Bed base

A bed base comprises a rectangular support having side members connected at corners by a corner connector assembly including a locator element in a leg of a plate member that interacts with a locator element in a side member. A cross-rail assembly includes an elongated bar member that fits in notches in upper edge sections of opposed side members and a pair of leg members near opposed ends the elongated bar member pass through the notches upon attaching the cross-rail assembly to the rectangular support.

INCORPORATION BY REFERENCE

Any and all U.S. patents, U.S. patent applications, and other documents, hard copy or electronic, cited or referred to in this application are incorporated herein by reference and made a part of this application.

DEFINITIONS

The word “rectangular” includes square.

BACKGROUND

U.S. Pat. Nos. 6,865,758; 6,925,666; and 7,155,762 disclose bed bases made from sheet metal and include side members connected at corners. One or more cross-rails span the width of the bed base, adding rigidity and support for a box spring and mattress. It is desirable to simplify the construction and assembly of the components of the bed base and reduce the cost of manufacture.

SUMMARY

My bed base has one or more of the features depicted in the embodiment discussed in the section entitled “DETAILED DESCRIPTION OF SOME ILLUSTRATIVE EMBODIMENTS.” The claims that follow define my bed base, distinguishing it from the prior art; however, without limiting the scope of my bed base as expressed by these claims, in general terms, one or more, but not necessarily all, of its features are:

One, my bed base employs a unique corner connector assembly to attach together adjacent side members of my bed base. This corner connector assembly has a pair of plate members and means for attaching the plate members together. The plate members are formed by a stamping a sheet steel plug. The attaching means may be a post element, for example, an elongated rod that extends between upper and lower aligned plate members. The post element may have an enlarged head at one end and a threaded portion at an opposed end. The lower plate member may include a threaded receptacle that receives the threaded end of the elongated rod. In one embodiment, the upper and lower plate members are essentially identical, except for the threaded receptacle.

Two, each plate member may include a pair of arms at a right angle. The pair of arms may have outer wall elements along outer edges of each arm that are substantially at a right angle to each other and to the arm to which they are attached and inner wall elements along inner edges of each arm that are substantially at a right angle to each other and to the arm to which they are attached. These inner and outer wall elements form a right angle channel in the plate member. A locator element in each arm of the plate member is adapted to engage and interlock with a locator element in each side member end of adjacent side members. At least some of the locator elements may comprise holes, and at least some of the locator elements may comprise projections that fit snugly within the holes.

Three, the post element may extend between and fasten together the upper and lower plate members and the locator elements on the plate members are interactive with the locator elements on side members. These locator elements engage and interlock upon insertion of the planar support members of the side members into the right angle channel of the upper plate member and insertion of the lower planar support member into the right angle channel of the lower plate member. For example, the locator elements on the plate members may be hollow cylindrical projections formed by stamping. There is a pair of such cylindrical projections in each individual plate member, one received in a circular hole functioning as a locator element in each adjacent planar support member. The circular hole has a diameter only slightly greater than the diameter of the cylindrical locator element inserted therein during assembly of adjacent side members. Such interactive locator elements lock together the adjacent side members so they do not separate.

Four, in one embodiment my bed base is a combination of a unique cross-rail assembly and a substantially rectangular mattress support including at least one pair of opposed, substantially parallel side members separated by a predetermined distance. Each side member may have at least one notch in an upper edge section thereof, with the notches in the opposed side members being aligned. The leg members at or near the ends of the bar member are separated by substantially the predetermined distance between the side members so that each leg member is individually received within a notch. In other words, the leg members at or near the ends of the bar member are separated by a distance substantially equal to the predetermined distance between the opposed side members. The cross-rail assembly includes an elongated bar member that extends between the opposed side members and fits in the aligned notches, and at least a pair of leg members, one at or near each opposed end of the elongated bar member. Each leg member passes through one notch in one side member upon attaching a cross-rail assembly to the mattress support. The leg members extend from the bar member in the same direction substantially at a right angle to the bar member. Typically, a third leg member is centrally positioned between the leg members at or near the ends of the bar member. The leg members at or near the ends of the bar member provide rigidity and support for the side members through which they extend.

