Patent Publication Number: US-6219863-B1

Title: Support structures and methods of fabricating support structures

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation, of application Ser. No. 09/066,135, filed Apr. 24, 1998, now abandoned. 
    
    
     FIELD OF THE INVENTION 
     This invention relates generally to the field of support structures and, more particularly, to a support structure and fabrication methods for support structures of a type for supporting the human body. 
     BACKGROUND OF THE INVENTION 
     For human beings, sleep is essential for sustaining physical and emotional health. Due to the essential importance of sleep in this regard, the prior art is replete with an array of apparatus and systems for not only promoting restful sleep, but also providing comfortable and, in some instances, therapeutic rest. Various mattress, box spring and support structure designs for supporting a sleeping surface are but few of the vast array of available sleep related features that have enjoyed considerable innovation throughout recent years. 
     Although much has been done to the structure of mattresses, box springs and structures for supporting mattresses and/or box springs, little attention has been devoted toward modular sleeping systems operative for only decreasing the high cost commonly associated with conventional frame and mattress sleeping systems, but also accommodating specific consumer needs of adaptability and convertibility of a sleeping assembly. The foregoing and other deficiencies inherent in the art therefore necessitate new and useful improvements. 
     Accordingly, it would be highly desirable to provide new and improved support structures and fabrication methods for support structures of a type for supporting a human body for sleep and/or rest. 
     It is a purpose of the present invention to provide a new and improved support structure that is easy to construct. 
     It is another purpose of the present invention to provide a new and improved support structure that may be converted into one or more of a plurality of body supporting orientations. 
     It is still another purpose of the present invention to reduce substantially the high costs associated with conventional frame and mattress sleeping systems. 
     It is a further purpose of the present invention to provide a new and improved support structure that is inexpensive. 
     It is yet a further purpose of the present invention to accommodate consumer sleeping and rest needs. 
     It is still a further purpose of the present invention to provide a new and improved modular sleeping system. 
     SUMMARY OF THE INVENTION 
     The above problems and others are at least partially solved and the above purposes and others are realized in a new and improved support assembly and fabrication method for a support assembly of a type for supporting the human body. In a specific embodiment, the support assembly is generally comprised of a first support structure including a first framework having first free ends and a first support member removably coupled with the first free ends, and a first plurality of slats supported by the first framework at first and second ends thereof, the first plurality of slats for receiving and supporting a first body supporting element having a supporting surface, one of the first and second ends of each one of the first plurality of slats removably coupled with the first removable support member. Further included is a second support structure including a second framework having second free ends and a second support member removably coupled with the second free ends, and a second plurality of slats supported by the second framework in series at first and second ends thereof, the second plurality of slats for receiving and supporting a second body supporting element having a supporting surface, one of the first and second ends of each one of the second plurality of slats removably coupled with the second removable support member. 
     Consistent with the foregoing, with the first and second removable support members removed from the first and second free ends and one of the first and second ends of each one of the first and second plurality of slats, further provided is a connector assembly engagable with one of the first and second ends of each one of the first and second plurality of slats and with the first and second free ends. In this regard, the connector assembly and the first and second plurality of slats operate to receive and support a selected body supporting element having a supporting surface greater than the supporting surface of each of the first and second body supporting elements. 
     In a specific embodiment, the connector assembly may include an elongate support structure having ends, means for detachably securing the ends of the elongate support structure with the first and second free ends of the first and second frameworks, and means for removably coupling one of the first and second ends of each one of the first and second plurality of slats with the elongate support structure intermediate the ends thereof. 
     In a further embodiment, the present invention may also include an adjustable support assembly. In this regard, and with one of the first and second plurality of slats removed from one of the first and second frameworks, the adjustable support assembly may be removably engaged with the one of the first and second frameworks, the adjustable support assembly for receiving and supporting an adjustable body supporting element and movable between a lowered orientation and an elevated orientation. In a particular embodiment, the adjustable support assembly may a linkage assembly removably engagable with the one of the first and second frameworks intermediate first and second ends thereof, the linkage assembly being movable between a lowered orientation and an elevated orientation and directed toward one of the first and second ends of the one of the first and second frameworks. Further included is a motor for moving the linkage assembly between the lowered orientation and the elevated orientation. 
