Bedding product with angled wedges for tilt feature

A bedding product such as an adjustable bed comprises a stationary frame which is inclined regardless of the position of the adjustable bed. The stationary frame is supported by multiple leg assemblies of different heights. Due to wedges sandwiched between the leg assemblies and mounting brackets of the stationary frame, the leg assemblies remain flat on the ground providing a stable support for the bedding product. Each leg assembly is secured to one of the mounting brackets.

FIELD OF THE INVENTION

This invention relates generally to bedding products such as bedding foundations and adjustable bed bases.

BACKGROUND OF THE INVENTION

Conventional bedding products often have a rectangular frame comprising two opposed side rails with a plurality of cross support members, or slats, extending across the side rails for supporting a box spring or foundation. Bed frames, for example, may further include several other components such as support leg assemblies which are usually secured to the side rails or cross members to support the bed frame about the floor. Such bed frames are typically manufactured and shipped to various retail outlets for offering to end consumers.

Adjustable bed bases are another bedding product having a rectangular frame. A deck or platform comprising multiple planks or boards hinged to each other for movement is attached to the rectangular frame. Leg assemblies are commonly attached to the frame to raise the adjustable bed base off the floor. Usually one or more motors underneath the platform cause lifting members to raise one or more of the planks or boards, which raises one or both ends of a mattress supported by the adjustable bed base platform.

Sometimes customers wish to incline a bedding product such that the head end of the bedding product is above the foot end of the bedding product. Some situations in which such an incline would be desirable include if the person using the bedding product is ill or wants to eliminate snoring. Alternatively, sometimes customers wish to raise the foot end of the bedding product is above the head end of the bedding product for medical or personal reasons.

Therefore, it would be desirable to be able to keep the frame of a bedding product like an adjustable bed base or a bed frame at an inclined position. In the case of an adjustable bed base it would be desirable to keep the frame of the adjustable bed base at an inclined position when the deck or platform of the adjustable bed base is flat or planar.

Manufacturers attempt to package the bed frames in an efficient and cost-effective manner. This often requires that various components of the bed frames be packaged in an unassembled state such that subsequent assembly is required before the consumer may use the bed frame. By way of example, the support legs may not come assembled to the bed frame. As a result, the practice of shipping such components separately, in an unassembled state, involves considerable amounts of time and cost for both the manufacturer and end-user.

Conventional assembly of a bed frame, for example, often requires hardware and tools, such as wrenches, screw drivers, etc. Accordingly, proper assembly relies on the retailer or consumer having the proper tools readily accessible. It can be frustrating when the person starts assembling the bed frame but then learns that they lack the proper tools required to complete the assembly. Moreover, proper assembly of the bed frame may be dependent on the skill set of the person performing the assembly. Thus, even with the correct tools, proper assembly of the bed frame may not be achieved. The improper assembly of the bed frame may frustrate the customer and result in negative product perception, phone calls or other communications from unsatisfied consumers, or product return and a demand for a refund.

In view of the above, there is an increasing need for manufacturers to provide bedding products that are easy to assemble and require a minimum number of tools.

It is therefore an objective of this invention to provide a bedding product which may be shipped in a partially assembled state with leg assemblies which may be attached to the bedding frame with wedges therebetween to keep the bedding product in an inclined position.

It is further an objective of this invention to provide a bedding product having adjustable leg assemblies, where a wedge may be sandwiched between each leg assembly and the frame of a bedding product without tools to keep the frame in an inclined position.

It is further an objective of this invention to provide a bedding product having adjustable legs and wedges which may be removed for shipping and storage and secured to a frame of a bedding product without tools.

SUMMARY OF THE INVENTION

According to one aspect of the invention, an adjustable bed base comprises a stationary frame having multiple mounting brackets secured thereto. The stationary frame may comprise opposed side members, a head end member extending between the opposed side members and a foot end member extending between the opposed side members. The mounting brackets may be secured to the stationary frame in any manner such as by welding for example.

The adjustable bed base further comprises multiple leg assemblies. Each of the leg assemblies is secured to one of the mounting brackets at an upper end and has a lower end resting on a supporting surface. Each of the leg assemblies may be adjustable in length. In one embodiment, two of the leg assemblies have a first length, two additional leg assemblies have a second length longer than the first length and two more leg assemblies have a third length longer than the second length.