Five, each side member may include a planar support along an upper edge. The notches are cut into the planar support and the side member and may at least partially surround a leg member extending through the notch. Each notch is configured and dimensioned so an exterior surface of the elongated bar member is substantially flush with an exterior surface of the planar support member upon attaching the cross-rail assembly to the rectangular support. This may be achieved by forming an aperture in the upper edge of the side member. For example, an inner edge of the upper planar support member may terminate in an inwardly oriented foot element that is substantially at a right angle to the upper planar support member and substantially parallel to the side member. Each notch partially extends into the foot element as well as through the upper planar support member and its side member to form the aperture. This aperture has essentially the same overall configuration and dimensions as the cross-section of the leg member extending therethrough. In one embodiment, the bar member and leg members at or near the ends of the bar member each may have a substantially rectangular cross-sectional configuration of substantially the same dimensions and the apertures formed by the notches have a substantially rectangular cross-sectional configuration of substantially the same dimensions as the leg members at or near the ends of the bar member.

Six, each side member may have a lower planar support member opposed to the upper planar support member. The planar support members extend inwardly substantially at a right angle to the side member from which the planar support members extend. Each lower planar support member may have an opening therein aligned with the notch in the upper planar support member. The leg members have a predetermined length so that, upon attaching the cross-rail assembly to the rectangular support, each leg member terminates next to the opening aligned with the notch through which the leg member extends. Each leg member may terminate at a lower end in a slider element that is next to an exterior surface of the lower planar support member.

These features are not listed in any rank order nor is this list intended to be exhaustive.

DETAILED DESCRIPTION OF SOME ILLUSTRATIVE EMBODIMENTS

As illustrated inFIG. 1, my bed base10includes three major structures: a rectangular support assembly16, a corner connector assembly12, and a cross-rail assembly14, each of which is interactive with side members16athrough16dto form my bed base for a box-spring mattress18shown in dotted lines inFIG. 2. One pair of substantially parallel side members16aand16care separated by a predetermined distance d1and another pair of substantially parallel side members16band16dare separated by a predetermined distance d2. Adjacent side members16aand16b,16band16c,16cand16d, and16dand16aare connected by a corner connector assembly12, providing individual corner connectors200a,200b,200c, and200din the respective corners70a,70b,70c, and70dof the rectangular support assembly16. Three cross-rail assemblies14connect the opposed side members16band16d. In general, the individual components of my bed base10are mainly made from metal tubes and sheet metal and formed using conventional stamping, welding, and bending techniques. The illustrated bed base10is sized to support a standard box-spring mattress18.

InFIG. 1the one embodiment of my bed base10is shown fully assembled. Kits of the disassembled components may be sold for different sizes, for example, twin, standard, queen, king and even custom size. The purchaser would assembly the components in the kits to make my bed base.

Rectangular Support Assembly

The rectangular support assembly16includes the four generally rectangular side members16a,16b,16c, and16dthat are first assembled. The individual side members16a,16b,16c,16d, are preferably made from roll formed sheet steel having a thickness of from about 16 to about 20 gauge. The sheet steel is bent into the desired configuration using conventional manufacturing equipment. The opposed side members16band16dare of the same length of about 71 inches and they typically do not vary no matter what the size of the box-spring and mattress being supported. Depending on the size of the box-spring and mattress being supported, the opposed side members16aand16chave a length ranging from about 26 to about 63 inches. For any type of box-spring and mattress being supported, the opposed side members16aand16care of the same length. For example, when a twin size box-spring and mattress is being supported, the length is 26 inches, when a full size box-spring and mattress is being supported, the length is 40 inches, when a king size box-spring and mattress is being supported, the length is 58 inches. All the side members16a,16b,16c, and16d, are of the same width×ranging from about 5 to about 18 inches.

As best shown onFIGS. 5 and 6, each individual side member16a,16b,16c, and16dhas a generally C-shaped cross-sectional configuration comprising a central, longitudinally extending, planar portion C with opposed edges E1and E2. The opposed ends E3and E4of each individual side member16a,16b,16c, and16dare mitered, that is, cut inward at an angle of substantially 45-degrees to enable the formation of a miter joint J at each corner70a,70b,70c, and70dof the adjoining adjacent ends E3and E4of the adjacent side members16aand16b,16band16c,16cand16d,16dand16a. To provide greater rigidity the opposed edges E3and E4each include an inwardly folded rectangular portion80formed from the planar portion C.