     In another embodiment, the adjustable support assembly may still further include another linkage assembly removably engagable with the one of the first and second frameworks intermediate first and second ends thereof, the linkage assembly being movable between a lowered orientation and an elevated orientation and directed toward the other one of the first and second ends of the one of the first and second frameworks. The motor previously disclosed, or another motor if desired, may be employed for moving the other linkage assembly between the lowered and elevated orientations. 
     Consistent with the foregoing, associated methods may also be provided. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and further and more specific objects and advantages of the instant invention will become readily apparent to those skilled in the art from the following detailed description thereof taken in conjunction with the drawings in which: 
     FIG. 1 illustrates a fragmented, partially exploded perspective view of a support assembly, in accordance with the present invention; 
     FIG. 2 illustrates a side elevational view of the support assembly of FIG. 1, portions therein being broken away for the purposes of illustration; 
     FIG. 3 illustrates an exploded perspective view of a leg assembly of the support assembly of FIG. 1; 
     FIG. 4 illustrates a perspective view of a coupler assembly for providing engagement and support of one or more of a plurality of slats of the support assembly of FIG. 1; 
     FIG. 5 illustrates a fragmented perspective view of a plurality of slats of the support assembly of FIG. 1, and further illustrating an adjustment element adjustably mounted therewith; 
     FIG. 6 illustrates an enlarged perspective view of the adjustment element of FIG. 5; 
     FIG. 7 illustrates a vertical sectional view taken along line  7 — 7  of FIG. 5; 
     FIG. 8 illustrates an exploded perspective view of another embodiment of a support assembly, the support assembly including a connector assembly for interconnecting a pair of opposing frameworks, in accordance with the present invention; 
     FIG. 9 illustrates an exploded fragmented perspective view of portions of the connector assembly and the pair of opposing frameworks of FIG. 8; 
     FIG. 10 illustrates an end elevational view of the connector assembly of FIG. 9 as it would appear assembled; 
     FIG. 11 illustrates an exploded perspective view of yet another embodiment of a support assembly, the support assembly including an adjustable support assembly carried by a framework, the adjustable support assembly shown as it would appear in a lowered orientation, in accordance with the present invention; and 
     FIG. 12 illustrates a side elevational view of the support assembly of FIG. 11, the adjustable support assembly shown as it would appear in an elevated orientation. 
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     The present invention provides, among other things, a new and improved support assembly and methods of fabricating one or more support assemblies of a type for supporting the human body for rest and/or sleep. The invention incorporates a modular infrastructure for allowing selected construction of the support assembly in a plurality of body supporting orientations for providing flexibility, adaptability and consumer flexibility. 
     Turning now to the drawings, FIG. 1 illustrates a fragmented, partially exploded perspective view of a support assembly  20 , in accordance with the present invention. Support assembly  20  is generally comprised of a framework  21  including first and second end support members  22  and  23  and first and second elongate side support members  24  and  25 . Preferably constructed of wood, a selected metal or other substantially rigid material, ends of first end support member  22  and ends of second end support member  23  are each engagable, such as with screws or other suitable mechanical fastening mechanism, with ends of first and second side support members  24  and  25  to form framework  21  having, in this specific example, a substantially rectangular or box shape as shown. So constructed, framework  21  is generally intended to have a first end  26  and a second end  27 . 