The adjustable bed base further comprises multiple wedges. Each of the wedges comprises a floor having an opening through the floor and lips extending upwardly from the floor on opposite sides of the floor to help keep the wedge stationary relative to the mounting backet. An opening extends through the floor of the wedge to allow a portion of one of the leg assemblies to pass through the opening and engage one of the mounting brackets. Each of the wedges is sandwiched between one of the leg assemblies and one of the mounting brackets. The wedges incline the stationary frame relative to a support surface or floor. The wedges further keep a bottom surface of each of the leg assemblies flat on the support surface regardless of the length of the leg assembly which provides increased stability to the adjustable bed base. The adjustable bed base remains in an inclined position regardless of the position of the adjustable bed.

The adjustable bed base further comprises a deck comprising multiple deck members hinged to each other. At least one of the deck members is secured to the stationary frame and remains stationary regardless of the positions of the other deck members. Motors function to move the deck members to adjust the position of a mattress supported by the deck. For example, a head end of the mattress may be raised above a lumbar portion of the mattress. Alternative or additionally, a foot end of the mattress may be lowered to raise the knees of someone laying down on the mattress. Due to the wedges of the present invention, when the deck is generally planar and supported by the stationary frame, both the deck and stationary frame are inclined at an angle and not horizontal. In most applications, the angle of inclination is at least two degrees. In other words, the stationary frame has a head end and a foot end, one of the head and foot ends being higher than the other of the head and foot ends regardless of the position of the deck members. An angle defined between a plane extending between the head and foot ends of the stationary frame and a horizonal plane would be at least two degrees.

In another aspect of the invention, the adjustable bed base comprises a stationary frame including multiple mounting brackets. The adjustable bed base further comprises multiple legs. Each of the legs is secured to one of the mounting brackets at an upper end and has a lower end resting on a supporting surface. Each of the legs may be adjustable in length. In one embodiment, the adjustable bed base has six legs. Two of the legs have a first length, two additional legs have a second length greater than the first length and two more legs have a third length greater than the second length. In any of the embodiments, any number of legs such as four or eight may be supported by the frame of the adjustable bed base.

The adjustable bed base further comprises multiple wedges. Each of the wedges comprises a floor having an opening through the floor and lips extending upwardly from the floor on opposite sides of the floor to help keep the wedge stationary relative to the mounting backet. An opening extends through the floor of the wedge to allow a portion of one of the legs to pass through the opening and engage one of the mounting brackets. Each of the wedges is sandwiched between one of the legs and one of the mounting brackets. The wedges incline the stationary frame relative to a support surface or floor. The wedges further keep a bottom surface of each of the legs flat on the support surface regardless of the length of the leg which provides increased stability to the adjustable bed base. The adjustable bed base remains in an inclined position regardless of the position of the adjustable bed.

The adjustable bed base further comprises a deck comprising multiple deck members hinged to each other. At least one of the deck members is secured to the stationary frame and remains stationary regardless of the positions of the other deck members. Motors function to move the deck members to adjust the position of a mattress supported by the deck. For example, a head end of the mattress may be raised above a lumbar portion of the mattress. Alternative or additionally, a foot end of the mattress may be lowered to raise the knees of someone laying down on the mattress. Due to the wedges of the present invention, when the deck is generally planar and supported by the stationary frame, both the deck and stationary frame are inclined at an angle and not horizontal. In most applications, the angle of inclination is at least two degrees. In other words, the stationary frame has a head end and a foot end, one of the head and foot ends being higher than the other of the head and foot ends regardless of the position of the deck members. An angle defined between a plane extending between the head and foot ends of the stationary frame and a horizonal plane would be at least two degrees.

According to another aspect of the invention, an adjustable bed movable between multiple positions is provided. The adjustable bed comprises an adjustable bed base having an inclined stationary frame. In one embodiment, the inclined stationary frame comprises opposed side members, a head end member extending between the opposed side members and a foot end member extending between the opposed side members. The inclined stationary frame further comprises multiple mounting brackets, each of the mounting brackets being secured to the inclined stationary frame.

The adjustable bed base further comprises multiple leg assemblies. Each of the leg assemblies is secured to one of the mounting brackets. The leg assemblies may be different lengths.

The adjustable bed base further comprises multiple wedges. Each of the wedges is sandwiched between one of the leg assemblies and one of the mounting brackets to incline the stationary frame relative to a planar support surface regardless of the position of the adjustable bed. Each of the wedges is identically formed and generally U-shaped having a floor with an opening through the floor and lips extending upwardly from the floor. The lips of the wedge engage one of the mounting brackets of the adjustable bed base to keep the wedge stationary. A portion of each leg assembly passes through the opening in the floor of the wedge and engages one of the mounting brackets.

The adjustable bed further comprises a deck comprising multiple deck members hinged together. At least one of the deck members is secured to the stationary frame is it too is stationary regardless of the positions of the other deck members. The other deck members are moved by operation of motors secured to the stationary frame of the adjustable bed.

The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and, together with the summary of the invention given above, and the detailed description of the drawings given below, explain the principles of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring toFIG.1, there is illustrated an adjustable bed10, including an adjustable bed base12for supporting a mattress14. The mattress14is shown in dashed lines. The adjustable bed10has a head end5and a foot end7. As best shown inFIG.2, the adjustable bed base12comprises a generally rectangular, stationary frame16supported by six leg assemblies18. In any of the embodiments, any number of leg assemblies18such as four or eight may be supported by the stationary frame16of the adjustable bed base12.

As best shown inFIG.2, the generally rectangular frame16of the adjustable bed base12comprises two side members22, a head member24extending between the side members22, a foot member26extending between the side members22and an intermediate member28extending between the side members22. Each of the side members22is hinged with hinge17to enable the adjustable bed base12to fold for shipping purposes as shown inFIG.10.

As best shown inFIGS.1and2, the adjustable bed base12further comprises a deck30comprising a head deck board32, a first lumbar deck board34, a second lumbar deck board36, a thigh deck board38and a foot deck board40. As best shown inFIG.2, the head deck board32is joined to the first lumbar deck board34with three hinges42secured to lower surfaces of the first lumbar deck board34and head deck board32. The first lumbar deck board34is stationary and secured to the side members22of the generally rectangular frame16of the adjustable bed base12. Similarly, the second lumbar deck board36is stationary and secured to the side members22of the generally rectangular frame16of the adjustable bed base12. The first lumbar deck board34is separated from the second lumbar deck board36with a gap35to allow the adjustable bed base12to fold or collapse into two parts for shipping purposes as shown inFIG.10. One deck board may be used in place of the first and second lumbar deck boards in some embodiments.

As best shown inFIG.2, the second lumbar deck board36is joined to the thigh deck board38with three additional hinges44secured to lower surfaces of the second lumbar deck board36and thigh deck board38. Lastly, the thigh deck board38is joined to the foot deck board40with three additional hinges46secured to lower surfaces of the thigh deck board38and foot deck board40.

The deck30is movable between a flat position shown inFIG.2and a fully adjusted position shown inFIG.3A. When the deck30is in its flat position, the deck boards32,34,36,38and40are generally co-planar and rest on top of an upper surface33of the side members22of the generally rectangular frame16of the adjustable bed base12. As best shown inFIG.3, when the deck30is in its flat position, the aligned deck boards32,34,36,38and40are generally co-planar in a plane P which is inclined at an angle8to a horizontal plane. The angle8may be any number but is typically between two and four degrees due to the construction of the wedges72,72′ described below.

As shown inFIG.3A, in the deck's fully adjusted position, the head deck board32is inclined, the front edge48of the head deck board32being above the rear edge50of the head deck board32due to operation of a motorized linear actuator60. Regardless of the deck's position, the first lumbar deck board34and second lumbar deck board36are stationary and secured to the side members22of the generally rectangular frame16of the adjustable bed base12. In the deck's fully adjusted position shown inFIG.3A, the thigh deck board38is inclined, the front edge52of the thigh deck board38being below the rear edge54of the thigh deck board38due to operation of a motorized linear actuator62. In the deck's fully adjusted position, the foot deck board40is inclined, the front edge56of the foot deck board40being above the rear edge58of the foot deck board40as seen inFIG.3A.

Although not shown, only one of the two linear actuators60,62may be activated such that only a portion of the deck30is inclined. As best shown inFIG.1, a foam border80surrounds the deck30for protection. As shown inFIG.1, the foam border80has gaps82therein to enable the adjustable bed base12to be folded in half for shipping purposes. SeeFIG.10. As is conventional in adjustable beds, a generally U-shaped mattress stop84is secured to the foot deck board40to prevent the mattress14from moving relative to the adjustable bed base12.

As best shown inFIGS.2,4A and4B, the generally rectangular frame16of the adjustable bed base12further comprises six mounting brackets64welded to the side members22of the generally rectangular frame16. As best shown inFIG.2, three of the mounting brackets64are welded to each side member22of the generally rectangular frame16.

FIGS.4A and4Billustrate one of the front corners at the head end5of the generally rectangular frame16. As best shown inFIGS.4A and4B, each of the mounting brackets64is a generally U-shaped unitary member. Each of the mounting brackets64comprises a generally planar floor66and two side walls68extending upwardly from the generally planar floor66. As best shown inFIG.4A, the generally planar floor66of the mounting bracket64has a lower surface67which is coplanar with the lower surface19of the side member22of the generally rectangular frame16. The side walls68of the mounting bracket64are perpendicular to the generally planar floor66of the mounting bracket64.

As best illustrated inFIG.6, a threaded boss70is welded or otherwise secured to the generally planar floor66of the mounting bracket64. The threaded boss70extends upwardly from the generally planar floor66of the mounting bracket64. Each of the side walls68is generally triangular. Because each of the mounting brackets64is welded to one of the side members22of the generally rectangular frame16, the mounting brackets64may be considered part of the generally rectangular frame16of the adjustable bed base12.

However, the mounting brackets64may be removably secured to the side members22of the generally rectangular frame16of the adjustable bed base12in which case the mounting brackets64would not be considered integral parts of the generally rectangular frame16of the adjustable bed base12.

As best shown inFIG.2, a leg assembly18is secured to each of the mounting brackets64of the generally rectangular frame16with a wedge72therebetween. The location of the mounting brackets64is not intended to be limited by the drawings; the mounting brackets64may be secured to other portions of the generally rectangular frame16. As best shown inFIG.2, the adjustable bed10has six mounting brackets64, six wedges72and six leg assemblies18.

As shown inFIGS.7and7A, one embodiment of wedge72is a unitary member comprising a main portion128and two wings130extending upwardly from the main portion128. An oval shaped opening126extends through the main portion128of the wedge72, as best shown inFIG.7. The wedge72has a generally U-shaped front surface132and a generally U-shaped rear surface134. Each of the wings130of wedge72has an inner surface135and outer surface136. The wedge72has a length L defined as the linear distance between the front and rear surfaces132,134, respectively. The wedge72has a uniform width W defined as the linear distance between outer surfaces136of the wings130, as shown inFIG.7. The main portion128of the wedge72has an upper surface138which slopes downwardly from back to front. The wedge72has a planar bottom surface140. As shown inFIG.7A, a plane defined by the upper surface138of the main portion128of wedge72forms an angle8to the horizontal plane defined by the bottom surface140of wedge72. The angle8may be any number but is typically between two and four degrees. In one preferred embodiment, the angle8is four degrees, as shown inFIG.7A. As best shown inFIG.7A, the main portion128of the wedge72decreases in thickness moving in the forward direction from the rear surface134to the front surface132of the wedge72. Thus, the main portion128of the wedge72has a tapered thickness, decreasing from back to front.

In another preferred embodiment, the angle8is two degrees as shown in wedge72′ ofFIG.7B. For simplicity like numbers represent like parts but with a prime after the number representing the part. Wedge72′ is a unitary member comprising a main portion128′ and two wings130′ extending upwardly from the main portion128′. An oval shaped opening126′ extends through the main portion128′ of the wedge72′. The wedge72′ has a generally U-shaped front surface132′ and a generally U-shaped rear surface134′. Each of the wings130′ of wedge72′ has an inner surface135′ and outer surface136′. The wedge72′ has a length L defined as the linear distance between the front and rear surfaces132′,134′, respectively. The wedge72′ has a uniform width W defined as the linear distance between outer surfaces136′ of the wings130′. The main portion128′ of the wedge72′ has an upper surface138′ which slopes downwardly from back to front. The wedge72′ has a planar bottom surface140′. As shown inFIG.7B, a plane defined by the upper surface138′ of the main portion128′ of wedge72′ forms an angle8to the horizontal plane defined by the bottom surface140′ of wedge72′.

As best shown inFIG.8, each leg assembly18has an adjustable length. Each leg assembly18includes a receiver74and a lower member76. As shown inFIG.8, the receiver74has an upper edge78, which abuts or otherwise contacts the lower surface140of wedge72upon assembly and a lower edge79. As best shown inFIG.6, receiver74comprises a wall84having an interior surface86defining a hollow interior88therein and an exterior surface90. As shown inFIGS.5and6, receiver74has an inner diameter D1and an outer diameter D2. Thus, the receiver74has a generally cylindrical shape. As best shown inFIG.8, receiver74has two rows91,93of aligned holes92, each hole92extending through the wall84of the receiver74. Although six aligned holes92are illustrated in row91and five aligned holes92are illustrated in row93, the receiver74may have any desired number of holes or openings of any desired shape in either row.

As best shown inFIG.6, at an upper portion of the receiver74, a washer95is secured inside the hollow interior88of the receiver74via welding, for example. As best shown inFIG.6, washer95has a central opening96therein through which passes a shaft98of a fastener100. The fastener100has a head102below the opening96of washer95. SeeFIGS.6and8. The shaft98of fastener100has external threads104, the function of which is described below.

As best shown inFIG.8, each leg assembly18further comprises a lower member76having an upper edge106and a lower edge108. As best shown inFIGS.5and8, lower member76comprises a wall110having an interior surface112defining a hollow interior114therein and an exterior surface116. As shown inFIGS.5and8, lower member76has an inner diameter D3and an outer diameter D4. Thus, the lower member76has a generally cylindrical shape. As shown inFIG.5, the outer diameter D4of the lower member76is slightly less than the inner diameter D1of receiver74so the lower member76may fit inside the hollow interior88of the receiver74.

As best shown inFIG.8, each leg assembly18further comprises a push pin assembly118secured inside the hollow interior114of the lower member76. The push pin assembly118includes a generally C-shaped spring120having a push pin122welded or secured to one end of the generally C-shaped spring120. As best shown inFIGS.5and8, the generally C-shaped spring120resides inside the hollow interior114of lower member76, the push pin122of push pin assembly118extending through one of the two openings124in the lower member76. When the leg assembly18is fixed at a desired height, the push pin122of push pin assembly118also extends through one of the holes92of receiver94. The leg assembly18stays at its desired height when the adjustable bed is in use. Because the push pin122of push pin assembly118extends through both one of the openings124in the lower member76and through one of the holes92of receiver94, the lower member76is fixed relative to the receiver94. The lower member76only moves when an operator pushes in the push pin122and then moves the receiver94so the push pin122extends through a different hole92of receiver94.

Each leg assembly18may further comprise a riser142which has a cavity144for receiving a lower portion of the lower member76of leg assembly18. Although in the embodiment of adjustable bed10shown, two of six leg assemblies18of adjustable bed base12are illustrated having a riser142, four or six of the leg assemblies18may have a riser142. Alternatively, none of the leg assemblies18may have a riser142.

As best shown inFIGS.3and3A, regardless of the position of the deck30the head end13of the generally rectangular frame16is above the foot end15of the generally rectangular frame16due to the wedges72or72′. Alternatively, the wedges72or72′ may be oriented to keep the generally rectangular frame16in a declined position such that the foot end15of the generally rectangular frame16is above the head end13of the generally rectangular frame16due to the wedges72or72′.

Although the drawings illustrate only leg assemblies having adjustable lengths, it is within the scope of the present invention that unitary legs, not adjustable in length, may be used in accordance with the present invention.

As best shown inFIGS.3and3A, a pair21of leg assemblies18proximate the head end13of the generally rectangular frame16are adjusted in length to be a length L1. Another pair23of leg assemblies18proximate the foot end15of the generally rectangular frame16are adjusted in length to be a length L2less than the length L1. A middle pair25of leg assemblies18between the head and foot ends13,15of the generally rectangular frame16are adjusted in length to be a length L3which is greater than length L2and less than length L1.