There extends outward in the same direction, respectively from each edge E1and E2,22an L-shaped shoulder support/stiffener50and50a. The support stiffeners50and50aface each other, with their feet23aand23bpointing at each other and their legs25aand25boriented horizontally to form longitudinal, planar support members22and22a. Each leg25aor25bis at a right angle to the planar portion C. The individual feet23aand23bextend from an outer tip OT of the leg25aor25b. Each longitudinal support member22and22a, or leg25aand25bhas substantially the same width W, typically from about ¾ to about 1¼ inches. The length of each individual leg25aand25bis usually the same as the length of the side member16a,16b,16c, or16dfrom which it extends.

In the individual side members16band16dthere are three cut out notches N, located on the upper planar support member22of the L-shaped shoulder support/stiffener50, spaced apart a distance which varies depending on the size of the box-spring and mattress being supported. Each individual pair of notches N is set back from the closest end E3or E4, as the case may be, by an equal distance, typically from about 6 to 12 inches. As shown inFIGS. 6,6A and8, the notches N are open along the upper planar support member22and form a guide-way and surrounding support structure for an individual leg member320passing through an aperture A in the upper planar support members22. Each notch N partially extends into the foot23aas well as partially through the planar portion C of a side member to form the aperture A. This aperture A has essentially the same overall configuration and dimensions as the cross-section of the leg member extending therethrough. For example, as illustrated inFIGS. 6 and 6A, the rectangular leg member320has one side with a width W2′ (FIG. 6) equal to the width W2of the aperture A and another side with a width W1′ (FIG. 6) equal to the width W1of the aperture A. When the leg member320is rectangular, the notches N each comprise a pair of substantially U-shaped cut-a-way sections U1and U2of the same configuration and dimensions, one cut-a-way section U1in the foot23aand the other cut-a-way section U2in the planar portion C of a side member. The spaced apart open mouths M of the cut-a-way sections U1and U2form the aperture A.

As depicted inFIG. 6, there are three cut out openings O, located on the lower planar support member22aof the L-shaped shoulder support/stiffener50a, spaced apart a distance which varies depending on the size of the box-spring and mattress being supported. In each side member16band16d, the individual notches N and openings O are in vertical alignment with each other. Upon assembly of my bed base10, the notches N in the side member16bare aligned with and in registration with the notches N in the side member16d.

Near the ends E3and E4of the individual side members16a,16b,16c, and16dthere are cut out holes CH1, CH2, CH3, and CH4. The cut out holes CH1and CH2are punched through the upper planar support member22while the cut out holes CH3and CH4are punched through the lower planar support member22a. Each cut out hole CH1and CH2is interactive with cylindrical post locator elements (not shown) of an upper plate member202of a corner connector assembly12and each cut out hole CH3and CH4is interactive with cylindrical post locator elements250cand250dof the lower plate member204. As discussed below, aligned holes H are formed in each corner70athrough70dat the joint J, allowing an elongated post206to pass from plate202to204, securing these plates together.

As best shown inFIGS. 5 and 5A, in the adjacent side members16aand16bis a cut-a-way h1in each of the legs25aand25bof the side member16aand a cut-a-way h2in each of the legs25aand25bof the side member16b. The cut-a-ways h1and h2are each ½ of a complete hole H that is created by connecting the mitered adjacent ends E3and E4of the side members16aand16bso they abut each other as depicted inFIG. 5A. For example, the hole H may be circular and the cut-a-ways h1and h2may be semicircular. Because the side members16a,16b,16c,16dare so designed as discussed above, the opposed pairs of side members16aand16c, and16band16d, are mirror images.

Corner Connector Assembly

Identical corner connector assemblies12are used so my bed base10has respectively at each of its corners70athrough70didentical corner connectors200a,200b,200c, and8200d. For example, as shown inFIGS. 5,6, and7the corner connector200asecurely connects the adjoining, adjacent ends E3and E4of the side members16aand16bat the corner70a. The four side members16a,16b,16c, and16ddo not have any other connection device other than the identical corner connectors200a,200b,200c, and200dat their respective adjacent ends E3and E4, which form and hold the corners70athrough70dfirmly together.