     To provide support above the ground, support assembly  20  may further include a plurality of leg assemblies each being generally designated by the reference character  30 . Referring momentarily to FIG. 3 illustrating an exploded perspective view of one of the plurality of leg assemblies  30 , each leg assembly  30  is generally comprised of a leg support member  31  engagable with framework  21  and a leg  32  engagable with leg support member  31 . In this regard, and with attention directed back to FIG. 1, ends of each leg support member  31  may be coupled, such as with one or more screws  34  as shown or other suitable detachably engagable mechanical engagement mechanism, with adjoining end and side support members of framework  21 . A leg  32  may then be coupled, such as with screws, etc., with a corresponding leg support member  31  in downwardly depending relation for engagement with a supporting surface for supporting framework  21  above the supporting surface as shown substantially in FIG.  2 . As a matter of preference, each end and side support member  22 ,  23 ,  24  and  25  may be formed with one or more grooves, each designated at  33 , for accommodating or otherwise receiving the ends of the leg support members  31  if so desired at each corner or framework  21 . 
     Regarding FIGS. 1 and 2, framework  21  bounds a space  40  and provides support for a plurality of slats proximate space  40  aligned substantially from first end  26  to second end  27 , each slat being generally designated by the reference character  41 . In a further and more specific aspect, slats  41  are engagable at first and second ends  42  and  43  thereof for support with the opposing first and second side support members  24  and  25  in substantially parallel and spaced-apart relation via coupler assemblies engagable with the opposing first and second side support members  24  and  25 , each being generally designated by the reference character  50 . 
     With attention directed to FIG. 4, and preferably constructed of wood, plastic, metal or other substantially rigid material, each coupler assembly  50  is generally comprised of a supporting element  51  including a pair of pins  52  and  53  supported in spaced apart and substantially parallel relation with an elongate body  54 , each pin  52  and  53  having first and second free ends  52 A and  52 B, and  53 A and  53 B, respectively, on either side of the elongate body  54 . Further included is a coupler  60  including a body  61  having, in this specific example, a plurality of recesses  62  each for receiving an end, such as second end  43  as shown, of each one of a plurality of slats  41 . 
     In operation, first free ends  52 A and  53 A are removably receivable by through holes  65  formed through, as shown for the purposes of illustration, second side support member  25 . Extending inwardly toward space  40  bound by framework  21 , second free ends  52 B and  53 B are each removably receivable by spaced-apart apertures  66  and  67  carried and formed with body  61  of coupler, with recesses  62  each available for removably receiving, in this specific example, a second end  43  of one of a plurality of slats  41 . 
     Although not shown, another coupler assembly  50  may also be provided with first side support member  24  for providing the desired engagement of the opposing first ends  42  and support of slats  41  with framework  21  as shown substantially in FIG.  1 . Furthermore, body  61  of coupler  60  is specifically provided with three recesses  62  operative for supporting three slats  41  in a substantially triangular orientation. However, body  61  may be implemented for supporting one or another selected plurality of slats  41  depending on specific needs without departing from the invention. 
     As shown in FIG. 1, a selected plurality of coupler assemblies  50  may be provided for engagement with a corresponding plurality of through holes  65  formed through the first and second side support members  24  and  25  from first end  26  to second end  27  of framework  21  for supporting a selected plurality of slats  41  at space  40 . In this manner of assembly, slats  41  are operative for receiving and supporting a body supporting element (not shown), such as a conventional mattress, having a body supporting surface for supporting a human body for sleep, rest, etc. In this regard, framework  21  may be sized specifically for receiving varying sizes of mattresses such as, for instance, a single-, ½ queen- or twin- size mattress. To remove slats  41  and each coupler assembly  50 , the foregoing operation need only be reversed. 
     With momentary reference to FIGS. 5 and 7, shown is the substantially triangular orientation of slats  41  as they would appear supported by opposing coupler assemblies  50  consistent a specific embodiment. Shown for the purposes of illustration is an adjustment element  70  captured by slats  41  for sliding movement in reciprocal directions as indicated by the double arrowed line A for allowing a user to adjust the firmness of each series of three slats  41 . In this regard, adjustment element  70 , of which is also shown in FIG. 6, is generally comprised of a body  71  having opposing ways or grooves  72  and  73  for receiving opposing edges  74  and  75  of adjacent and opposing ones of slats  41  and a free end  76  for sliding receipt against the lowermost one of the plurality of slats  41 . By positioning adjustment element  70  at one or more selected locations via sliding movement along the length of slats  41  substantially from first ends  42  to second ends  43 , the firmness slats  41  cooperate to exhibit may be adjusted as desired. 
     Consistent with the present invention, it may be desirable to couple a pair of support assemblies  20  together to form a bigger support assembly. In a further and more specific aspect, a pair of support assemblies, each of substantially identical construction to support assembly  20 , may be coupled together to form another support assembly operative for receiving and supporting a mattress or other body supporting element, or a plurality of mattresses or body supporting elements, defining a body supporting surface greater than the body supporting surface of each body supporting element receivable and supportable by either one of the previously separate support assemblies. To this end, the desired construction of support assembly  20  to accommodate, for instance, a single-, ½ queen-, or twin-size mattress allows a user to couple a pair of support assemblies together to accommodate, for instance, a queen- or king-size mattress, or a plurality of one or more mattresses of a group including single-, ½ queen- and twin-size mattresses. 
     To this end, and with attention directed to FIG. 8, illustrated is an exploded perspective view of another embodiment of a support assembly generally designated by the reference character  80 . Support assembly  80  is generally comprised of a joining of first and second support assemblies  81  and  82  of identical construction to support assembly  20  previously discussed. In this regard, the same general reference characters set forth to describe the various structural features of support assembly  20  will also be used to describe the structural features of first and second support assemblies  81  and  82  as set forth in the ensuing discussion of FIGS. 8-10. However, in the interests of clarity, reference characters used to describe the first and second support assemblies  81  and  82  common to support assembly  20  will include prime (“′”) and double prime (“″”) symbols, respectively. 
     Consistent with the foregoing, support assembly  81  is generally comprised of a first framework  21 ′. First framework  21 ′ includes first and second end support members  22 ′ and  23 ′ and a first side support member  24 ′, second side support member (corresponding to second side support member  25 ) having been removed to expose free ends of first and second end support members  22 ′ and  23 ′. The leg assemblies (not shown) are intended also to have been removed from the second side support member and the first and second end support members  22 ′ and  23 ′. For the purposes of orientation, the free ends of first and second end support members  22 ′ and  23 ′ are herein defined as first and second free ends  85  and  86  of support assembly  81 . 
     Support assembly  82  is generally comprised of a second framework  21 ″. Second framework  21 ″ includes first and second end support members  22 ″ and  23 ″ and a second side support member  25 ″, first side support member (corresponding to first side support member  24 ) having been removed to expose free ends of first and second end support members  22 ″ and  23 ″. The leg assemblies (not shown) are intended also to have been removed from the first side support member and the first and second end support members  22 ″ and  23 ″. For the purposes of orientation, the free ends of first and second end support members  22 ″ and  23 ″ are herein defined as first and second free ends  87  and  88  of support assembly  82 . 
     To couple first and second support assemblies  81  and  82  together, provided is a connector assembly  90  operative for engaging together the first free ends  85  and  87  and the second free ends  86  and  88  of first and second support assemblies  81  and  82 , and for providing structural support for slats (not shown). Connector assembly  90  is generally comprised of an elongate support structure  91  shown, in this specific example, as first and second substantially coextensive support elements  92  and  93  each having a forward end  94  and  95  and a rearward end  96  and  97 . With attention directed to FIG. 9, first and second support elements  92  and  93  are engagable at forward ends  94  and  95  with first end support members  22 ′ and  22 ″ at first free ends  85  and  87  of first and second frameworks  21 ′ and  21 ″ in substantially perpendicular relation via screws  98  as shown, or other suitable detachably engagable mechanical engagement mechanism. Although not shown, first and second support elements  92  and  93  are also engagable at rearward ends  96  and  97  with second end support members  23 ′ and  23 ″ at second free ends  86  and  88  of first and second frameworks  21 ′ and  21 ″ in substantially perpendicular relation via screws, or other suitable detachably engagable mechanical engagement mechanism. To then secure first and second frameworks  21 ′ and  21 ″ together, first and second support elements may be engaged together in substantially coextensive, opposing and substantially parallel relation to thus join together first free ends  85  and  87  and second free ends  86  and  88 . In this manner of assembly, first and second frameworks  21 ′ and  21 ″ cooperate to define a support assembly suitable for supporting one or more mattresses or body supporting elements having a total body supporting surface greater than the body supporting elements previously receivable and supportable by either one of the first or second support assemblies  81  or  82  alone. 
     To provide support assembly  80  with an infrastructure suitable for supporting one or more body supporting elements, slats  41  (not shown) may be mounted for support at their first and second ends via coupler assemblies  50  (not shown) with first side support member  24 ′ and first support element  92  of connector assembly  90 , and with second side support member  25 ″ and second support element  93  of connector assembly  90 . 
     To interconnect the first and second support elements  92  and  93  together, FIG. 9 illustrates an engagement assembly  100  including, in a specific example, a pair of blocks  101  and  102  positioned outboard of a respective one of the first and second support elements  92  and  93 . Further included is a bolt  103  receivable into and through through-holes formed through the blocks  101  and  102  and first and second support elements  92  and  93 , a washer  104  and a nut  105  threadably engagable with the bolt  103  for securing together and capturing washer  104 , the blocks  101  and  102  and the first and second support elements  92  and  93  therebetween, the configuration of which may be easily be seen in FIG. 10. A selected plurality of engagement assemblies  100  may be provided in spaced apart relation along substantially the entire length of first and second support elements  92  and  93  as desired for securing the first and second support elements  92  and  93  together. Furthermore, blocks  101  and  102 , although not essential for providing engagement of the first support element  92  with the second support element  93 , are provided to give support to an adjustable support assembly  110  shown generally in the dotted outline in FIGS. 9 and 10, further details to be discussed presently. 
     Because the slats  41  of the present invention have been disclosed as removably engagable with support assemblies  20  and  80 , they may be removed and in their place, adjustable support assembly  110  installed or otherwise secured therewith such as with screws, bolts or other suitable detachably engagable mechanical fasteners. Referring now to FIG. 11, shown for the purposes of discussion in this regard is second support assembly  82  of support assembly  80  as it would appear assembled including first and second end support members  22 ″ and  23 ″, second side support member  25 ″ and second support element  93  of connector assembly  90 , all shown as they would appear interconnected in the manner discussed previously in combination with FIGS. 8-10. For the purposes of orientation, framework  21 ″ of support assembly  82  is generally intended to include first end  26 ″ and second end  27 ″. In the interests of clarity, adjustable support assembly  110  may be coupled with framework  21  of support assembly  20  or with framework  21 ′ of support assembly  81  in a manner substantially similar to that of the ensuing discussion. In this regard, rather than coupling adjustable support assembly  110  with second side support member  25 ″ and second support element  93  of support assembly  82  to be discussed presently, adjustable support assembly  110  may be coupled with first and second side support members  24  and  25  of support assembly  20 , and with first side support member  24 ′ and first support element  92  of support assembly  81  if desired. 
     Adjustable support assembly  110  is engagable with framework  21 ″ proximate space  40 ″ intermediate first and second ends  26 ″ and  27 ″ and is movable between a lowered orientation as shown in FIG.  11  and an elevated orientation as shown in FIG.  12 . Assembly  110  is operative for receiving and supporting an adjustable body supporting element or mattress much like the conventional adjustable mattresses found with conventional adjustable beds commonly found in hospitals, retirement homes, etc. 
     In this specific embodiment, adjustable support assembly  110  is generally comprised of first and second linkage assemblies  111  and  112 , first linkage assembly  111  being directed toward first end  26 ″, and second linkage assembly  112  being directed toward second end  27 ″. First linkage assembly  111 , of which is designed for accommodating the upper torso of the human body, includes first and second braces  120  and  121  engagable via screws or other suitable detachably engagable mechanical fasteners with second support element  93  and second side support member  25 ″ in substantially opposing relation. Also included are opposing first linkage elements  122  and  123  each having and end  122 A and  123 A mounted with framework  21 ″ as shown toward first end  26 ″ for pivotal movement, and opposing pivotally attached second linkage elements  124  and  125  terminating with free ends connected with an elongate member  126 . 
     Although movement of first linkage assembly  111  between lowered and elevated orientations may be carried out manually, a motor  127  may be employed as shown. In this regard, motor  127 , which may be provided as a conventional electric motor having either a self-contained power source or a power cord (not shown) for coupling with a conventional power outlet, is operative for actuating a first axle  128  for rotation in one or more predetermined directions for moving first linkage assembly  111  between lowered and elevated orientations. 
     To transfer movement of first axle  128  to first linkage assembly  111  in this regard, first axle  128  is coupled with first brackets  130  (only one shown) of a link assembly  131 , each first bracket  130  being mounted for pivotal movement at an end with one of the first and second braces  120  and  121 . Link assembly  131  further includes arms  132  (only one shown) each mounted for pivotal movement with another end of one of brackets  130  and with one of second bracket  133 . Ends of first linkage elements  122  and  123  confronting ends of second linkage elements  124  and  125 , respectively, are each mounted with one of second brackets  133  for pivotal movement, and ends of second linkage elements  124  and  125  confronting ends of first linkage elements  122  and  123 , respectively, are in turn substantially rigidly mounted with a corresponding one of second brackets  133 . Rotation of first axle  128  in predetermined directions upon selected actuation of motor  127  may be initiated for moving first linkage assembly  111  between the lowered orientation as set forth in FIG. 11, and the elevated orientation as set forth in FIG.  12 . 
     Second linkage assembly  112  includes opposing first linkage elements  140  and  141  having ends  140 A and  141 A mounted with framework  21 ″ as shown toward second end  26 ″ for pivotal movement and opposing pivotally attached second linkage elements  144  and  145  terminating with free ends connected with an elongate member  146 . Although movement of second linkage assembly  112  between lowered and elevated orientations may be carried out manually like first linkage assembly  111 , motor  127  may be employed as shown. In this regard, motor  127  may also be implemented for actuating a second axle  148  for rotation in one or more predetermined directions for moving second linkage assembly  112  between lowered and elevated orientations, second axle  148  being spaced from first axle  128 . 
     To transfer movement of second axle  148  to second linkage assembly  112  in this regard, second axle  148  is coupled with a link assembly  150  and, more particularly, to arms  151  (only one shown) of link assembly  150 . Each arm  151  is in turn mounted for pivotal movement at a free end thereof with a bracket  152  (only one shown) each fixed with one of the second linkage elements  144  and  145 . Rotation of second axle  148  in predetermined directions upon selected actuation of motor  127  may be carried out for moving second linkage assembly  112  between the lowered orientation as set forth in FIG. 11, and the elevated orientation as set forth in FIG.  12 . 
     In summary, the present invention provides modular and interconnectable components suitable for allowing conversion of a support assembly from a first orientation for supporting one of a single-, ½ queen- and twin-size mattress, to a second orientation for supporting one of a queen- and king-size mattress, or perhaps a plurality of single-, ½ queen- and twin-size mattresses. The slats herein disclosed for providing selected support may be removed, in addition to the corresponding coupler assembly  50 , for allowing the easy installation of an adjustable support assembly as desired in the various embodiments. 
     The present invention has been described above with reference to a preferred embodiment. However, those skilled in the art will recognize that changes and modifications may be made in the described embodiments without departing from the nature and scope of the present invention. Various changes and modifications to the embodiment herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variations do not depart from the spirit of the invention, they are intended to be included within the scope thereof which is assessed only by a fair interpretation of the following claims.