Patent Publication Number: US-10321768-B2

Title: Foldable bed frame with sloping stop

Description:
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/908,656 (filed on Nov. 25, 2013) and 61/931,349 (filed on Jan. 24, 2014), which are incorporated by reference herein as though set forth herein in full. 
    
    
     FIELD OF THE INVENTION 
     The present invention pertains, among other things, to bed frames, e.g., for supporting a mattress and/or box spring, as well as to components thereof and systems, methods and techniques for using any of the foregoing items. 
     BACKGROUND 
     Bed frames are the structures used to support a bed&#39;s box spring and/or mattress, elevating them off the floor, e.g., so that the bed is at a more comfortable height, making it is easier to get into and out of the bed. A variety of different conventional bed frames exist. Some are wooden platforms. Probably the most common and least expensive type, however, is a steel frame that typically includes, a peripheral structure, often one or more cross beams to provide additional support, and multiple legs. Unfortunately, the present inventor has discovered that most of such conventional steel bed frames, while adequate for the foregoing basic purpose, often are cumbersome to deal with, e.g., in terms of packaging, shipping, and then subsequent assembly and disassembly when it is desired to move the bed frame to a different location. 
     SUMMARY OF THE INVENTION 
     The present invention addresses these issues and primarily concerns: a foldable bed frame; various components of such a frame; and methods for folding, unfolding and using such a frame. Generally speaking, a bed frame according to the present invention typically has two main configurations: one in which the frame is folded up for storage, shipment or the like; and another in which the frame is completely unfolded and ready for use, e.g., to support a box spring and mattress. The completely unfolded configuration sometimes is referred to herein as the operational configuration. 
     Thus, one embodiment of the invention is directed to a bed frame that has: a left side component (e.g.,  75 ) that includes an elongated left side rail (e.g.,  14 ) and an extending segment (e.g.,  76  or  77 ) at each end, each such extending segment pivotally attached to the elongated left side rail and capable of being pivoted from substantially parallel the left side rail to substantially perpendicular to the left side rail; and a right side component (e.g.,  85 ) that includes an elongated right side rail (e.g.,  15 ) and an extending segment (e.g.,  86  or  87 ) at each end, each such extending segment pivotally attached to the elongated right side rail and capable of being pivoted from substantially parallel the right side rail to substantially perpendicular the right side rail. Each of the elongated left side rail and the elongated right side rail includes two main sections (e.g.,  21  and  22  or  41  and  42 ) that are pivotally attached to a shorter center member (e.g.,  25  or  45 ). At each end, the extending segments of the left side component and the right side component detachably couple to each other, forming lateral components of a bed frame assembly. 
     Another embodiment is directed to a bed frame that includes a center component (e.g.,  65 ), a left side component (e.g.,  75 ) and a right side component (e.g.,  85 ). The center component includes an elongated center support (e.g.,  12 ) and a pair of opposite first extending segments (e.g.,  66  or  67 ) at each end, each of the first extending segments pivotally attached to the elongated center support and capable of being pivoted from substantially parallel said center support to substantially perpendicular said center support. The left side component includes an elongated left side rail (e.g.,  14 ) and a second extending segment (e.g.,  76  or  77 ) at each end, each such second extending segment pivotally attached to the elongated left side rail and capable of being pivoted from substantially parallel said left side rail to substantially perpendicular said left side rail. The right side component that includes an elongated right side rail (e.g.,  15 ) and a third extending segment (e.g.,  86  or  87 ) at each end, each said third extending segment pivotally attached to the elongated right side rail and capable of being pivoted from substantially parallel said right side rail to substantially perpendicular said right side rail. Each of the elongated center support, the elongated left side rail and the elongated right side rail includes two main sections (e.g.,  21  and  22  or  41  and  42 ) that are pivotally attached to a shorter center member (e.g.,  25  or  45 ). Each pair of the first extending segments detachably attaches to one of the second extending segments and one of the third extending segments to provide a bed frame assembly. 
     The foregoing summary is intended merely to provide a brief description of certain aspects of the invention. A more complete understanding of the invention can be obtained by referring to the claims and the following detailed description of the preferred embodiments in connection with the accompanying figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the following disclosure, the invention is described with reference to the attached drawings. However, it should be understood that the drawings merely depict certain representative and/or exemplary embodiments and features of the present invention and are not intended to limit the scope of the invention in any manner. The following is a brief description of each of the attached drawings. 
         FIG. 1  is a top perspective view of a completely unfolded and assembled bed frame (i.e., ready for use, or in its operational configuration), according to a representative embodiment of the present invention. 
         FIG. 2  is a top perspective view of the central portion of the bed frame&#39;s center support, in its operational configuration. 
         FIG. 3  is a perspective first side view of the central portion of the center support, in a partially folded configuration. 
         FIG. 4  is a second side perspective view (opposite the first side) of the central portion of the center support, in a partially folded configuration. 
         FIG. 5  is a top, inner side perspective view of the central portion of a side rail, in its unfolded (or operational) configuration. 
         FIG. 6  is an outer side elevational view of the central portion of the side rail in a folded configuration. 
         FIG. 7  is a top perspective view of the central portion of the side rail in the folded configuration. 
         FIG. 8  is an inner side perspective view of the central portion of the side rail in the folded configuration. 
         FIG. 9  is a top perspective view of one side rail component and a portion of the center support component, with one of the segments at the foot of the center support component being partially folded, and with the adjacent segments of the two components at the head of the bed frame attached to each other. 
         FIG. 10  is a top perspective view of one side rail component and a portion of the center support component, with the adjacent segments at the foot of the two components, which attach to each other when in operational use, being partially folded, and with the adjacent segments of the two components at the head of the bed frame attached to each other. 
         FIG. 11  is a top plan view showing the center support component and the side rail components in their completely folded configuration with their leg glides removed. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT(S) 
     The bed frame  10  shown in  FIG. 1  can function as an ordinary bed frame. That is, it can support a box spring and/or mattress placed on top of it. The depicted bed frame  10  includes a center support  12  and two side rails  14  and  15 , with the bed frame  10  preferably sized to accommodate a box spring and/or mattress of a standard size (e.g., twin, full, double, queen, king or California king). However, unlike conventional bed frames, the present frame  10  can be folded up for easier storage, shipping or the like. For example, the central portion of each of center support  12  and side rails  14  and  15  includes two seams (and corresponding pivot points), and each preferably can be bent at a 90° angle so that the entire frame  10  essentially can be folded in half along its length. In fact, in embodiments where a gap is provided between such seams, the maximum folded-up dimension of the present bed frame  10  is less than half the full length of the frame when in operational use. Still further, as discussed in greater detail below, other portions of the center support  12  and side rails  14  and  15  also can include foldable joints (e.g., of a conventional nature) and detachment points so that the entire bed frame  10  can be just partially disassembled and then the resulting beams easily folded, so that the entire bed frame  10  fits in a small box that can be hand carried and/or readily shipped and then quickly and easily removed and assembled. 
       FIG. 2  shows a close-up view of the central portion of center support  12  while in the operational orientation. As shown, center support  12  includes two main sections  21  and  22 . In addition, as shown in  FIG. 3 , sections  21  and  22  are joined together with the use of a shorter member  25  (preferably, approximately 3-8 inches in length and, in the currently preferred embodiment, approximately 3¾ inches long) that is pivotally attached to each of sections  21  and  22  using a corresponding rivet  27 . In alternate embodiments, pins or other pivoting elements may be used in place of rivets  27 . 
     In the present embodiment, each of elements  21 ,  22  and  25  has an L-shaped cross-section, consisting of two elongated panels  12 A and  12 B, integrally formed together and at least approximately perpendicular to each other (e.g., forming an angle of 80-100° or, more preferably, 85-95°). In operational use, for each of elements  21  and  22 , one of such panels  12 A preferably is substantially horizontal and functions as a flat bottom surface for the bed frame, and the other panel  12 B preferably is a substantially vertical side panel extending downwardly, while the panels  12 A and  12 B for element  25  parallel and overlap the corresponding panels for element  21  and  22 , with element  25  disposed inside of elements  21  and  22 . As shown most clearly in  FIG. 3 , rivets  27  join sections  21  and  22  to member  25  along such elements&#39; downwardly extending side panels  12 B. 
     In the current embodiment, portions  28  of panels  12 B have been punched (or dented) so that they bulge inwardly and essentially act as stops, maintaining sections  21  and  22  at approximately right angles with respect to member  25  when the bed frame  10  is in the folded-up configuration. Still further, punches (or other protrusions)  28  can provide for easier folding, by functioning as a kind of guide, allowing for additional leverage and/or stabilizing the various segments relative to each other while the component is being folded up. In alternate embodiments, punches  28  can be replaced with any other protruding elements, such as any other protrusions formed into the material that is used to fabricate sections  21  and  22  (typically steel), or separate elements such as rivets. When punches  28  are used, the protrusions typically are formed with smoothly sloping sides so that the edges of member  25  gradually engage with such protrusions, essentially locking the components together. More preferably, each such protrusion is formed by essentially hammering the opposite side of the panel  12 B at the same time (i.e., in the same step) that the holes and/or notches are cut or otherwise formed into such sections  21  and  22 . As result, both the cost of a rivet (or other separate component) and the additional manufacturing step of inserting it can be eliminated. 
     In addition, attached to the downwardly extending side panel  12 B of member  25  in the present embodiment (e.g., using a pair of rivets  30 ) is a leg  23  for supporting the frame  10  when in operational use. In the current embodiment, each leg of the bed frame (including leg  23 ) includes an upper post portion (e.g., post portion  23 A) and a lower glide portion (e.g., glide portion  23 B), with the glide portion  23 B capable of being slid onto the post portion  23 A (e.g., for operational use) and slid off of it (e.g., for storage and/or shipment). However, in alternate embodiments any or all of the legs of a bed frame according to the present invention can be provided with a caster, other type of roller, or other type of bottom portion, and/or can be provided as a single unitary piece. When the bed frame  10  is unfolded into the operational configuration, notches  29  engage with the sides of rivets  30  depicted in  FIG. 4 , thereby securing center support  12  so that sections  21  and  22  together provide a flat surface and remain aligned with each other. 
     Similar to center support  12 , each of side rails  14  and  15  includes two main sections  41  and  42  (typically made of steel) joined together through the use of a central member  45 . All of such elements preferably also have L-shaped cross-sections. However, elements  41 ,  42  and  45  preferably are oriented so as to form the bottom  14 A and side  14 B surfaces of the bed frame when it is in operational use (as opposed to center support  12 , which is only intended to provide a single flat bottom surface of the frame).  FIGS. 5-8  depict the central portion of the left side rail  14 , with right side rail  15  preferably having the same (but mirror-image) structure. 
     In the present embodiment, member  45  is pivotally attached to sections  41  and  42 , using rivets  47  in the components&#39; sidewall panels  14 B. However, in alternate embodiments pins or any other pivoting elements may be used in place of rivets  47 . In addition, in the present embodiment a support leg  43 , which supports the bed frame when in operational use, is attached to the bottom panel  14 A of one of the sections (section  41  in the present embodiment), using a pair of rivets  50 . 
     Also, in the current embodiment, punches  48  are provided in the side panels  14 B of sections  41  and  42 , generally have the same characteristics as punches  28  (described above), and essentially act as stops, contacting the edge of member  45 &#39;s side panel  14 B and thereby maintaining sections  41  and  42  at approximately right angles with respect to member  45  when the frame is in the folded-up configuration. Still further, punches  48  can also provide for easier folding, by functioning as a kind of guide, allowing for additional leverage and/or stabilizing the various segments relative to each other while the component is being folded up. However, in alternate embodiments, punches  48  can be replaced with any other protruding element, such as any of the alternatives described above in reference to punches  28 . 
     Preferably, member  45  is 3-8 inches in length and made of steel and, in the present embodiment, is approximately 3¾ inches long, and also includes openings  51  in its bottom panel  14 A. When the bed frame  10  is unfolded into the operational configuration, one of the openings  51  (depending upon whether used in the right side rail or the left side rail) accommodates one of the rivets  50 , as shown most clearly in  FIG. 5 . In certain embodiments, openings  51  and/or the heads of rivets  50  (or bolts or other elements used to secure leg  43  to section  41  or  42 ) are provided with a resilient material (e.g., in the form of a washer or grommet) so that a compression fit occurs when the bed frame is unfolded into the operational configuration, thereby helping to lock sections  41  and  42  into the desired relationship. 
     The preceding discussion focused on the folding of center support  12  and side rails  14  and  15 . In the present embodiment: (1) the center support  12  folds downwardly i.e., so that the two main sections  21  and  22  rotate downwardly (from the top perspective shown in  FIGS. 1, 9 and 10 ); (2) when center support  12  is folded in this manner, leg  23  also extends downwardly, at least approximately parallel to sections  21  and  22  (e.g., as shown in  FIGS. 4 and 5 ); and (3) each of side rails  14  and  15  folds upwardly i.e., so that the two main sections  41  and  42  rotate upwardly (from the top perspective shown in  FIGS. 1, 9 and 10 ), and leg  43  ends up extending off to the side, at least approximately perpendicular to sections  41  and  42  (e.g., as shown in  FIGS. 6-8 ). 
     Also in the current embodiment, each of members  12 ,  14  and  15  is part of a larger main component of the bed frame  10 . More specifically, center support  12  is part of a center component  65  that also includes a pair of oppositely extending segments  66  and  67  at the head of the bed frame and a pair of oppositely extending segments  68  and  69  at the foot of the bed frame. Each of such segments  66 - 69  preferably also has an L-shaped cross section (with a top panel and a panel that extends downwardly along the outer edge of the top panel) and is pivotally attached to the corresponding end of center support  12 , using a pivot element  72 , such as a rivet or a pin. As a result, each of segments  66 - 69  can be folded inwardly toward, and ultimately parallel with and overlapping, center support  12 , and it also can be unfolded to be at least substantially perpendicular to center support  12 , with its outer side wall parallel with and abutting the end of center support  12 . 
     Similarly, each of side rails  14  and  15  is part of a larger side rail component.  FIGS. 9 and 10  show side rail component  75 , of which side rail  14  is a part. The side rail component  85  (shown in  FIG. 11 ), of which side rail  15  is a part, essentially is the mirror image of component  75  (e.g., including pivoting segments  86  and  87 ) and therefore is not separately discussed. 
     Side rail component  75  includes an inwardly extending segment  76  at the head of the bed frame and an inwardly extending segment  77  at the foot of the bed frame. Each of such segments  76  and  77  also has an L-shaped cross section (with a top panel and a panel that extends downwardly along the outer edge of the top panel) and is pivotally attached to the corresponding end of side rail  14 , using a pivot element  72 . As result, each of segments  76  and  77  can be folded inwardly toward, and ultimately parallel with and underneath, side rail  14 , and it also can be unfolded to be at least substantially perpendicular to side rail  14 , with its outer side wall parallel with and abutting the end of side rail  14 . 
     In the current embodiment, each pair of adjacent segments detachably attaches to each other. Thus, segment  66  attaches to segment  76  and segment  68  attaches to segment  77 . Similarly, segment  67  attaches to the adjacent segment  86  of component  85  and segment  69  attaches to the corresponding adjacent segment  87  of component  85 . A variety of different attachment mechanisms can be used for this purpose, such as screws, nuts, latches and/or clips. However, in the preferred embodiments, the attachment mechanism described in commonly assigned U.S. Pat. No. 5,161,268 (which is incorporated by reference herein as though set forth herein in full) is used, in order to provide the bed frame  10  with an adjustable width, thereby enabling it to accommodate different mattress/box-spring sizes. In the present embodiment, in order to best implement such an attachment mechanism, the segments for components  75  and  85  are configured in such a way that they are not exactly mirror images of each other, i.e., so that both attachments at the head of the bed frame are made in the same direction and both attachments at the foot of the bed frame are made the same direction. 
     As will be readily appreciated, a bed frame according to the present invention can be quickly and easily assembled into its operational configuration and then just as quickly and easily taken apart and folded up for storage and/or transportation. From the operational configuration shown in  FIG. 1 , one simply removes the glides  23 B from all of the legs ( 23  and  43 ), detaches the adjacent segments (e.g., adjacent segments  66  and  76 , adjacent segments  68  and  77 , and the corresponding adjacent segments on the other side of the bed frame  10 ), folds those segments inwardly toward their corresponding main bed frame components (i.e., components  65 ,  75  and  85 , respectively), and then folds center support  12  downwardly and each of side rails  14  and  15  upwardly. The result is a set of compact components, as shown in  FIG. 11 . In addition, these components can be further compacted by stacking components  65 ,  75  and  85  on top of each other, so that the entire bed frame can fit into a fairly small box. 
     For this purpose, the present inventor has discovered that using central members  25  and  45  with a maximum length of around 4-4½ inches and, more preferably, a maximum length of 3¾ inches, can allow all of the components to fit in a box that is small enough to fit to the cross on a standard-sized palette. More specifically, a bed frame  10  of the present invention, when in its operational configuration, has a length of 70½ inches, a depth of 9 inches, and a width that is adjustable from 38¾ to 72¾ inches. Nevertheless, when disassembled and folded as described above, the entire bed frame  10  can fit into a box of dimensions 36 inches by 15 inches by 4 inches, which also can fit into the trunk of a small car. When desired, the components can be removed from the box and placed into their operational configuration by simply reversing the steps mentioned above. In addition, when using central members  25  and  45  having a maximum length of 3¾ inches, the entire bed frame  10  can fit into a box that is small enough to fit three across on a standard-sized forklift pallet. However, in alternate embodiments central members  25  and  45  have a maximum length, e.g., of 12 inches or even 24 inches. 
     As noted above, in the present embodiment each of the center support  12 , left side rail  14  and right side rail  15  includes two main sections that are pivotally attached to each other through the use of a central member. The use of such a central member allows the main sections to be folded at least substantially parallel to each other and also, in some embodiments, somewhat decreases the overall length of the overall component (at the cost of a somewhat increased width). However, in alternate embodiments the two main sections are directly pivotally attached to each other. 
     In any event, the two main sections of each such component preferably are at least approximately end-to-end when in the operational configuration and then can be folded so that they are at least approximately parallel to each other for storage, shipping, etc. Any folding that stops short of the point where the two main sections are parallel will increase the width of the component, as folded, and therefore is less optimal. Any folding beyond the point at which the two main sections are parallel does not reduce the overall width and, therefore, generally speaking, does not provide significant benefit. 
     The present embodiment uses components having an L-shaped cross section, which provides strength while reducing manufacturing costs. However, in alternate embodiments, U-shaped cross-sections (e.g., using three elongated panels with the and panels at least approximately perpendicular to the middle panel), cross-sections of other shapes, or any combination instead may be used. 
     For instance, in certain alternate embodiments, the shorter center member for any or all of the center support  12 , left side rail  14  and right side rail  15  could be implemented as a flat piece. Although such a configuration typically with that provide the same degree of structural strength, such a center member generally could be placed anywhere on the inside or outside of the corresponding main sections, allowing the corresponding component to be folded in any desired manner. 
     In the foregoing embodiment, the extending segments of the left side component  75  (i.e., segments  76  and  77 ) detachably couple to the corresponding segments of the right side component  85  (i.e., segments  86  and  87 ) through the extending segments of the center component  65  (i.e., segments  66  and  67  for segment  76  and  68  and  69  for segment  77 ) in order to provide a complete lateral support at the head of the bed frame  10  and another complete lateral support at the foot of the bed frame  10 , respectively, when the bed frame is fully assembled and in its operational state. However, in alternate embodiments (e.g., where cost reduction is desired), the center component  65  is omitted and/or the adjacent segments of the left side component  75  and the right side component  85  either directly detachably attach to each other or are detachably coupled to each other through any other type of component. As used herein, the term “coupled”, or any other form of the word, is intended to mean either directly connected or connected through one or more other elements or components (e.g., for reinforcement or for any other purpose). 
     In the preferred embodiments of the invention, a single component can serve as the center member ( 25  and  45 , respectively) for any of the center support  12  (if used), the left side rail  14  and/or the right side rail  15 . That is, a single component preferably is manufactured so as to have all of the features (e.g., all of the openings) described above for center members  25  and  45 , even if all of such features are not actually utilized in each usage scenario (i.e., when installed as part of the center support  12 , the left side rail  14  or the right side rail  15 ) or, stated differently, all three center members  25  and  45  are identical to each other. For example, as indicated in  FIG. 5 , in the present embodiment one panel of such a common component includes four openings (two in central portion and one at each end), while the other (perpendicular or approximately perpendicular) panel includes two openings (in the central portion). As a result of using such a common component, tooling and manufacturing costs typically can be significantly reduced. 
     Additional Considerations. 
     In the event of any conflict or inconsistency between the disclosure explicitly set forth herein or in the attached drawings, on the one hand, and any materials incorporated by reference herein, on the other, the present disclosure shall take precedence. In the event of any conflict or inconsistency between the disclosures of any applications or patents incorporated by reference herein, the more recently filed disclosure shall take precedence. 
     Words such as “optimal”, “optimize”, “minimize”, “maximize”, “best” and similar words are used throughout the above discussion. However, it should be understood that, except to the extent clearly indicated to the contrary, such words are not used in their absolute sense, but rather are intended to be viewed in light of other constraints, such as user-specified constraints and objectives, as well as cost and processing constraints. 
     In the above discussion, certain methods are explained by breaking them down into steps listed in a particular order. However, it should be noted that in each such case, except to the extent clearly indicated to the contrary or mandated by practical considerations (such as where the results from one step are necessary to perform another), the indicated order is not critical but, instead, that the described steps can be reordered and/or two or more of such steps can be performed concurrently. 
     Similarly, in the discussion above, functionality sometimes is ascribed to a particular module or component. However, functionality generally may be redistributed as desired among any different modules or components, in some cases completely obviating the need for a particular component or module and/or requiring the addition of new components or modules. The precise distribution of functionality preferably is made according to known engineering tradeoffs, with reference to the specific embodiment of the invention, as will be understood by those skilled in the art. 
     In the discussions above, the words “include”, “includes”, “including”, and all other forms of the word should not be understood as limiting, but rather any specific items following such words should be understood as being merely exemplary. 
     Several different embodiments of the present invention are described above, with each such embodiment described as including certain features. However, it is intended that the features described in connection with the discussion of any single embodiment are not limited to that embodiment but may be included and/or arranged in various combinations in any of the other embodiments as well, as will be understood by those skilled in the art. 
     Thus, although the present invention has been described in detail with regard to the exemplary embodiments thereof and accompanying drawings, it should be apparent to those skilled in the art that various adaptations and modifications of the present invention may be accomplished without departing from the spirit and the scope of the invention. Accordingly, the invention is not limited to the precise embodiments shown in the drawings and described above. Rather, it is intended that all such variations not departing from the spirit of the invention are to be considered as within the scope thereof as limited solely by the claims appended hereto.