, metal, ceramic, or fiberglass. 
   Referring first to  FIGS. 1 ,  7  and  8 , the headboard comprises a pair of posts  12  with at least one cross support  14  extending between them. The pair of posts  12  is integrated as a single piece of material with the cross support  14  at intersection points  22 . As shown in  FIG. 1 , the headboard  10  can include multiple cross supports  14 , in which case the space between adjacent cross supports is preferably sized to be compliant with locally applicable law and regulations. 
   Each post  12  can be any shape such as columns, cylinders, oblong shapes, or any of a number of stylistic shapes so long as it provides adequate vertical support for the single piece headboard  10 . Each cross-support  14  likewise can be any shape including stylistic shapes and letters so long as it provides adequate support in compression or tension between the posts  12  of headboard  10 . See  FIG. 2  for illustration of a stylized form of cross piece  14 . 
   A stacking projection  18 , which can be either a projection that is centered on top of each of the two posts or any number of projections located elsewhere, is preferably integrated as a single piece with post  12 , with cross support  14 , with both, or with any part on the headboard  10  at an intersection point  24 . The stacking projection  18  can also be a dowel or pin that is secured in the post  12 . A stacking recess  20  is disposed at the opposite end of each post  12 , and is a recess that can be created by material being removed or omitted during fabrication. The stacking recess  20  can be either a recess centered at the bottom of the each of the posts or any number of recesses located elsewhere on the single piece headboard  10  as shown in  FIG. 1 . 
   The stacking projection  18  can be any suitable shape for which the stacking recess  20  is complementary so that the projection  18  can be received snuggly in the recess  20  to form a joint  68  illustrated in  FIG. 8 . Here the stacking projection  18  is a monolithic shape with dimensions nearly identical to, but slightly smaller than, stacking recess  20 . Preferably, the stacking recess  20  is sized to provide a close tolerance fit with the stacking projection  18 . 
   The joint  68  is at a location in which the stacking projection  18  of a first single piece headboard  10  comes within near proximity of the stacking recess  20  of a second single piece headboard  10 , as in the case when one bed is stacked on top of another. Such a joint is particularly illustrated in  FIGS. 7 and 8 . The joint  68  can function to prevent any misorientation or slippage between the two single piece headboards when they are stacked or otherwise touching in a case where orientation or stability is important. The stacking projection  18  and the stacking recess  20  can also function to prevent any misorientation or slippage between the single piece headboard  10  and other furniture that contains stacking supports and stacking recesses that can interact with the stacking supports  18  or the stacking recesses  20 . 
   One or more additional bedpost units  26  can be secured to the front, back, or both front and back of the post section  12  of the single piece headboard  10  as shown in  FIG. 1  to provide additional bulk to the posts  12 , to increase their supporting capacity, and to render an appearance that is more traditional. Inasmuch as a preferred material for the single piece headboard  10  is plywood, a preferred material for the additional bedpost units  26  is also plywood of the same composition as the single piece headboard. When secured to the posts  12 , the additional bedpost units  26  effectively become a continuation of the plywood lamination of the posts. Each additional bedpost unit  26  can be oriented on its corresponding post  12  by using pegs  35  that can be received in corresponding orientation apertures  16  on the post  12  and bedpost orientation apertures  28  on the additional bedpost unit  26 . The location of the respective apertures  16 ,  28  can be disposed as appropriate and convenient, depending upon a particular configuration. Once the additional bedpost unit  26  and corresponding post  12  are properly in register, the additional bedpost unit  26  can be fastened to the headboard  10  using glue, fasteners, or other methods. 
   The orientation aperture  16  and the bedpost unit orientation aperture  28  can be holes cut by the CNC machine in the initial cutting step, or they can be any depression or hole in which the peg  35  can interact. The peg  35  could be a cylindrical shape as shown in  FIG. 1  or it could be any shape, that can fit or rest inside orientation aperture  22  and the bedpost unit orientation aperture  26  and the exact shape is understood not to be limiting on the scope of this invention. The post  12  could provide adequate support without the additional bedpost unit  26 . 
   While the additional bedpost unit  26  can provide additional structural support for the single piece headboard  10  or the single piece head board  10  stacked with another bed unit or other furniture, its presence is understood not to be limiting on the scope of this invention. 
   A tab insert channel  32 , with a series of tab insert locations  34 , provides support for a bed frame as explained below. The tab insert channel  32  is a long, “U-shaped” channel that can be made to a length somewhat shorter than the height of the post  12  and can be comprised of steel or any other suitable material. The tab insert locations  34  can be notches stamped, pressed, or otherwise shaped into the tab insert channel  32  or, preferably, they can be pins made out of the same material as tab insert channel  32  or another suitable material, and are welded, fastened, peened or otherwise attached to the tab insert channel  32 . Each tab insert location  34  could serve as a height adjustment location when attaching a bed frame to the single piece headboard  10 . 
   Each single piece headboard  10  has a tab insert channel  32  mounted to each one of the two posts  12  or into the two of the additional post unit  26 , using glue, fasteners, compression fit, or other attachment methods. The tab insert channel  32  can also be mounted at any number of other locations in the headboard  10 . A recess  30  can be made in the additional bedpost unit  26  or the posts  12  so the tab insert channel  32  will be recessed into the headboard  10  or into the additional bedpost unit  26 . The recess  30  can be any depression or opening made by either removing or omitting material during the initial fabrication process, or removing material after fabrication of the single piece headboard  10  or the additional bedpost unit  26 . 
     FIGS. 3–6  illustrate elements of a bed frame  54  according to the invention, which can, but need not, be used with single piece headboards  10  as described above.  FIG. 3  depicts a single piece side rail  36  of the bed frame  54 . The single piece side rail  36  can be any structure crafted as a single unit that is positioned along either one or both sides of the bed frame  54 . The single unit can be blocked out of a larger piece of material using any number of cutting or material removal methods including but not limited to blanking out the material using a press or other blanking device or cutting using an automatic programmed machine such as a computer numerical control (CNC) machine or manual cutting. Cutting tools employed can include, but are not limited to, wire electrical discharge machining (EDM), mechanical blades, lasers, ultrasonic or water jet streams, or other cutting devices. The single unit can also be created from a collection of smaller units forming a single mass including, but not limited to, any molding, sintering, or material deposition operation. 
   A number of different steels could serve as the material for the single piece side rail  36  as could any other suitable material including, but not limited to, any wood, plastic, metal, ceramic, or fiberglass. 
   The single piece side rail  36  includes a railing  38 , a reinforcement flange  40 , a support ledge  42 , a gusset  44 , and a fastening tab  46 . The railing  38  is the main horizontal support and extends from the first gusset  44  to the second gusset  44  or to the end of the single piece side rail  28 . The fastening tab  46  contains two or more tabs which preferably are shaped like flat “J-shaped” hooks and are used to hang the single piece side rail  28  with on the tab insert locations  34  of the tab insert channel  32 , or similar structure in a headboard. The fastening tabs  46  can be located at the end of the gusset  44  or the end of the railing  38 . 
   The support ledge  42  is integrated as a single piece of material with the railing  38  by rolling over a portion of the railing  38  at bend  50  and also rolling a bend  52  so that the support ledge  42  extends generally perpendicularly from the railing  38 . Similarly, a reinforcement flange  40  is a long segment running parallel to the single piece side rail  36  and preferably integral with it. The reinforcement flange  40  provides additional strength to the single piece side rail  36 . The reinforcement flange  40  can be formed by rolling over a portion of the railing  38  at bend  48 , at an inward angle preferably between zero and ninety degrees. The reinforcement bar can extend along the length of the railing  38 . 
   Preferably, the distance between the bend  50  at the top of the railing  38  and the bend  52  where the support ledge  42  extends away from the railing is less than 50% of the distance between the bend  50  and the bend  48 , preferably 25%. That distance defines a lip  53  adjacent to the support ledge. 
   The gusset  44  is a support structure that can be any relevant shape, comprising enough material to provide strength and stability near the junction with the headboard. The side rail  36  can have the gusset  44  on either or both ends of the rail. The gusset  44  preferably protrudes above the support ledge  42 , rather than below the railing  38  as in the prior art. Consequently, a clean horizontal line beneath the side rail  36  can be seen all the way to the headboard to which it is mounted, allowing for additional space underneath the bed frame where items such as furniture can be placed freely against the headboard. 
   The single piece side rail  36  can be manufactured by cutting the shape required for the railing  38 , the reinforcement flange  40 , the support ledge  42 , the gusset  44 , and the fastening tab  46  from a single flat piece of steel. The reinforcement flange  40  and the support ledge  42  can then be bent into the positions shown in  FIG. 4  or similar positions using roll forming or another bending method. 
     FIG. 5  illustrates an embodiment of a bed frame  54  comprising a pair of cross supports  56  attached to each end of two single piece side rails  36  on top of the support ledge  42 . The cross supports  56  can be welded to the side rail  36 , but can also be attached by using fasteners or by other methods. Preferably, at least one cross support  56  has a lip  57  and support ledge  59  sized roughly equivalent to the lip  53  and support ledge  42  of the side rails  36 . Additionally or alternatively, at least one cross support  56  can be angle stock  61 . A pair of cross braces  63  serves to keep the side rails  36  roughly parallel. A number of support ledge holes  58  can be created at various spots in the support ledge  42  which can allow a system of springs  60  to be attached through the support ledge holes  58  to the bed frame  54 . The system of springs  60  are coils of metal or any other material of any shape that can be drawn between two or more side rails that can support a mattress. 
     FIG. 6  illustrates an alternative to the system of springs  60 , wherein a series of boards  64  form a foundation in the bed frame  54 . The series of boards  64  define a flat support surface that can consist of a single board or multiple boards made out of wood, metal, plastic, or other materials. An indentation  66  can be fabricated in various locations in the support ledge  42  of each single piece side rail  36  to hold the boards in the series of boards  64  apart from each other. The indentations  64  can be any elevation made by distorting or adding additional material to a section of the support ledge  42 . The series of boards  64  can support a mattress. The lips  53 ,  57  prevent the boards and any mattress thereon from moving laterally, retaining them over the bed frame  54 . 
   While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.