Abstract:
A bed foundation capable of being assembled by the end user or a retailer. The bed foundation utilizes support members having I-beam construction, thereby reducing noise and greatly increasing the strength of the foundation. The foundation is also constructed to provide a flush, uniform top surface onto which top panels are attached. The flush uniform top surface also contributes to noise reduction and increased strength. The foundation, when unassembled, can be packed into a single, relatively small container, thereby significantly reducing shipping costs.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     Bed foundations, or “box springs” as they are often called, typically include a wooden frame to which a plurality of metal supports are attached and arranged to form a substantially planar upper surface. A sheet of cardboard is placed over the metal supports to create a continuous upper surface. The underside of the frame is then covered with a thin unwoven polyester material to hide the unimpressive construction from the consumer.  
         [0002]     One problem with this traditional foundation design pertains to the weak areas between the metal supports. If too much pressure is placed between the metal supports, the cardboard gives way and a puncture results.  
         [0003]     Another problem with this design is its inherent lack of rigidity. The foundation design was aimed at producing an economic platform for placement on a metal bed frame, capable of supporting a mattress. Longevity was not a primary consideration. The lack of rigidity considerably reduces the life of the foundation, and possibly the mattress, and also results in undesirable noises, such as squeaking and creaking, when a user&#39;s weight is shifted on the mattress supported thereby.  
         [0004]     Yet another problem with this design is that it is not conducive to either disassembly, or final assembly by a retailer or an end user. Thus, the foundation must be assembled at the factory and shipped in an assembled state. Doing so adds significantly to the shipping costs due to the dimensions of the assembled foundation.  
         [0005]     There is a need for an economic foundation that includes with a strong, continuous upper surface free of weak areas that could be compromised through normal use, or even predictable misuse.  
         [0006]     There is also a need for a bed foundation designed to prevent annoying noises arising from a loss of rigidity. Preferably this design is capable of providing a stable platform for a mattress over an extended lifetime.  
         [0007]     There is also a need for a bed foundation that is capable of being assembled by an end user or a retailer such that the foundation may be shipped in an unassembled state. Preferably, this foundation is capable of being shipped in a single, relatively small, container when unassembled such that a lower shipping charge applies.  
       BRIEF SUMMARY OF THE INVENTION  
       [0008]     The present invention is directed toward a bed foundation that addresses the above-identified needs. The bed foundation utilizes longitudinal and transverse members having I-beam construction, and a plurality of cross members placed across the longitudinal members to provide a rigid frame. The cross members are topped with a layer of plywood, further adding to the rigidity of the frame. The pieces are held together with traditional fasteners, such as screws, thereby simplifying final assembly.  
         [0009]     The I-beam construction of the longitudinal and transverse members has many advantages over the prior art. First, a support member having I-beam construction is approximately three times stronger than a solid support member having the same weight. Second, I-beam construction minimizes beam “racking” or twisting of the support member. Additionally, increasing strength and eliminating racking minimizes noise. The increased strength of this foundation also increases its versatility. For example, the hospitality industry uses approximately six different metal bed frames. The bed foundation of the present invention is strong enough to be used will all of these different frames. Indeed, the foundation is so strong that it may be supported only at the ends of the foundation, whereas standard foundations must be supported along their longitudinal sides.  
         [0010]     One aspect of the present invention provides a bed foundation comprising a plurality of longitudinal members each having an upper surface defining a plurality of grooves. A pair of transverse end members are operably attached to opposite ends of the longitudinal members. A plurality of cross members are operably disposed in the grooves of the longitudinal members. There is at least one top panel operably disposed on upper surfaces of the longitudinal members. The foundation is constructed and arranged such that the upper surfaces of the cross members are substantially flush with the upper surfaces of the longitudinal members, thereby creating a substantially planar support grid onto which the top panel is operably disposed.  
         [0011]     Another aspect of the present invention provides a bed foundation comprising a plurality of parallel longitudinal members. Each of the longitudinal members includes an upper portion, a middle portion, and a lower portion. The upper and lower portions are thicker than the middle portion, thereby forming an I-beam construction. The foundation includes a pair of parallel transverse end members, operably connected to opposite ends of the longitudinal members. Each of the transverse members also has an upper portion, a middle portion, and a lower portion configured such that the upper and lower portions are thicker than the middle portion, thereby forming an I-beam construction. The foundation further includes a plurality of cross members transversely spanning, and operably attached to the longitudinal members. Additionally, there is at least one top panel operably disposed on top of the cross members. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]      FIG. 1  is queen-sized embodiment of the present invention in an unassembled state;  
         [0013]      FIG. 2  is a partial perspective view of a queen-sized embodiment of the present invention;  
         [0014]      FIG. 3  is a cross-section elevation of a member having an I-beam construction, taken along lines  3 - 3  of  FIG. 2 ;  
         [0015]      FIG. 4  is a cross-section elevation of a member having an I-beam construction, taken along lines  4 - 4  of  FIG. 2 ; and,  
         [0016]      FIG. 5  is a perspective view of an inverted king-sized embodiment of the present invention 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0017]     Referring now to the drawings, and first to  FIG. 1 , there is shown a bed foundation  10  of the present invention in an unassembled state. The bed foundation  10  includes at least two longitudinal members  12 , at least two transverse members  14 , a plurality of cross members  16 , and at least one top panel  18 .  
         [0018]     Preferably, the longitudinal members  12  are configured to have an I-beam construction, with an upper portion  20 , a lower portion  22  and a middle portion  24 , the upper and lower portions  20 ,  22  being thicker than the middle portion  24 . Additionally, the longitudinal members  12  preferably include end portions  26  that are thicker than the middle portion  24 , thereby framing the middle portion  24  in a panel-like fashion. The I-beam construction of a longitudinal member  12  is shown in  FIG. 3 .  
         [0019]     The upper portions  20  of the longitudinal members  12  also include upper surfaces  28  that define a plurality of notches or grooves  30 . The grooves  30  are arranged and sized to accommodate the cross members  16 . The arrangement of the grooves  30  is such that the grooves  30  of adjacent longitudinal members  12  align with each other to receive a cross member  16  that is perpendicular to the length of the longitudinal member  12 . The grooves  30  are sized such that when the cross members  16  are placed in the grooves  30 , top surfaces  32  of the cross members  16  are substantially flush with the upper surfaces  28  of the longitudinal members  12  receiving the cross members  16 . This configuration is best shown in  FIG. 2 .  
         [0020]     Though any rigid materials, including plastic, may be used, the longitudinal members  12  are preferably made of wood. More preferably, the upper portions  20 , lower portions  22 , and end portions  26 , are made of a relatively inexpensive material such as pine. The middle portions  24 , are preferably made of MDF, particle board, or plywood.  
         [0021]     Similar to the construction of the longitudinal members  12 , the transverse members  14 , seen in  FIG. 4 , are preferably configured to have an I-beam construction, with an upper portion  34 , a lower portion  36  and a middle portion  38 , the upper and lower portions  34 ,  36  being thicker than the middle portion  38 . Additionally, the transverse members  14  preferably include end portions  40  that are thicker than the middle portion  38 , thereby framing the middle portion  38  in a panel-like fashion.  
         [0022]     Like the longitudinal members  12 , any rigid materials, including plastic, may be used to construct the transverse members  14 . However, the transverse members  14  are preferably made of wood. More preferably, the upper portions  20 , lower portions  22 , and end portions  26 , are made of a relatively inexpensive material such as pine. The middle portions  24 , are preferably made of MDF, particle board, or plywood.  
         [0023]     The construction of the transverse members  14  may be identical to the construction of the longitudinal members  12 .  FIG. 3  shows a longitudinal member  12  of solid construction whereas  FIG. 4  shows a transverse member  14  having a panel construction. One skilled in the art will realize that the construction shown in  FIG. 3  may apply to transverse members  14  just as the panel construction of  FIG. 4  may apply to longitudinal members.  
         [0024]     The cross members  16  are substantially straight pieces sized to rest within the grooves  30  such that the top surfaces  32  of the cross members  16  are substantially flush with the upper surfaces  28  of the longitudinal members. Though a variety of cross member widths, and inter-cross-member spacing, may be used to accomplish the present invention, consideration should be given to the structural integrity of the resulting foundation  10 . Thus, narrow cross members should be accompanied by relatively small spacing between cross members, thereby resulting in the use of more cross members. Conversely, wider cross members might accommodate larger inter-cross-member spacing. These considerations are important to ensure a sufficiently rigid surface, thereby preventing unwanted noises, and to reduce the chances of a puncture in one of the top panels  18 . Any rigid material may be used to form the cross members  16 . Preferably, the cross members  16  are wood. More preferably, the cross members  16  are a cost effective wood such as pine.  
         [0025]     The top panels  18  are planar pieces that rest on the upper surfaces  28  of the longitudinal members  12 , the top surfaces  32  of the cross members  16 , and on upper surfaces  42  of the transverse members  14 . The top panels  18  are flat, rigid pieces that are preferably resistant to warping, such as extruded plastic or more preferably, plywood or particle board. The thickness and strength of the top panels  18  should also be considered when determining the optimal spacing between the cross members. Thicker top panels  18  can be used in conjunction with fewer cross members. Though cardboard has been discussed as undesirable, given the appropriate number of cross members, closely spaced, cardboard could function adequately to be considered within the scope of the invention.  
         [0026]     In an assembled state, as is shown in  FIG. 2  with the exception of one of the top panels  18 , the various components of the foundation  10  are held together with fasteners  44 . Any suitable fasteners are acceptable. Preferably, the fasteners  44  are screws, nails, pins, bolts, biscuits, glue, or the like. The fasteners  44  are shown connecting the transverse members  14  to the longitudinal members  12 . Additionally, any type of fastener  44  may be used to secure the cross members  32  to the transverse members  14 , and/or the top panels  18  to any or all of the members  12 ,  14 , and  16 . The use of these fasteners  44 , as well as the structural integrity provided by the grooves  30 , allow the foundation  10  to be constructed at a location other than the factory in which the individual pieces are manufactured. Additionally, shipping costs are greatly reduced as the various members  12 ,  14  and  16 , may all be packaged together in a compact package. The queen-sized embodiment, shown in  FIGS. 1 and 2 , has a shipping package size of approximately 78×30.25×3.75 inches. More importantly, the length of the package into which the foundation fits is less than 108 inches in length and less than 165 inches in length and girth combined. Girth is defined as the distance around the package at its widest point in a direction perpendicular to the length. The length being the longest side of the package. Therefore, the package is can be shipped using commercial shipping companies such as United Parcel Service of America, Inc. (UPS). Packages exceeding 108 inches in length and 165 inches in length plus girth require special, more expensive, courier services.  
         [0027]     The queen-sized embodiment of the foundation  10  shown in  FIGS. 1 and 2  includes three longitudinal members  12 , two transverse members  14 , and a plurality of cross members  16  that span the entire width of the foundation  10 . Though this embodiment of the foundation  10  could be resized to any bed size, a preferred embodiment of a king-sized foundation  10  is shown in  FIG. 5 . The foundation  10  of  FIG. 5  is completely assembled and inverted to show its various components.  
         [0028]     Not unlike many convention box springs, the king-sized foundation  10  of  FIG. 5  includes two smaller subfoundations  10   a  and  10   b  juxtaposed to form a larger foundation  10 . These subfoundations  10   a  and  10   b  also serve individually as twin-sized foundations. Thus, the cross members  16  span the entire widths of the smaller foundations  10   a  and  10   b , but do not span the width of the entire foundation  10 . Because the widths of the individual subfoundations  10   a  and  10   b  are smaller than the queen-sized foundation, the center longitudinal member may be replaced with a joist member  46 . The joist member  46  is less expensive than the longitudinal members  12  as it does not have I-beam construction and is smaller. The joist member  46  is supported at the ends of the subfoundations  10   a  and  10   b  by braces  48  attached to the transverse members  14 . The joist member  46  has grooves  50  that match the grooves  30  of the longitudinal members  12  and that are sized to accept the cross members  16 .  
         [0029]     Like the queen-sized embodiment, the king-sized foundation  10  of  FIG. 5  saves on shipping costs by being able to fit into a package that is not oversized. Each subfoundation  10   a  and  10   b , in an unassembled state, can be placed into a single container having a shipping package size of approximately 78×39×2.06 inches. More importantly, the length of the package into which the foundation fits is less than 108 inches in length and less than 165 inches in length and girth combined. Therefore, the package is can be shipped using commercial shipping companies such as United Parcel Service of America, Inc. (UPS). Packages exceeding 108 inches in length and 165 inches in length plus girth require special, more expensive, courier services.  
         [0030]     The invention has herein been described in its preferred embodiments to provide those skilled in the art with the information needed to apply the novel principles and to construct and use the embodiments of the examples as required. However, it is to be understood that the invention can be carried out by specifically different devices and that various modifications can be accomplished without departing from the scope of the invention itself, which is set out in the following claims: