Easy to assemble bed base, two-component connector and kit

A bed base and bed base kit includes four side members, each being symmetrical about its longitudinal axis. The side members are assembled into a rectangular structure with the members positioned to stand vertically upright on their edges. Opposed side members are of the same length and are connected at adjacent ends by a two-component connector. A first component of the connector is attached to the opposed ends of each one of a first pair of opposing side members and a second component is attached to the opposed ends of each one a second pair of opposing side members. The second components are offset from the longitudinal axis of the one side member to which they re attached. Thus, when the side members are assembled to form the rectangular structure, the respective edges of the side members are substantially flush with each other.

BACKGROUND OF INVENTION

Bed bases are commonly used structures to support above a floor a box-spring and mattress. Typically, they are made up of a number of pieces that are shipped unassembled and then assembled by an installer at the location where the bed base is to be used. In many prior art bed bases the pieces are frequently numerous and sometimes require the use of tools to connect them together. This adds cost to manufacturing, shipping and installing of the bed base. Ideally, a bed base should have a minimum number of pieces, be easy to package and ship, and be conveniently and quickly assembled.

SUMMARY OF INVENTION

This invention, with its several desirable features, is summarized in the CLAIMS that follow. After reading the following section entitled “DETAILED DESCRIPTION,” one will understand how the features of this invention provide its benefits. The benefits of this invention include, but are not limited to: (1) lost cost manufacture due to minimizing the number of pieces comprising the bed base, (2) convenience of use and assembly, (3) ease in packaging of the pieces of the bed base into a kit and ease in handling and shipping this kit, and most importantly, (4) the speed at which the pieces may be assembled into the bed base.

The bed base of this invention includes side members, each having opposed edges and opposed ends and each being symmetrical about its individual longitudinal axis. The side members are of equal width and they are positioned to stand vertically upright on one edge. The side members are preferably made from sheet metal that may be bent into a substantially C-shape cross-sectional configuration to form longitudinal, planar support members along the opposed edges of each side member. These support members assist in orienting the side members vertically. The support members are on opposite sides of a central, longitudinal, planar portion of each side member. Preferably, each support member extends outward in the same direction from the planar portion and each support member has substantially the same width and length. One support member is along one of the planar portion edges at substantially a right angle to the planar portion and the other support member is along the other of the planar portion edges at substantially a right angle to the planar portion.

At each opposed end of each side member is one component of a two-component connector. The two-component connector includes a keyhole component and a locking component. Upon assembly of the side members to form the bed base, the locking component on one side member is received in the keyhole component of an adjacent and adjoining side member. Upon connection, the respective edges of the side members are brought into a position relative to each other where their respective edges are substantially flush with each other.

The keyhole component has (a) a first opening with an enlarged central portion and a pair of narrow portions extending outward in opposite directions from the central portion, and (b) a second opening with an enlarged central portion and a pair of narrow portions extending outward in opposite directions from the central portion. The first and second openings are spaced apart a predetermined distance and each openings is equidistant from a central longitudinal axis of the side member to which the keyhole component is attached.

The locking component has first and second outwardly extending finger elements that each have an enlarged head on a narrow neck, the head being sized to pass through a central portion of an opening in a keyhole component but larger than the narrow portions of the opening and the narrow neck being sized to be received in one of the narrow portions. The first and second finger elements are spaced apart a distant equal to the predetermined distance that the openings are spaced apart and offset with respect to a central longitudinal axis of the side member to which the locking component is attached a distance sufficient to bring the opposed edges of a pair of side members together so that the edges of the side members being connected are substantially flush upon assembly of the side members.

One component of the two-component connector may include a catch element and the other component may include a receptacle. Upon manually engaging the two components of the two-component connector, one component moves laterally over a face portion of the other component to attain an interlocking relationship between the catch element and the receptacle, with the catch element seated in the receptacle. Preferably, at least one of the components is made of a malleable material and the catch element is formed in the malleable material. This catch element extends outward from a face portion and is positioned at a predetermined location along the one component to be received in the receptacle of the other component to attain the interlocking relationship.

With a bed base having a substantially rectangular structure, four side members are employed. Optionally, the opposed ends of the side members, in particular the support members, are at an angle of substantially, 45° so that the ends of adjacent and adjoining side members form a miter joint. The connectors at each miter joint holds together the adjoining side members forming the miter joint. The side members of one pair each have first lengths that are equal to each other and the side members of another pair each have second lengths that are equal to each other and longer than the first lengths. All the side members are of equal width. The side members of the same length are opposed to each other. Each side member of one pair having the same length has a keyhole component at both opposed ends thereof. Each side member of the other pair having the same length has a locking component at both opposed ends thereof. The side members are assembled into the rectangular structure with the side members of the one pair being opposed to each other and the side members of the other pair being opposed to each other. This rectangular structure has corners formed by adjoining and adjacent opposed ends of the pairs of side members. These adjoining and adjacent opposed ends are connected together by interlocking the keyhole and locking components of each two-component connector at the corners. The opposed side members of at least one pair of opposed side members are substantially symmetrical and the keyhole component is substantially symmetrical.

Optionally, there is a brace element at each corner of at least one pair of diagonally opposed corners. Preferably, each brace element overlaps adjacent, longitudinal support members of the adjoining, adjacent ends of the side members forming the diagonally opposed corners. The brace elements may include a pair of pin members, one pin member received in a hole in one adjacent, longitudinal support member and the other pin member received in a hole in the other adjacent, longitudinal support member.

It may be desirable for the bed base to include a box-spring/mattress support bar that extends between a pair of opposed side members. Preferably, the support bar has opposed ends with a pin member at or near each end. One pin member is received in a hole in one opposed member of the pair of opposed support members and the other pin member is received in a hole in the other opposed side member of said pair. These holes in the pair of opposed support members are aligned so that the support bar is at a right angle to the support members. Preferably, the support bar has opposed ends and a bracket is mounted to each end of the support bar to move laterally between an extended position and a retracted position. Optionally, each bracket may have a catch element that holds the bracket in the retracted position.

This invention also includes the unique two-component connector used to attach the side members together and a kit wherein the various unassembled pieces of the bed base are placed in a package.

DETAILED DESCRIPTION

This invention includes both a bed base10as illustrated inFIGS. 1 through 9and a bed base kit100as illustrated in FIG.10. For example, the bed base kit100includes all the necessary pieces to assemble, the bed base10depicted inFIGS. 1-9. The bed base10is sized to support a standard double box-spring102(shown in phantom lines). Kits for twin, queen, king and even custom size box-springs and mattresses are also within the scope of this invention. As discussed subsequently in greater detail, the number of pieces in the kits of this invention will vary depending on the size of the box-springs and mattresses being supported by the bed base.

The bed base10includes (a) four generally rectangular side members12,12a,14,14a, (b) a pair of box-spring/mattress support bars16,16aextending between, and at right angles to, the pair of opposed side members12,12a, and (c) four corner brace plates18,18aand20,20a. The members12,12a,14, and14aare first assembled into a rectangular structure9(FIG. 2) with adjoining, adjacent ends E3and E4of the side members12,12a,14, and14apositioned at right angles to each other to form the rectangular structure's corners70athrough70b. A two-component connector11shown in detail inFIGS. 5,6, and7A and7B securely connects the adjoining, adjacent ends E3and E4at each corner70athrough70b.

The individual side members12,12a,14, and14aare 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 members12,12aare of the same length of about 71 inches and they 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 members14,14ahave a length ranging from about 26 to about 63 inches. For any type of box-spring and mattress being supported, the opposed side members14,14aare 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 58⅞ inches. All the side members12,12a,14,14aare of the same width x ranging from about 5 to about 18 inches. Each individual side member12,12a,14,14ais symmetrical about its central longitudinal axis L.

As best shown onFIGS. 3 and 4, each individual side member12,12a,14, and14ahas 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 member12,12a,14, and14aare cut inward at an angle of substantially 45° to enable the adjoining, adjacent ends E3and E4of adjoining, adjacent side members to form a miter joint at each corner70athrough70b. Such a miter joint J is depicted inFIG. 4showing the adjoining, adjacent side members12and14with their respective adjoining, adjacent ends E3and E4abutting each other.

There extends outward in the same direction, respectively from each edge E1and E2, an L-shaped shoulder support/stiffener22and22a. The support/stiffeners22and22aface each other, with their feet23pointing at each other and their legs25oriented horizontally to form longitudinal, planar support platforms. Each longitudinal support platform, or leg25, has substantially the same width w, typically from about ¾ to about 1¼ inches. The length of each individual leg25is the same as the length of the side member from which it extends. Each leg25is at a right angle to the planar portion C. The individual feet23extend from an outer tip of the leg25from which it extends and each has the same width w1, typically from about ¾ to about 1¼ inches. The length of the individual feet is the same as the length of the leg from which it extends. Preferably, for any bad base w and w1are equal, typically each being I inch.

In the individual side members12,12a,14and14athere are two pairs of these holes26,26anear opposed end E3and E4. The individual holes26are in the legs25that extend from the edge E1and the individual holes26aare in the legs25that extend from the edge E2. The individual holes26and26ain each pair of holes are in alignment with each other. In the individual side members12,12athere are two additional pairs of holes, referred to as intermediate holes28,28a, spaced apart a distance d, which varies depending on the size of the box-spring and mattress being supported. Each individual pair of intermediate holes28,28ais set back from its closest end E3or E4, as the case may be, by an equal distance d1, typically from about 6-12 inches. The individual holes28are in the legs25that extend from the edge E1and the individual holes28aare in the legs25that extend from the edge E2. The individual holes28and28ain each pair of holes are in alignment with each other.

Because the side members12,12a,14and14aare so designed as discussed above, the two halves of each individual side member partitioned along its longitudinal axis L are mirror images, making each side member symmetrical about its longitudinal axis. Each individual side member12,12a,14and14ais also symmetrical about a central axis ZZ passing through the center of each side member and at a right angle to the individual member's longitudinal axis L. This feature of structural symmetry of the side members12,12a,14and14ais important for quick and easy assembly of the bed base of this invention, as will be better understood upon reading the section entitled “Bed Base Assembly.”

As best shown inFIGS. 5 and 6, the two-component connector11with each component made from steel sheet. The two-component connector11includes (a) a keyhole component K, one attached, respectively, to each of the opposed ends E3and E4of the members12and12a, and (b) a locking component LK, one attached, respectively, to each of the opposed ends E3and E4of the members14and14a. These components K and LK are fastened securely by rivets31to the planar portions C of the side members12,12a,14, and14a. The rivets31pass through holes32in these components K and LK. These components K and LK are all attached to the inside surfaces S of the planar portions C of the side members12,12a,14, and14a, so that they all face inwardly upon assembly of these side members to form the bed base10.

The keyhole component K has a generally L-shape configuration and in one leg29are the holes32for the rivets31and in another leg30are two identically, symmetrically shaped oblong-type openings32aand32baligned along an axis XX of this leg30. There is a centrally located hole34with its center coincident with the center a of the leg30and the longitudinal axis L intersecting this center a at a right angle to the leg30. This hole34serves as a receptacle for a catch element54on the locking component LK. The centers a1and a2respectively of the openings32aand32bare equidistant from the longitudinal axis L of the side members to which each keyhole component K is attached. Each opening32aand32bhas an enlarged central, circular portion36and a pair of narrow rectangular portions38aand38b, each with rounded outer terminal ends39. These narrow portions38aand38bextend outward in opposite directions from the central portion36at equal distances from the center of the circular portion36, centers a1or a1as the case may be. They lie along a common line which is substantially at a right angle to the longitudinal axis L. Thus, each opening32aand32bis symmetrical about its respective center a1or a1as the case may be, and these openings32aand32b, being positioned equidistant from the longitudinal axis L and aligned along the axis XX, make the leg30symmetrical.

The locking component LK has two plates40and42connected by a narrow section44. The holes32for the rivets31are in the plate42and a pair of fingers50and50aextend outwardly from the inside surface SS of the plate40. The locking component LK, preferably being made of a malleable material such as steel sheet, has the catch element54formed in this malleable material by partially punching the steel sheet. The catch element54extends outward from the inside surface SS of the plate40. Each finger50and50ahas an enlarged head H mounted on an end of a narrow neck N. The neck N is sufficiently long to facilitate interconnecting the keyhole component K and the locking component LK by allowing the neck N to slide along the either portion38aor38bwhile the head rides on the surface S1of the leg30of the keyhole component K. Each head H is sized to pass through the central portion36of the symmetrically shaped openings32aand32bin the keyhole component K but are larger than the narrow portions38aand38b. The narrow neck N is sized to be received in the one of narrow portion38aor38bupon assembly of the bed base10.

The fingers50and50aare aligned along the longitudinal axis YY of the plate40and the catch element54is along this axis YY between the fingers, closest to the finger50a. The longitudinal axis YY is substantially at a right angle to the longitudinal axis L. The catch element54is positioned at a predetermined location along the axis YY to be received in the hole34of the keyhole component K to attain an interlocking relationship upon connecting the two components K and LK of the two-component connector11. Each locking component LK is attached to the central portion C of a side member14or14a, as the case may be, so that the center Z of the catch element54is along the central longitudinal axis L of the side member to which it is attached. This positions the center of the head H of the finger50a distant of d3from the edge E1and the center of the head H of the finger50aa distant of d4from the edge E2. The distance d4is greater than the distance d3. The distant between the centers of the heads H of the fingers50and50ais equal to the distant d5between the centers a1and a2of the symmetrically shaped openings32aand32bin the keyhole component K.

It is important that each locking component LK of each pair of locking components mounted to a side member14and14abe positioned correctly on the side member to which it is attached to properly interconnect with its counterpart keyhole component. As shown inFIG. 7A, the position of each pair of components LK is such that, when the heads H of the fingers50and50aare aligned, respectively, with the centers a1and a2of the openings38aand38bin the keyhole component K, the top edge E1of the side member14is below the top edge E1of the side member12a distance d8. This distance d8is equal to the distance d7between each center a1and a2and each of the rounded ends39of the portions38aand38bof the openings32aand32b. The distance d6between the head H of the finger50aand the center Z of the catch element54is equal to the distance d7and the distance d8. Consequently, the installer can only move the two side members12and14this distance d8only in one direction to lock the side members together. Specifically, the installer moves the side members12and14relative to each other to bring the catch element54of the locking component LK into locking engagement with the hole34in the keyhole component K to connect securely the adjoining, adjacent side members12and14. This simplifies the assembly of the bed base10, enabling the installer to assemble more rapidly all the side members12,12a,14, and14ainto the rectangular structure9.

As best shown inFIGS. 1 and 9, each support bar16and16ahas an L-shaped arm82that has at each opposed ends thereof a bracket76mounted thereto to move laterally between an extended position shown in dotted lines inFIG. 9 and aretracted position shown in solid lines in FIG.9. There is a catch element78, similar to the catch element54, that holds the bracket76in the retracted position by locking engagement with a hole80in the arm82to which the bracket is attached, in this case the opposed ends of the support bar16a. The details of this bracket are discussed in U.S. Pat. No. 5,920,930. Inward from each opposed end of the support bars16and16ais a cutaway section92. The cut-away sections92on each support bar16and16aare spaced apart from each other by a distance equal to the distance q between the opposed feet23of the side members12and12a. Each cut-away section92has a width that is about equal to the width w of the legs25. A pair of stands83extend at right angles downward from intermediate locations along the arm82between the cut-away sections92. More than two stands83may be used when larger bed bases are provided in the case of queen and king sizes.

As shown inFIG. 8, near each opposed end of each support bar16and16ais a downward projecting pin90. Each one of these pins90at the opposed ends of the supports bar16and16ais positioned between the bracket76at an adjacent opposed end and the adjacent cut-away section92. As illustrated inFIG. 1, when the support bars16and16aare placed at right angles to the side members12and12aon top of the opposed edges E1, the cut-away sections92in each support bar16and16afit snugly over these opposed edges. As depicted inFIG. 8, the pins90on each support bar16and16aare aligned to pass through the intermediate holes in the legs25of the opposed side member12and12a, in this case the opposed aligned holes28. If the side members12and12awhere inverted, the pins90would pass through the aligned intermediate holes28a.

Bed Base Assembly

The installer assembles the four side members12,12a,14,14aby standing them vertically upright on their edges E2and connecting together the keyhole component K and locking component LK of the two-component connectors11at adjoining, adjacent ends E1and E2of adjoining, adjacent side members. For example, to interlock the two components K and LK of the connector11at the adjoining, adjacent ends E3and E4of the side members12and14, the installer first aligns the fingers50and50a, respectively, with the enlarged central, circular portions36of the openings32aand32bas shown in FIG.7A. Next, the installer moves the two components K and LK into engagement with each other, passing the heads H of the fingers50and50athrough the openings32aand32bin the keyhole components K. The fingers50and50apass through the openings32aand32band a backside face60of the keyhole component K is pushed against a front side face62of locking component LK.

With the fingers50and50aextending through openings32aand32b, the installer pushes the side member12downward in the direction indicated by the arrow F while the edge E2of the side member14rests against a floor. This moves the locking component LK laterally over the backside face60of the keyhole component K to press the necks N of the fingers50and50arespectively against the rounded outer ends39of the rectangular portions38aand38bof the opening32aand32b. As shown inFIG. 7B, the heads H are external to the rectangular portions38aand38band the catch element54snaps into locking engagement with the hole34to lock the components K and LK together. Thus, when adjoining side members12,12a,14, and14aare assembled to form the rectangular structure, the respective edges E1and E2are flush with each other as shown in FIG.7B. Because of the symmetry of the side members12and12a, the installer never needs to be concerned whether or not these members are in inverted, because of they have identical mirror halves. The side members14and14aare always positioned by the installer in the same manner with the finger50a, the finger nearest the edge E2closest to the floor. The installer, however, place the side members12and12aon the floor and then attach the side members14and14a.

Connecting the two-component connectors11at each corner70athrough70dforms the rectangular structure9. When the installer has assembled the rectangular structure9, the brace plates18and18aare attached at each diagonally opposed corners70aand70cand the brace plates20,20aare attached at diagonally opposed corners70band70d. As illustrated inFIG. 1, each brace plate18,18a,20, and20ahave a pair pins80,80a. The brace plate at each corner70athrough70boverlaps and is mounted to adjoining, adjacent side members, with one pin of each pair extending through the holes26in the legs25at adjacent ends of adjoining, adjacent side members. For example, the one pin80is received in the hole26in the leg25of the support/stiffener22of the side member12and the other pin80aon this same brace plate18is received in the hole26in the leg25of the support/stiffener22of the side member14.

The installer places the box-spring/mattress support bars16and16aon top of the rectangular structure9to extend between the opposed side member12and12aas shown in FIG.1. As discussed above, one pin90at one opposed end of a support bar is received in the hole28in one leg25of the side member12and the other pin90is received in the hole28in the one leg25of the opposed side member12a. The holes in the legs25of the opposed side members12and12aare aligned so that the support bars16and16aare each at a right angle to these opposed side members.

Bed Base Kit

The bed base kit100includes a package104containing all the pieces to assemble the bed base10: namely, the four side members12,12a,14, and14a, the four corner brace plate18,18a,20, and20a, and the two box-spring/mattress support bars16and16a. The package may be substantially smaller that that depicted, requiring the individual pieces to be stacked on top of each other. A smaller package would be more convenient to ship. Each component K and LK of the two-component connectors11are attached to the side members12,12a,14, and14a, with each side member having the same type of component at each opposed end and each pair of side members having the same length employing identical components. Specifically, the side members12and12ahave the keyhole component K at each opposed end E3and E4and the side members14and14ahave the locking component LK at each opposed end E3and E4.

When a twin size bed base is provided, fewer pieces are needed than the kit100depicted in FIG.10. In the case of a twin size bed base, a kit includes four side members, only one pair of corner brace plates, and only one box-spring/mattress support bar. The dimensions of the side members and the box-spring/mattress support bar would be appropriate for supporting the twin size box-spring. The corner brace plates would be attached to diagonal corners.

Alternate Brace Plate

An alternate form of a brace plate, designated by the numeral200, as shownFIG. 11, employs a plate202with a triangular shape. The pair pins80aextend from the underside of the plate202and are positioned to be received in the holes26near the corners of the assembled side members as discussed above.

Scope of the Invention

The above presents a description of the best mode contemplated of carrying out the present invention, 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 this invention. This invention is, however, susceptible to modifications and alternate constructions from that discussed above which are fully equivalent. Consequently, it is not the intention to limit this invention to the particular embodiments disclosed. On the contrary, the intention is to cover all modifications and alternate constructions coming within the spirit and scope of the invention as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of the invention: