Patent Publication Number: US-7900300-B1

Title: Mattress foundation corner connector and assembly method

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is a Continuation-In-Part of U.S. patent application Ser. No. 12/152,194, filed May 13, 2008 now U.S. Pat. No. 7,703,155, the disclosure of which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to mattress foundation assemblies. In particular, the present invention relates to improved mattress foundation corner connectors, mattress foundation assemblies, and a method for constructing the mattress foundation assembly. 
     2. Description of Related Art 
     Typically, mattress foundations and bases are constructed by hand from various pieces of Pine or other lightweight woods. These built-up mattress foundations are generally formed in 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 used in order to assemble the numerous components of the mattress foundations. Once aligned, the various pieces or components are typically nailed together. 
     SUMMARY OF THE INVENTION 
     However, constructing mattress 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 mattress foundation. 
     Thus, the present invention relates generally to improved mattress foundation assemblies. In particular, the present invention relates to improved mattress foundation corner connectors, mattress foundation assemblies, and a method for constructing the mattress foundation assembly. 
     In various exemplary embodiments, the mattress foundation assembly is constructed of Medium Density Fiberboard (MDF) and 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 mattress foundation assembly comprises four shaped perimeter rails (first and second side rail elements and first and second header elements), joined to four corner connector elements. The profile of the perimeter rails has been designed to provide smooth, rounded horizontal outer edges, and includes a recessed notch to accommodate a flush-mounted top deck panel. Vertical grooves are notched into the interior face of the perimeter rails and serve to align the interior support ribs and spine element during the assembly process, without the need for external jigs and fixtures. 
     The interior support ribs and spine element are attached together in an interlocking fashion by means of engineered half-lap joints and form the load distribution structure of the mattress foundation. The ribs and spine element, along with the top deck panel also serve to square the entire mattress foundation assembly during and after assembly. 
     Aesthetically, the corner connector elements serve to round the vertical outer edges of the mattress foundation assembly, while maintaining the radii of the mattress foundation assembly&#39;s top and bottom edges. Structurally, the corner connector elements provide substantial impact resistance to corner loading and flexible resistance to parallelogram deformation. In various exemplary embodiments, these qualities are improved through the inclusion of a series of molded gussets inside the corner connector elements. 
     The top 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 top deck panel is particularly critical for foam mattresses and is a major improvement over currently constructed mattress foundations, which use soft cardboard atop lumber slats. 
     In various exemplary embodiments, there is elements of the mattress foundation assembly are fastened together with adhesives. Alternatively, screws or other fastening means may be used to assemble the elements of the mattress foundation. In still other embodiments, both adhesive and screws or other fastening means may be used. 
     Accordingly, this invention provides a mattress foundation assembly of improved design. 
     This invention separately provides a mattress foundation assembly having a lower overall part count when compared to other mattress foundations. 
     This invention separately provides a mattress foundation assembly having improved structural stability. 
     This invention separately provides a mattress foundation assembly that can be assembled without the need for external jigs and/or fixtures. 
     This invention separately provides a mattress foundation assembly that can be scaled to accommodate any size mattress. 
     This invention separately provides a mattress foundation assembly that is less expensive to manufacture. 
     This invention separately provides a corner connector element of improved design. 
     This invention separately provides a scalable corner connector element. 
     This invention separately provides a corner connector element that is relatively light weight. 
     This invention separately provides a corner connector element that can be produced in mass quantity from plastic, wood, or other any other suitable material. 