As shown inFIGS.4A and4B, in order to secure one of the leg assemblies18to one of the mounting brackets64of the generally rectangular frame16of the adjustable bed base12, the fastener100of the receiver74of the leg assembly18extends through the oval shaped opening126in the main portion128of wedge72and into the threaded boss70of the mounting bracket64. The external threads104of fastener100engage the internal threads of the threaded boss70of the mounting bracket64so that upon rotation of the leg assembly18, the leg assembly18is secured to the mounting bracket64with the wedge72sandwiched therebetween.

As best shown inFIG.4B, the wedge72is sized so that one of the wings130abuts an outer surface23of one of the side members22of the generally rectangular frame16. The other wing130of the wedge72abuts an inner edge of one of the mounting brackets64. This alignment helps keep the wedge72in place and enables a user to quickly and easily pass the fastener100of the leg assembly18through the oval shaped opening126of the wedge72and into the threaded boss70of the mounting bracket64.

All the wedges of adjustable bed10are identical to impart the desired angle of inclination or declination to the adjustable bed base12. In the illustrated embodiment of adjustable bed10, six wedges72are shown. However, six wedges72′ could be used to impart a different angle of inclination or declination to the adjustable bed base12.

As best shown inFIGS.5and6, upon assembly, the bottom surface140of wedge72stays horizontal or parallel the floor or supporting surface3. The bottom surface140of wedge72abuts and contacts the upper edge78of receiver74of leg assembly18. As best shown inFIG.4B, the upper surface138of the main portion128of wedge72contacts and remains flush with a lower surface19of a side member22of generally rectangular frame16. Additionally, the upper surface138of the main portion128of wedge72contacts and remains flush with the lower surface67of floor66of mounting bracket64. As best shown inFIGS.5and6, due to the construction of the wedge72, upon assembly, the leg assembly18remains in a generally vertical orientation, providing stability to the leg assembly18. In addition, the mounting bracket24and side member22of the generally rectangular frame16remain inclined. The generally rectangular frame16remains inclined at an angle8determined by the construction of the wedges and remains stationary regardless of the positions of the deck members. As seen inFIG.6, the lower surfaces19of side members22of the generally rectangular frame16remains inclined at an angle8relative to a horizontal plane P.

FIGS.9and9Aillustrate a bedding foundation200constructed in accordance with the present invention. The bedding foundation200has the same parts as the adjustable bed10but a different bed base212. The bed base212is the similar to adjustable bed base12but has a unitary deck member230in place of an articulated deck30and frame side members222which are not hinged. For simplicity like numbers represent like parts.

Although none of the leg assemblies18of bedding foundation200are illustrated having a riser142, it is within the scope of the present invention that two, four or all six leg assemblies of bedding foundation200may have risers142. It is also with the scope of the present invention that bedding foundation200may be foldable with hinged frame side members and a foldable deck.

The adjustable bed base12may be shipped in a container300.FIG.10illustrates container300showing the adjustable bed base12folded in half or in a collapsed position with the leg assemblies18and wedges72separated from the adjustable bed base12. AlthoughFIG.10shows the adjustable bed base12folded a certain direction, those skilled in the art will appreciate that the adjustable bed base may be folded the other direction. The container300includes six leg assemblies18including six risers142and six wedges72. Although not shown, the risers may be packaged in plastic and so may be the wedges and the leg assemblies for protection during shipping.

Alternatively, the container300may contain only two or four risers142or any number of risers142. The container300may be shipped via United Parcel Service or any other shipping company and assembled at the destination without tools. In some applications, four or eight or any number of leg assemblies18and risers142and wedges72may be shipped in the container depending upon the design of the adjustable bed or bedding foundation. The size and configuration of container300are not intended to be limited by the drawings. Any size container may be used of any shape.

The various embodiments of the invention shown and described are merely for illustrative purposes only, as the drawings and the description are not intended to restrict or limit in any way the scope of the claims. Those skilled in the art will appreciate various changes, modifications, and improvements which can be made to the invention without departing from the spirit or scope thereof. The invention in its broader aspects is therefore not limited to the specific details and representative apparatus and methods shown and described. Departures may therefore be made from such details without departing from the spirit or scope of the general inventive concept. The invention resides in each individual feature described herein, alone, and in all combinations of any and all of those features. Accordingly, the scope of the invention shall be limited only by the following claims and their equivalents.