Patent Publication Number: US-9422961-B1

Title: Connector element with protrusion and tang fixation and associated frame assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This patent application claims priority to U.S. patent application Ser. No. 29/477,795, filed Dec. 27, 2013, the entire disclosure of which is incorporated herein by reference. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX 
     Not Applicable. 
     NOTICE OF COPYRIGHTED MATERIAL 
     The disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. Unless otherwise noted, all trademarks and service marks identified herein are owned by the applicant. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to the field of foundation assemblies. In particular, the present invention relates to improved connector elements, foundation assemblies, and a method for constructing foundation assemblies. 
     2. Description of Related Art 
     Typically, foundations and bases are constructed by hand from various pieces of pine or other lightweight woods. These built-up foundations are formed in a generally rectangular fashion and are sometimes sawed at each corner in an effort to replicate the rounded corners of conventional mattresses. 
     Various external jigs and fixtures must be used in order to assemble the numerous components of the foundations. Once aligned, the various pieces or components are typically nailed together. 
     Any discussion of documents, acts, materials, devices, articles, or the like, which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each claim of this application. 
     BRIEF SUMMARY OF THE INVENTION 
     However, constructing foundations using known methods is typically time-consuming, requires relatively skilled workers, requires numerous components and tools, and does not always result in a secure or square foundation. Even with the introduction of certain improved connector elements, assembly typically still requires use of screws or nails to hold the various components of the foundation assembly together. 
     Thus, the present invention relates generally to improved foundation assemblies. In particular, the present invention relates to improved connector elements, foundation assemblies, and a method for constructing a foundation assembly. 
     In various exemplary embodiments, the foundation assembly of the present invention is constructed of Medium Density Fiberboard (MDF) and/or plastic components. The overall part count is significantly lower than that of other foundations. This low parts count greatly reduces the number of contact points between components in the assembly, and virtually eliminates the potential for bothersome squeaks caused by friction. 
     In various exemplary embodiments, the foundation assembly comprises four shaped perimeter rails (first and second, opposing side rail elements and first and second, opposing header elements), joined to four connector elements. The profile of the perimeter rails provides smooth, rounded, horizontal outer edges, and includes a recessed notch to accommodate a flush-mounted deck panel. 
     In various exemplary, non-limiting embodiments, the connector elements comprise a body portion formed by a substantially planar first abutment surface, a substantially planar second abutment surface, and a corner surface. The first abutment surface extends to a first terminating edge and the second abutment surface extends to a first terminating edge. The first abutment surface and the second abutment surface are formed at substantially 90° relative to one another, and wherein the corner surface extends between the first terminating edge of the first abutment surface and the first terminating edge of the second abutment surface. 
     A first portion of the first abutment surface extends from a substantially planar bottom surface to a substantially planar deck panel support surface and a second portion of the first abutment surface extends from the bottom surface above the deck panel support surface. 
     A first portion of the second abutment surface extends from the bottom surface to the deck panel support surface and a second portion of the second abutment surface extends from the bottom surface above the deck panel support surface. 
     A first deck panel corner abutment surface extends substantially perpendicularly from a first terminating edge of the deck panel support surface between the first portion of the first abutment surface and the second portion of the first abutment surface. 
     A second deck panel corner abutment surface extends substantially perpendicularly from a second terminating edge of the deck panel support surface between the first portion of the second abutment surface and the second portion of the second abutment surface. 
     In various exemplary, non-limiting embodiments, the first deck panel corner abutment surface and the second deck panel corner abutment surface are formed at substantially 90° relative to one another. One or more substantially dowel-shaped protrusions extend perpendicular to the first abutment surface and one or more substantially dowel-shaped protrusions extend perpendicular to the second abutment surface. 
     At least one first deflectable flexible finger extends from the first abutment surface. At least a portion of a primary surface of the at least one first deflectable flexible finger extends substantially perpendicular to the first abutment surface, and wherein the at least one first deflectable flexible finger comprises a tang that extends, proximate a tip of the at least one first deflectable flexible finger, beyond the primary surface of the at least one first deflectable flexible finger. 
     At least one, optional second deflectable flexible finger extends from the first abutment surface. At least a portion of a primary surface of the at least one second deflectable flexible finger extends substantially perpendicular to the second abutment surface, and wherein the at least one second deflectable flexible finger comprises a tang that extends, proximate a tip of the at least one second deflectable flexible finger, beyond the primary surface of the at least one second deflectable flexible finger. 
     In various exemplary, nonlimiting embodiments, the connector element of the present invention also includes a first side support shoulder that extends perpendicular to the first abutment surface, proximate the bottom surface and a second side support shoulder that extends perpendicular to the second abutment surface, proximate the bottom surface. 
     In various exemplary, nonlimiting embodiments, the connector element of the present invention also includes a substantially planar first side surface and a substantially planar second side surface. At least a portion of the first side surface extends substantially perpendicular to the first abutment surface and at least a portion of the second side surface extends substantially perpendicular to the second abutment surface. The first side surface and the second side surface are formed at substantially 90° relative to one another, the primary surface of the at least one first deflectable flexible finger is substantially parallel to the first side surface, and the primary surface of the at least one second deflectable flexible finger is substantially parallel to the second side surface. 
     Aesthetically, the connector elements serve to round the vertical outer edges of the foundation assembly, while maintaining the radii of the foundation assembly&#39;s top and bottom edges. Structurally, the connector elements provide substantial impact resistance to corner loading and flexible resistance to parallelogram deformation. 
     The deck panel is typically a sheet of thinner MDF, or other material, which provides a single, solid surface upon which the mattress will sit. A solid deck panel is particularly critical for foam mattresses, for example, and is a major improvement over currently constructed foundations, which use soft cardboard atop lumber slats. 
     In various exemplary embodiments, elements of the foundation assembly may optionally be fastened together with adhesives, if desired. Alternatively, screws or other fasteners may optionally be used, but are not necessary, to assemble the elements of the foundation. In still other embodiments, both adhesive and screws or other fasteners may be used. 
     Accordingly, this invention provides a foundation assembly of improved design. 
     This invention separately provides a foundation assembly having a lower overall part count when compared to other foundations. 
     This invention separately provides a foundation assembly having improved structural stability. 
     This invention separately provides a foundation assembly that can be assembled without the need for external jigs and/or fixtures. 
     This invention separately provides a foundation assembly that can be scaled to accommodate any desired size or dimension. 
     This invention separately provides a foundation assembly that is less expensive to manufacture. 
     This invention separately provides a foundation assembly that can be held together without the use of nails, screws, fasteners, or adhesives. 
     This invention separately provides a connector element of improved design. 
     This invention separately provides a connector element that allows for assembly of foundation components without the use of tools. 
     This invention separately provides a scalable connector element. 
     This invention separately provides a connector element that is relatively lightweight. 
     This invention separately provides a connector element that can be produced in mass quantity from plastic, wood, or other any other suitable material. 
     These and other aspects, features, and advantages of the present invention are described in or are apparent from the following detailed description of the exemplary, non-limiting embodiments of the present invention and the accompanying figures. Other aspects and features of embodiments of the present invention will become apparent to those of ordinary skill in the art upon reviewing the following description of specific, exemplary embodiments of the present invention in concert with the figures. While features of the present invention may be discussed relative to certain embodiments and figures, all embodiments of the present invention can include one or more of the features discussed herein. Further, while one or more embodiments may be discussed as having certain advantageous features, one or more of such features may also be used with the various embodiments of the invention discussed herein. In similar fashion, while exemplary embodiments may be discussed below as device, system, or method embodiments, it is to be understood that such exemplary embodiments can be implemented in various devices, systems, and methods of the present invention. 
     Any benefits, advantages, or solutions to problems that are described herein with regard to specific embodiments are not intended to be construed as a critical, required, or essential feature(s) or element(s) of the present invention or the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       As required, detailed exemplary embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms, within the scope of the present invention. The figures are not necessarily to scale; some features may be exaggerated or minimized to illustrate details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention. 
       The exemplary embodiments of this invention will be described in detail, with reference to the following figures, wherein like reference numerals refer to like parts throughout the several views, and wherein: 
         FIG. 1  illustrates an upper, left perspective view of a first exemplary embodiment of a connector element according to this invention; 
         FIG. 2  illustrates an upper, front perspective view of a first exemplary embodiment of a connector element according to this invention; 
         FIG. 3  illustrates a left side view of a first exemplary embodiment of a connector element according to this invention; 
         FIG. 4  illustrates a right side view of a first exemplary embodiment of a connector element according to this invention; 
         FIG. 5  illustrates a left side rotational view of a first exemplary embodiment of a connector element according to this invention; 
         FIG. 6  illustrates a right side rotational view of a first exemplary embodiment of a connector element according to this invention; 
         FIG. 7  illustrates a front view of a first exemplary embodiment of a connector element according to this invention; 
         FIG. 8  illustrates a rear view of a first exemplary embodiment of a connector element according to this invention; 
         FIG. 9  illustrates a top view of a first exemplary embodiment of a connector element according to this invention; 
         FIG. 10  illustrates a bottom view of a first exemplary embodiment of a connector element according to this invention; 
         FIG. 11  illustrates a bottom isometric view of a first exemplary embodiment of a connector element according to this invention; 
         FIG. 12  shows a cross-sectional view of an exemplary side rail element according to this invention; 
         FIG. 13  shows a left side view of a first exemplary embodiment of a connector element aligned with an exemplary side rail element according to this invention; 
         FIG. 14  shows a left side view of a first exemplary embodiment of a connector element attached to an exemplary side rail element according to this invention; 
         FIG. 15  shows a top view of a first exemplary embodiment of a connector element aligned with an exemplary side rail element and an exemplary header element according to this invention; 
         FIG. 16  shows a top view of a first exemplary embodiment of a connector element attached to an exemplary side rail element and an exemplary header element according to this invention; 
         FIG. 17  shows an upper, isometric perspective view of a first exemplary embodiment of a connector element aligned with an exemplary side rail element and an exemplary header element according to this invention; 
         FIG. 18  shows a top perspective view of a first exemplary embodiment of a connector element attached to an exemplary side rail element and an exemplary header element according to this invention; 
         FIG. 19  shows an exploded perspective view of a first exemplary embodiment of certain of the components of a foundation assembly according to this invention; 
         FIG. 20  shows a top isometric perspective view of a partially assembled foundation assembly according to this invention; 
         FIG. 21  shows a bottom perspective view of a partially assembled foundation assembly according to this invention; and 
         FIG. 22  shows a top isometric perspective view of a partially assembled foundation assembly, including an exemplary deck panel according to this invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     For simplicity and clarification, the design factors and operating principles of the connector elements and foundation assemblies according to this invention are explained with reference to various exemplary embodiments of one or more connector elements and/or foundation assemblies according to this invention. The basic explanation of the design factors and operating principles of the connector elements and foundation assemblies is applicable for the understanding, design, and operation of the connector elements and foundation assemblies of this invention. It should be appreciated that the connector elements and/or the foundation assemblies can be adapted to many applications where a simplified connector element and/or a foundation or other assembly is needed. 
     As used herein, the word “may” is meant to convey a permissive sense (i.e., meaning “having the potential to”), rather than a mandatory sense (i.e., meaning “must”). Unless stated otherwise, terms such as “first” and “second” are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements. 
     The term “coupled”, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. The terms “a” and “an” are defined as one or more unless stated otherwise. 
     Throughout this application, the terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include”, (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are used as open-ended linking verbs. It will be understood that these terms are meant to imply the inclusion of a stated element, integer, step, or group of elements, integers, or steps, but not the exclusion of any other element, integer, step, or group of elements, integers, or steps. As a result, a system, method, or apparatus that “comprises”, “has”, “includes”, or “contains” one or more elements possesses those one or more elements but is not limited to possessing only those one or more elements. Similarly, a method or process that “comprises,” “has,” “includes” or “contains” one or more operations possesses those one or more operations but is not limited to possessing only those one or more operations. 
     It should also be appreciated that the terms “foundation”, “foundation assembly”, “corner connector”, and “connector element” are used for basic explanation and understanding of the operation of the systems, methods, and apparatuses of this invention. Therefore, the terms “foundation”, “foundation assembly”, “corner connector”, and “connector element” are not to be construed as limiting the systems, methods, and apparatuses of this invention. Thus, the terms “foundation” and “foundation assembly” are to be understood to broadly include any structures or devices capable of supporting a load, while the terms “corner connector” and “connector element” is to be understood to broadly include any structure or device capable of joining two elements at a given angle. 
     Turning now to the drawing Figs.,  FIGS. 1-11  show a first exemplary embodiment of a connector element  105  according to this invention. In an illustrative, non-limiting embodiment of this invention, as illustrated in  FIGS. 1-11 , the connector element  105  comprises at least some of a main body portion  110 , a deck panel support surface  115 , a first side surface  121 , a second side surface  122 , a corner surface  130 , a first abutment surface  131 , a second abutment surface  132 , a deck panel corner abutment surface  136 , a corner  139 , and a bottom surface  138 . 
     As illustrated in  FIGS. 1-11 , the main body portion  110  extends from the substantially planar bottom surface  138  to the substantially planar deck panel support surface  115  and is formed by a substantially planar first abutment surface  131 , a substantially planar second abutment surface  132 , and a corner surface  130 . 
     The first abutment surface  131  extends substantially perpendicularly from a terminating edge of the first side surface  121  to a first terminating edge. Likewise, the second abutment surface  132  extends substantially perpendicularly from a terminating edge of the second side surface  122  to a first terminating edge. The first abutment surface  131  and the second abutment surface  132  are formed at substantially 90° relative to one another. 
     The corner surface  130  extends from a terminating edge of the first abutment surface  131  to a terminating edge of the second abutment surface  132 . 
     A first portion of the first abutment surface  131  and the second abutment surface  132  extend above the deck panel support surface  115 , while a second portion of the first abutment surface  131  and the second abutment surface  132  terminates at the deck panel support surface  115 . 
     In various exemplary embodiments, as illustrated in  FIGS. 1-11 , an interior portion of the main body portion  110  (wherein the interior portion is defined substantially between the bottom surface  138 , the deck panel support surface  115 , the first side surface  121 , and the second side surface  122 ) is at least partially hollow. In these exemplary embodiments, one or more ribs  155  may optionally be formed within the hollow portion  157  of the interior portion. The one or more ribs  155  may provide additional strength and/or rigidity to the main body portion  110 . 
     In various exemplary embodiments, the deck panel corner abutment surface  136  extends substantially perpendicularly from a terminating edge of the deck panel support surface  115 . 
     The corner  139  is defined by the deck panel corner abutment surface  136 . In various exemplary embodiments, the deck panel corner abutment surface  136  is a curved surface. 
     In various exemplary embodiments, as illustrated in  FIGS. 1-11 , one or more recesses  133  are optionally formed in the first abutment surface  131  in an area between the protrusions  135 . The one or more recesses  133  may provide additional strength and/or rigidity to the first abutment surface  131  and/or the corner connector  105 . 
     One or more substantially dowel-shaped protrusions  135  extend perpendicularly from the first abutment surface  131  and the second abutment surface  132 . As illustrated in  FIGS. 1-11 , the connector element  105  includes three substantially dowel-shaped protrusions  135  extending from the first abutment surface  131  and three protrusions  135  extending from the second abutment surface  132 . It should be appreciated that the number of protrusions  135  is a design choice based on the desired appearance and functionality of the connector element  105 . 
     The protrusions  135  are formed so as to be aligned with and positioned within appropriately sized, mating recesses  167  and  177  formed in the header elements  160  and the side rail elements  170 , respectively. In this manner, the appropriate connector element  105  can be more readily aligned with the appropriate header element  160  and/or side rail element  170  when the foundation assembly  100  is assembled. 
     While the protrusions  135  are illustrated and described as being substantially cylindrical, with a substantially circular profile, in various exemplary, nonlimiting embodiments, each of the protrusions  135  may have a substantially circular, rectangular, square, or triangular profile. 
     At least one first deflectable flexible finger  140  extends from the first abutment surface  131 . At least a portion of a primary surface  143  of the at least one first deflectable flexible finger  140  extends substantially perpendicular to the first abutment surface  131 , and wherein the at least one first deflectable flexible finger  140  comprises a tang  149  that extends, proximate a tip  144  of the at least one first deflectable flexible finger  140 , beyond the primary surface  143  of the at least one first deflectable flexible finger  140 , to form a camming surface  146  and a shoulder  148 . 
     At least one second deflectable flexible finger  140  extends from the second abutment surface  132 . At least a portion of a primary surface  143  of the at least one second deflectable flexible finger  140  extends substantially perpendicular to the second abutment surface  132 , and wherein the at least one second deflectable flexible finger  140  comprises a tang  149  that extends, proximate a tip  144  of the at least one second deflectable flexible finger  140 , beyond the primary surface  143  of the at least one second deflectable flexible finger  140 , to form a camming surface  146  and a shoulder  148 . 
     Each deflectable flexible finger  140  comprises a stem  142 , which terminates at a tip  144 , and a shoulder  148  and a camming surface  146 , which extend from a side portion of the stem  142 . 
     In various exemplary, nonlimiting embodiments, the connector element  105  also includes a first side support shoulder  151  that extends perpendicular to the first abutment surface  131 , proximate the bottom surface  138  and a second side support shoulder  152  that extends perpendicular to the second abutment surface  132 , proximate the bottom surface  138 . 
     The first side surface  121  and the second side surface  122  are substantially planar and are formed at substantially 90° relative to one another. At least a portion of the first side surface  121  extends substantially perpendicular to the first abutment surface  131  and at least a portion of the second side surface  122  extends substantially perpendicular to the second abutment surface  132 . The first side surface  121  and the second side surface  122  are formed at substantially 90° relative to one another, the primary surface  143  of the at least one first deflectable flexible finger  140  is substantially parallel to the first side surface  121 , and the primary surface  143  of the at least one second deflectable flexible finger  140  is substantially parallel to the second side surface  122 . 
     One or more optional attachment apertures (not illustrated) may be formed in or through the deck panel support surface  115 , the first side surface  121 , and/or the second side surface  122 . If included, the one or more optional attachment apertures may be sized so as to allow a fasteners, such as, for example, a screw, to more easily attach to the connector element  105 . 
     In various exemplary embodiments, the connector element  105  is substantially rigid and is formed of a polymeric material such as a polymeric composite. Alternate materials of construction may include one or more of the following: wood, steel, aluminum, titanium, and/or other metals, as well as various alloys and composites thereof, glass-hardened polymers, polymer or fiber reinforced metals, carbon fiber or glass fiber composites, continuous fibers in combination with thermoset and thermoplastic resins, chopped glass or carbon fibers used for injection molding compounds, laminate glass or carbon fiber, epoxy laminates, woven glass fiber laminates, impregnate fibers, polyester resins, epoxy resins, phenolic resins, polyimide resins, cyanate resins, high-strength plastics, nylon, glass, or polymer fiber reinforced plastics, thermoform and/or thermoset materials, and/or various combinations of the foregoing. Thus, it should be understood that the material or materials used to form the connector element  105  is a design choice based on the desired appearance and functionality of the connector element  105 . 
     It should be appreciated that the connector element  105  may be integrally formed. Alternatively, suitable materials can be used and sections are elements made independently and attached or coupled together, such as by adhesives, staples, screws, nails, or other fasteners, to form the connector element  105 . 
     It should be understood that the overall size and shape of the connector element  105 , and the various portions thereof, is a design choice based upon the desired functionality and/or appearance of the connector element  105 . Additionally, it should be appreciated that the connector element  105  is formed such that multiple connector elements  105  may be positioned and used as each of the four corners of a foundation assembly  100 . Therefore, multiple connector elements do not have to be formed for a specific location at a specific corner of a foundation assembly  100 . 
     As illustrated in  FIGS. 13-22 , the connector element  105  may be used to construct a foundation assembly  100 . As illustrated in  FIGS. 13-22 , the foundation assembly  100  comprises at least some of a plurality of connector elements  105 , header elements  160  (each header element  160  having recesses  167  and tang receiving grooves  165 ), side rail elements  170  (each side rail element  170  having recesses  177  and tang receiving grooves  175 ). 
       FIG. 12  shows a cross-sectional view of an exemplary header element  160  (or side rail element  170 ) according to this invention. As illustrated in  FIG. 12 , the header elements  160  each include one or more recesses  137  formed in each end. It should be understood that each of the one or more recesses  137  is formed so as to allow one of the protrusions  135  of the connector elements  105  to be positioned within the recess  137 . Thus, for example, if the connector element  105  includes three protrusions  135 , three mating recesses  137  will be formed in each end of the header elements  160  and the side rail elements  170 . Each of the header elements  160  also includes a recessed notch  169  to accommodate a flush-mounted deck panel  180 . 
     Each of the header elements  160  has at least one tang receiving groove  165  formed on an interior side of the header element  160 , perpendicular to the longitudinal axis of the header element  160 . These one or more tang receiving grooves  165  are formed so as to accept at least a portion of a tang  149 , as described herein. 
     While elements of the header elements  160  are illustrated in  FIG. 12 . It should be appreciated, however, that the features of the side rail elements  170  correspond to the elements of the header elements  160  and may, in fact, be identical to the elements of the header elements  160 . However, typically the rail elements  170  are longer in length than the header elements  160 . 
     Due to the shape and placement of the first side surface  121 , the second side surface  122 , the first abutment surface  131 , and the second abutment surface  132 , so long as the header elements  160  are of an equal length and the side rail elements  170  are of an equal length, and so long as each of the header elements  160  and the side rail elements  170  has a terminating end that is parallel and perpendicular to the longitudinal axis of the element, when the interior side of the element is positioned against a corresponding first side surface  121  or the second side surface  122  of a connector element  105  and the terminating end is positioned against a corresponding first abutment surface  131  or second abutment surface  132 , the header elements  160  will be parallel to one another and the side rail elements  170  will be parallel to one another. 
     In order to construct a foundation assembly  100 , four connector elements  105  are positioned at locations proximate the four corners of the finished foundation assembly  100 . 
     When properly positioned, the header elements  160  and the side rail elements  170  are each guided, by the interaction of the protrusions  135  with the recesses  167  and  177  and receipt of the protrusions  135  within the recesses  167  and  177 . 
     In this manner, an end surface of the header elements  160  and the side rail elements  170  contacts an appropriate first abutment surface  131  or second abutment surface  132 , and an inner surface of the header elements  160  and the side rail elements  170  contacts an appropriate first side surface  121  or second side surface  122 . 
     As illustrated in  FIGS. 13-18 , a corner connector  105  is properly aligned with and urged toward a header element  160  (or side rail element  170 ), the side surface  122  and/or a portion of the primary surface  143  contacts an inner surface of the header element  160  (or side rail element  170 ). As the corner connector  105  is further or urged, the camming surface  146  of the tang  149  contacts the inner surface of the header element  160  and the finger  140  is flexed inwardly so as to ride along the inner surface of the header element  160 . 
     The fingers  140  continues to be flexed inwardly until shoulders  148  passed beyond an edge of the tang receiving groove  165 , whereupon the spring bias of the stressed stem  142  causes the fingers  140  to snap outwardly and the tang  149  is urged into the tang receiving groove  165 , to assume the position as illustrated in  FIG. 14 . 
     When the tang  149  is positioned within the tang receiving groove  165 , the shoulder  148  contacts and engages a sidewalls surface of the tang receiving groove  165 , firmly mounting the header element  160  on the corner connector  105 . When assembled, the interaction of the tang  149  with the tang receiving groove  165  restraining axial movement of the header element  160  with respect to the corner connector  105 . Particularly, when a withdrawing force is applied to the header element  160 , the abutting relation of the shoulder  104  and the tang receiving groove  165  will preclude axial movement, thereby precluding the disengagement of the corner connector  105  and the header element  160 . 
     It is further noted that if the angle of the shoulder  148  includes an undercut, the greater the withdrawing force applied the header element  160 , the stronger the engagement between the tangs  149  and the tang receiving grooves  165  becomes, as the withdrawing force will cause tangs  149  to further flex inward restraining the movement of the header element  160 . 
     While  FIGS. 13 and 14  illustrate a corner connector  105  being attached to a header element  160 , it should be appreciated that the corner connector  105  may be attached to a side rail element  170  (as illustrated in  FIGS. 15-18 ) in the same manner. 
     Once each of the corner connectors  105 , header elements  160 , and side wall elements  170  are attached, coupled, or secured together, the assembly  100  is partially assembled as illustrated in  FIGS. 20 and 21 .  FIGS. 20 and 21  show a top and bottom view, respectively, of a partially assembled foundation, wherein the deck panel  180  has not yet been added to the assembly  100 . 
     Finally, as illustrated in  FIG. 22 , the deck panel  180  can be placed atop the deck panel support surfaces  115 , within the recessed notch  169  of the header elements  160  and the recessed notch  179  of the side rail elements  170 , so as to be flush-mounted with a top surface of the header elements  160 , the rail elements  170 , and the connector elements  105 . 
     Once assembled, the foundation assembly  100  can be placed in a bed frame (not shown) for receiving a mattress. 
     While this invention has been described in conjunction with the exemplary embodiments outlined above, the foregoing description of exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting and the fundamental invention should not be considered to be necessarily so constrained. It is evident that the invention is not limited to the particular variation set forth and many alternatives, adaptations modifications, and/or variations will be apparent to those skilled in the art. 
     Furthermore, where a range of values is provided, it is understood that every intervening value, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and is also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention. 
     It is to be understood that the phraseology of terminology employed herein is for the purpose of description and not of limitation. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. 
     In addition, it is contemplated that any optional feature of the inventive variations described herein may be set forth and claimed independently, or in combination with any one or more of the features described herein. 
     Accordingly, the foregoing description of exemplary embodiments will reveal the general nature of the invention, such that others may, by applying current knowledge, change, vary, modify, and/or adapt these exemplary, non-limiting embodiments for various applications without departing from the spirit and scope of the invention and elements or methods similar or equivalent to those described herein can be used in practicing the present invention. Any and all such changes, variations, modifications, and/or adaptations should and are intended to be comprehended within the meaning and range of equivalents of the disclosed exemplary embodiments and may be substituted without departing from the true spirit and scope of the invention. 
     Also, it is noted that as used herein and in the appended claims, the singular forms “a”, “and”, “said”, and “the” include plural referents unless the context clearly dictates otherwise. Conversely, it is contemplated that the claims may be so-drafted to require singular elements or exclude any optional element indicated to be so here in the text or drawings. This statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely”, “only”, and the like in connection with the recitation of claim elements or the use of a “negative” claim limitation(s).