The corner connector200ashown inFIGS. 5,6, and7is illustrative of all the corner connectors200a,200b,200c, and200d. The illustrative corner connector200aincludes (a) a top plate member202, (b) a bottom plate member204with an internally threaded tubular receptacle224(FIG. 7) connected via an annular flange226to the underside of the bottom plate204, and (c) an elongated post206to securely join the top plate and bottom plate. The top plate202and the bottom plate204have substantially identical configurations and dimensions, for example, each includes a pair of arms202a,202band204a,204bthat are at a right angle to each other. The top plate202and the bottom plate204each have therein a right angle channel209and each include an outer right angle wall210and an inner right angle wall220. The outer right angle wall210is opposed to and in registration with the inner right angle wall220.

As best shown inFIG. 5B, the outer right angle wall210is divided into two sections210aand210bwith adjacent ends210cand210dtouching or almost touching. Upon assembly, the section210aextends along an exterior surface of the planar portion C of the side member16a, and the section210bextends along an exterior surface of the planar portion C of the side member16b. As best shown inFIG. 5, the top plate202has an inner right angle wall220that is divided into two sections220aand220bwith a gap G between adjacent ends220cand220d. The section220aextends along the foot23aof the L-shaped support stiffener50of the side member16a. The section220bextends along the foot23bof the L-shaped support stiffener50of the side member16b. As best shown inFIG. 5, the bottom plate204has an inner right angle wall220that is divided into two sections220aand220bwith a gap between adjacent ends220cand220d. The section220aextends along the foot23aof the L-shaped support stiffener50aof the side member16a. The section220bextends along the foot23aof the L-shaped support stiffener50aof the side member16b. The inner right angle wall220, and the outer right angle wall210form the right angle channels209respectively in the top plate202and bottom plate204of the corner connector assembly12. The channels209have widths W1about equal to the width W of the L-shaped support stiffeners50and50a.

The top plate202and bottom plate204each have therein holes203aand203bthat are vertically aligned when the plates202and204are mounted at the ends E3and E4of the side members16aand16band form the corner70aas depicted inFIGS. 5 and 6. The plates202and204each include a pair of holes213aand213b, one hole in each arm of the plates. These holes213a, and213bare stamped through the plates202and204. As shown inFIG. 5, this process produces cylindrical post locator projections250cand250dextending from the underside of the plates202and204.

The right angle, adjoining adjacent ends E3and E4of the side members16aand16bare connected by the corner connector200awith the top plate202and the bottom plate204positioned so their right angle channels209overlap these ends as shown inFIGS. 5 and 6. The cylindrical post locator projections250cand250drespectively engage and interlock with the cut out holes CH1and CH2in the upper planar support member22of the side members16aand16b, and with the cut out holes CH3and CH4in the lower planar support member22aof the side members16aand16b. The elongated post206couples together the top plate202and the bottom plate204. The elongated post206extends between the plates,202and204, and is positioned through a hole H that is created by adjoining the mitered adjacent ends E3and E4of the corner70a.

As illustrated inFIG. 5, the elongated post206has an enlarged head end206aof greater diameter than the hole203aand a threaded lower end206b. Upon assembly, the post206passes through the hole203aand the enlarged head end206abears against an exterior surface of the top plate202. As depicted inFIG. 7, the threaded lower end206bis screwed into an internally threaded tubular receptacle224, that has been forced fitted into the hole203bin the bottom plate204. The receptacle224, located on the underside of the bottom plate204, has an annular flange226(FIG. 5) projecting outward from a side of the receptacle The flange226assists in securing the tubular receptacle224to the bottom plate204. The length of the post206is sufficient so that its threaded lower end206bextends into the cylindrical tubular receptacle224.

During assembly of the bed base10, the plates202and204are respectively mounted on the upper edge UE and lower edge LE of the adjacent side members16aand16b,16band16c,16cand16d,16dand16a, thus forming the individual corners70athrough70dof the rectangular support structure16. The right angle channels209of the top plate202and bottom plate204respectively receive therein the upper edge UE and lower edge LE, including the leg support members25aand25bof the planar support member22and the foot support member23bof the planar support member22a. The top plate202overlaps the upper edge UE of the adjacent side member's16aand16band the bottom plate204overlaps the lower edge LE of the adjacent side members16aand16b. As the threaded end206bof the post206is screwed into the cylindrical tubular receptacle224, the top plate202and bottom plate204are connected together and drawn towards each other so these plates each bear snugly against the edges UE and LE including the upper planar support member22and lower planar support member22aof the adjacent side members16aand16b, thus forming the individual corner connector200aof the corner70a. The planar support members22and22a, having widths equal to the width of the channels209, fit snug within the channels209.

Cross-Rail and Side Member Assembly

As best illustrated inFIG. 6, each cross-rail assembly14comprises an elongated bar member310and three leg members, opposed outer leg members320and an optional third leg member320acentered approximately in the middle of the elongated bar member310. The bar member310and leg members320and320amay each have substantially rectangular cross-sectional configuration of the same dimensions. Each individual leg member of the pair of leg members320is located near the elongated bar member's310opposed ends E10and E11. The leg members320and320aall project in the same direction at a right angle to the elongated bar member310. The leg members320and320aare of substantially the same length and each leg terminates at an open lower end325. The elongated bar member310terminates at opposed ends E10and E11in a stop element340. The stop element340is shaped in the form of an L-shaped arm350. The stop element340is separated by a distance greater than the predetermined distance between the opposed side members16band16dto accommodate the box-spring mattress18. The L-shaped arm350of the stop element340prevents the box-spring mattress18from sliding off the bed base10.

FIGS. 6 and 6Abest illustrate the configuration and dimensional relationship between a notch N and an individual leg member320received within the notch. For example, an individual notch N in the side members16band16dis sized and configured to receive both the elongated bar member310and an individual leg member320. For example, with the elongated bar members310and the individual leg members320substantially rectangular and of substantially the same dimensions, the depth, breath, and shape of each notch N enables the elongated bar member310to fit snug within the notch N and horizontally oriented with an individual leg member320projecting through an upper planar support member22and extending downward to the opening O in the lower planar support member22a. This arrangement of components and their configuration and dimensions, creates an exposed exterior surface ES of the elongated bar member310that is substantially flush with an exterior surface ES1of the upper planar support member22located on the side members16band16d, resulting in a flush surface FS (FIG. 1) supporting the box-spring mattress18. This allows the box spring mattress18to lay flat on top of the planar support members22of the rectangular support structure16.

As illustrated inFIGS. 1 and 6, when the cross-rail assembly14is placed at a right angle to the side members16band16d, individual leg members320in each cross-rail assembly14pass through an individual notch N in the planar support member22and fit snugly against the interior surfaces of SS4of the side members16band16d. The leg members320, which are within the support assembly16, are separated by a distance d2that is substantially equal to the predetermined distance between internal surfaces of the opposed side members16band16d. Because of their length, rigidity, and position immediately adjacent the interior surface SS4of the side members16band16d, the leg members320provide support for the side members16band16dso that, even through these side members are of thin sheet metal, they do not buckle. With the individual openings O aligned with individual notches N, the lower ends325of the leg members320are then next to an interior surface SS5of the lower planar support member22a. As shown inFIG. 8, a slider element330passing through an opening O is screwed into a threaded internal element321in the open lower ends325of the leg members320. My bed base10rests on an external surface330aof the slider element330upon assembly and is oriented substantially horizontally.

As shown inFIG. 9, an alternate embodiment of my cross rail assembly14ahas a leg member320bwith a terminal end E8that extends a very slight distance through a rectangular opening O′ in the lower planar support member or stiffener leg25b. The dimensions of the rectangular opening O′ are slightly greater than the rectangular perimeter of the leg member320b. A slider element330is connected to the terminal end E8.

My corner connector assembly and combination of the cross-rail assembly and opposed side members are illustrated in the same embodiment, namely, my bed base10. My corner connector assembly and cross-rail assembly-side members combination may, however, be used independently of each other.

SCOPE OF THE INVENTION

The above presents a description of the best mode I contemplate of carrying out my bed base, and of the manner and process of making and using it, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which it pertains to make and use my bed base. My bed base is, however, susceptible to modifications and alternate constructions from the illustrative embodiment discussed above which are fully equivalent. Consequently, it is not the intention to limit my bed base to the particular embodiment disclosed. On the contrary, my intention is to cover all modifications and alternate constructions coming within the spirit and scope of my bed base as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of my invention: