Patent Publication Number: US-8990979-B1

Title: Ready-to-assemble bed foundation

Description:
BACKGROUND 
     The disclosure is directed to a ready-to-assemble bed foundation. More specifically, the bed foundation includes a pair of exterior side beams connectable to a pair of transverse end members having openings. The foundation also includes an interior beam between the side beams having opposing end portions configured to engage the openings in the transverse end members. 
     Ready-to-assemble bed foundations are known. Many are expensive and difficult to assemble, while others are of the type having a solid panel immediately below a mattress or box spring. These panels are often bulky or otherwise not suited to cost-effective shipping and storage. Other prior art foundations prevent access to the area below the mattress for storage, or do not provide for the addition of a slipcover. Thus, the prior art has not adequately addressed the need for a ready-to-assembly bed foundation that is economical to manufacture and easy to assemble, provides a comfortable yet stable support, permits access to a storage area under the bed, and provides for the addition of a slipcover. 
     SUMMARY OF THE DISCLOSURE 
     The present invention fulfills one or more need in the art by providing a ready-to-assemble bed foundation including a pair of exterior side beams having two ends, a pair of transverse end members having two ends, each of the side beams and end members having a corner block attached to each end, and a pin with a flange for each pair of corner blocks. The corner blocks are configured to mate together to hold a side beam in contact at a right angle to an end member and to be held together by the pin, the corner blocks having a mounting flange to mount the block to the respective beam and upstanding lamella that can interleave with lamella of an adjacent block. Each lamella has a shaped lumen that is coaxial with the lumens of the other lamella of the block and has at least portions that are substantially cylindrical, so that each lumen can receive the pin. A lumen of an end lamella of one block includes a circumferential recess making a space for a flange of the pin. A lumen of the adjacent lamella of the other block includes a keyway providing a path for the flange of the pin to pass through when the pin is inserted into the aligned lumens so the flange can reside within the circumferential recess. 
     The circumferential recess may extend three quarters of the way around the lumen. In some embodiments the corner blocks are identical. One or more of the lumens may be arch-shaped. 
     Preferably, the pin is hollow. In an embodiment, a foot has a threaded rod at its top, so the threaded rod can be passed through the pin and held in place with a nut, providing a foot to hold the foundation off of a floor. A slipcover may be included for placement over the foundation. A collapsible mattress may be included. Typically, slats are included that can be installed to span the exterior beams as assembled. 
     These and other embodiments of the foundation will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top perspective view of an embodiment of a ready-to-assemble foundation for a bed. 
         FIG. 2  is an enlarged top perspective view of fastening system for joining slats to the foundation. 
         FIG. 3  is a top perspective view of the inside of a corner of an embodiment of the ready-to-assemble foundation. 
         FIG. 4  is a top perspective view of a joint between an interior beam and a transverse end member of an embodiment of a ready-to-assemble foundation for a bed. 
         FIG. 5  is a top perspective view of a slipcover on the ready-to-assemble bed foundation. 
         FIG. 6  is a top perspective view of a mattress suitable for use with embodiments of the foundation in a mattress container. 
         FIG. 7  is a top perspective view of an embodiment of a bed foundation having an optional slipcover and a mattress atop the foundation and slipcover. 
         FIG. 8  is a perspective view of a first corner connector. 
         FIG. 9  is a perspective view of a second corner connector configured to cooperate with the first corner connector. 
         FIG. 10  is a perspective view of a pin for use with the first and second corner connectors. 
         FIG. 11  is a perspective view of a combined foot and connecting pin. 
         FIG. 12  is a perspective view of the ready to assemble foundation with slip cover adjacent a shipping carton sized and configured to receive the ready to assemble foundation with slip cover. 
         FIG. 13  is a perspective view of a third corner connector adapted to be used with another third corner connector. 
         FIG. 14  is a perspective view of two third corner connectors joined together awaiting pin insertion. 
     
    
    
     DESCRIPTION OF THE VARIOUS EMBODIMENTS 
     The illustrations and descriptions thereof are for the purpose of describing embodiments of a bed foundation, and are not intended to limit the invention to any particular embodiment shown or described. Those of ordinary skill will recognize that the foundation described by the appended claims is subject to numerous embodiments. 
       FIG. 1  shows a foundation  10  for a platform bed. The foundation  10  includes a pair of exterior side beams  20  and  40  extending longitudinally between a pair of transverse end members  30  and  50  to form a generally rectangular outer frame. An interior support beam  80  may optionally be centrally located between the beams  20  and  40 . Each of a plurality of flexible, spaced apart slats  70  extends longitudinally from one of the exterior side beams  20  or  40  to the interior beam  80  and has a top surface generally coplanar with the top surface of the frame. 
     The exterior side beam  20  is substantially identical to the beam  40  and includes an upper  22  and lower member  24  spaced vertically by a plurality of blocks  29  between the members  22  and  24 . The upper member  22  includes a plurality of spaced apart slots for receiving the slats  70  and provide, with ends of the slats  70 , a generally planar top surface for the frame. 
     The transverse end member  30  is substantially identical to the member  50  and includes a pair of longitudinal members  32  and  34  spaced vertically by a plurality of blocks  37 ,  38  and  39 . The blocks  37  and  38  are spaced to provide an opening sized and positioned for receiving an end portion  81  of the interior beam  80 . In the embodiment of the foundation  10  shown in  FIG. 1 , the opening between the blocks  37  and  38  is slightly larger than the end portion  81 , which allows the end portion  81  to float within the opening. This allows the interior beam  80  to move slightly while being retained in place. Such movement provides “give” when an occupant of the bed moves. 
       FIG. 2  shows a fastener  72  for repeatedly coupling to and removing the slat  70  from the exterior side member  20 , which includes slots such as the slot  27  defined by opposing walls  23  and  26  and a substantially horizontal surface  28  between the walls  23  and  26 . The slat  70  includes an opening  77  and the surface  28  includes an opening  25  for receiving a fastener  72 , which has stem  73  surrounded by a flexible flanges  74 . Fasteners  72  are of the type often referred to as “Christmas tree” fasteners. The openings  77  and  25  are sized to provide engagement between the slat  70  and the beam  20  that remains intact during ordinary use of the foundation yet without the need for special tools permits removal of the fastener  72 , enabling removal of the slat  70  for storage or transportation of the foundation. Each slat  70  includes an opening at its opposite end like the opening  77  for receiving an additional fastener  72  and the beam  40  shown in  FIG. 1  includes openings such as the opening  77 . 
       FIG. 3  shows an inside corner of the foundation  10  including a connector  90 . The exterior beam  20  is coupled to the transverse end members  30  with the connector  90 . This structure is replicated at the other corners of the outer frame of the foundation  10 . The connector is made of three components, a right corner block  68 , a left corner block  70 , and a pin  72 . The right corner block  68 , left corner block  70 , and pin  72  can be made of injection molded plastic, such as glass-filled nylon. 
     As seen in  FIGS. 8 and 9 , the corner blocks  68  and  70  each have a mounting flange  74  having holes  75  for screws to pass through and into the respective beams  20 ,  30 ,  40  and  50  to hold the corner block in place. The mounting flange  74  has three upstanding lamella  76 ,  78 ,  80 , each with a shaped lumen  82 ,  182 ,  282 . The upstanding lamella can interleave with lamella of an adjacent block. The lumens are coaxial and have at least portions that are substantially cylindrical, so that they can securely receive a pin  110  (see  FIG. 10 ) that engages inside walls of the lumens snuggly and avoids wiggles or squeaks. Lumen  182  of lamella  76  of the block  79  includes a partially circumferential recess  183  extending three quarters of the way around the lumen, making a space for a flange  112  of pin  110 . Lumen  282  of lamella  76  of the block  68  includes two opposed keyways  283  (only one is shown in  FIG. 8 ), providing a path for the flange  112  to pass through when the pin  110  is inserted into the aligned lumens to reside within the recess  183 . As seen in  FIG. 10 , the pin is preferably hollow. 
     In a preferred embodiment, the keyways  283  align with one or the other of the ends of the partially circumferential recess  183 . That positioning permits the flange  112  to be inserted to be resident in the recess  183  and for the pin  110  to be turned using handles  114  to no longer be aligned with the keyways, preventing a simple pulling motion to remove the pin. If disassembly is desired, the handles can be turned to re-align the flanges with the keyways, so the pin can be withdrawn, and the two blocks  68  and  70  can be pulled apart. Since the blocks  68  and  70  are mounted on the beams, pulling the blocks apart results in the separation the beams and to disassemble the foundation. 
       FIGS. 13 and 14  show blocks that combine the features of the two corner block designs above into one block, so only one mold would be needed, and the one molded block serves where two different blocks  68 ,  70  were used above. In addition to reducing the cost of the mold, this design simplifies inventory for foundation preparation (one SKU, instead of two) and simplifies the mounting of the blocks on the bed frame beams, since there is no wrong choice of block for an installer. Furthermore, this design permits the pin to be inserted from either direction, which can be another benefit. 
     As seen in  FIG. 13 , the corner blocks  368  each have a mounting flange  74  having holes  75  for screws to pass through and into the respective beams  20 ,  30 ,  40  and  50  to hold the corner block in place. The mounting flange  74  has three upstanding lamella  376 ,  378 ,  380 , each with a shaped lumen. The lumens are coaxial and have at least portions that are substantially cylindrical, so that they can securely receive a pin  110 , as before. Lumen  390  of lamella  376  of includes a partially circumferential recess  392  extending three quarters of the way around the lumen, making a space for the flanges  112  of pin  110 . Lumen  382  of lamella  380  includes two opposed keyways  383 , providing a path for the flanges  112  to pass through when the pin  110  is inserted into the aligned lumens to reside within the recess  183 . 
       FIG. 14  shows two of the blocks  368  engaged, but without the pin inserted. In either end of the aligned lumens, the keyway  383  provides a path for the flange  112  of the pin to travel to become resident in recess  292 . Turning the pin locks the blocks together. 
     As seen  FIG. 13  the lumens of lamella  376  and  380  are circular (other than the recess  392  and keyways  383 ). The lumen of lamella  378  is arched, with the curved part of the arch being aligned with the inside of the lumens of lamella  376  and  380 , forming a surface of right cylinder. The arch, design allows a little flexion during pin insertion, with a tight fit to improve surface contact, which helps minimize squeaks. The tighter fit improves the strength, with each lamella supporting the other more directly. 
       FIG. 4  is view of an end of the interior beam  80 , which also includes an upper member  86  and lower member  84  spaced vertically by a plurality of blocks such as the blocks  83  (shown in  FIG. 1) and 89 . The upper member  86  includes a generally horizontal planar surface for supporting the slats  70  without the need for fastening the slats  70  to the member  86 . The beam  80  includes two opposing end portions, such as the end portion  81  shown, which is configured extend into the opening between the blocks  37  and  38  of the transverse end member  30  when the foundation is assembled. 
       FIG. 5  shows the foundation  10  with a slipcover  98  over the generally rectangular frame of the foundation  10 . The slipcover  98  may optionally include an integrally formed padding  99  for placement above the foundation and a zipper seam  97  to facilitate installation of the foundation  10  in the slipcover  98 . 
       FIG. 6  shows a mattress  94  in a collapsed configuration. The mattress  94  shown is vacuum-packed into a handy transparent shipping and carrying bag  93  including handles  95 . The disassembled foundation  10  can likewise be packaged in a carton, with or without carrying handles, or bag such as the bag  93  shown. The bag  93  provides a convenient container for carrying the mattress  94  and/or bed foundation  10  from a store to a vehicle, and further for transport from the vehicle into a residence for assembly. Alternatively, the mattress  94  can be sold to a customer from a catalogue or internet site and shipped in this collapsed configuration. 
       FIG. 7  shows the mattress  94  in an uncollapsed configuration atop the foundation  10  and optional slipcover  98 . A consumer can convert the mattress to the uncollapsed configuration shown after transport to a residence by simply removing the mattress  94  from the bag  93  shown in  FIG. 5 , unrolling it and allowing it to allow the mattress to expand. 
     The bed foundation can be provided in various sizes including but not limited to twin, double, queen, king and California king. 
       FIG. 11  shows a bed foot  104 , enabling the use of the foundation without a bed frame. The foot  104  includes a pin  106  having a straight, threaded shaft to pass through the center of installed pin  110  and receive a nut (not shown), such as a wingnut. The foot portion  100  extends down below the connector toward the floor. The foot portion  100  can make contact with the floor, or more preferably, a glide or caster (not shown) is inserted in a hole  112  at the bottom of the foot  100 . Thus, the side beams and transverse end members have connectors adjacent ends thereof, the connectors including flanges that can be interleaved with aligned openings through the interleaved flanges, and pins extend through the aligned openings receive the pins and the feet for the foundation to rest on a floor. Other forms of connection of the foot to the pin can be used, such as a press-fit shape on the top of the foot, or connections other than a threading with a nut. 
       FIG. 12  shows the foundation unassembled, with the slipcover  98  folded on top. As can be seen, these collapsed components can fit into a carton  114  for easy shipping and storage. 
     Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. All such modifications and improvements have not been included herein but may properly fall within the scope of the appended claims.