     These and other features and advantages of this invention are described in or are apparent from the following detailed description of the exemplary, non-limiting embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       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  shows a right perspective view of a first exemplary embodiment of a corner connector element according to this invention; 
         FIG. 2  shows a left perspective view of a first exemplary embodiment of a corner connector element according to this invention; 
         FIG. 3  shows a front perspective view of a first exemplary embodiment of a corner connector element according to this invention; 
         FIG. 4  shows a top view of a first exemplary embodiment of a corner connector element according to this invention; 
         FIG. 5  shows a bottom view of a first exemplary embodiment of a corner connector element according to this invention; 
         FIG. 6  shows a right plan view of a first exemplary embodiment of a corner connector element according to this invention; 
         FIG. 7  shows a right perspective view of a second exemplary embodiment of a corner connector element according to this invention; 
         FIG. 8  shows a left perspective view of a second exemplary embodiment of a corner connector element according to this invention; 
         FIG. 9  shows an exploded perspective view of a first exemplary embodiment of certain of the components of a mattress foundation assembly according to this invention; 
         FIG. 10  shows a cross-sectional view of an exemplary side rail element according to this invention; 
         FIG. 11  shows a perspective view of a partially assembled mattress foundation assembly according to this invention; 
         FIG. 12  shows a perspective view of a partially assembled mattress foundation assembly according to this invention; 
         FIG. 13  shows a perspective view of a partially assembled mattress foundation assembly according to this invention; and 
         FIG. 14  shows a perspective view of an assembled mattress foundation assembly according to this invention. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     For simplicity and clarification, the design factors and operating principles of the mattress foundation corner connectors and mattress foundation assemblies according to this invention are explained with reference to various exemplary embodiments of mattress foundation corner connectors and/or mattress foundation assemblies according to this invention. The basic explanation of the design factors and operating principles of the mattress foundation corner connectors and mattress foundation assemblies is applicable for the understanding, design, and operation of the mattress foundation corner connectors and mattress foundation assemblies of this invention. It should be appreciated that the mattress foundation corner connectors and/or the mattress foundation assemblies can be adapted to many applications where a simplified corner connector and/or a foundation assembly is needed. 
     It should also be appreciated that the terms “mattress foundation”, “mattress foundation assembly”, and “corner connector” are used for basic explanation and understanding of the operation of the systems, methods, and apparatuses of this invention. Therefore, the terms “mattress foundation”, “mattress foundation assembly”, and “corner connector” are not to be construed as limiting the systems, methods, and apparatuses of this invention. Thus, the terms “mattress foundation” and “mattress foundation assembly” are to be understood to broadly include any structures or devices capable of supporting a load, while the term “corner connector” 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. 1-6  show a first exemplary embodiment of a corner connector element  105  according to this invention. In an illustrative, non-limiting embodiment of this invention, as illustrated in  FIGS. 1-6 , the corner connector element  105  comprises at least some of a main body portion  110 , a top surface  115 , a first side surface  121 , a second side surface  122 , a radiused surface  130 , a first abutment surface  131 , a second abutment surface  132 , a first corner abutment surface  135 , a second corner abutment surface  136 , a corner  139 , and a bottom surface  140 . 
     As illustrated in  FIGS. 1-6 , the main body portion  110  extends from the substantially planar bottom surface  140  to the substantially planar top surface  115 . 
     The first side surface  121  and the second side surface  122  are substantially planar and are formed at substantially 90° relative to one another. One or more optional attachment apertures  118  may be formed in or through the first side surface  121  and the second side surface  122 . If included, the one or more optional attachment apertures  118  may be sized so as to allow a fastening means, such as, for example, a screw, to more easily attach to the corner connector element  105 . 
     The first abutment surface  131  extends substantially perpendicularly from a terminating edge of the first side surface  121 . Likewise, the second abutment surface  132  extends substantially perpendicularly from a terminating edge of the second side surface  122 . The radiused 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  extends above the top surface  115 , while a second portion of the first abutment surface  131  and the second abutment surface  132  terminates at the top surface  115 . 
     In various exemplary embodiments, as illustrated in  FIGS. 1-6 , an interior portion of the main body portion  110 , wherein the interior portion is defined substantially between the bottom surface  140 , the top 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 strengthening ribs  155  may optionally be formed within the hollow portion  150  of the interior portion. The one or more strengthening ribs  155  may provide additional strength and/or rigidity to the main body portion  110 . 
     In various exemplary embodiments, the first corner abutment surface  135  extends substantially perpendicularly from a terminating edge of the top surface  115  and the second corner abutment surface  136  extends substantially perpendicularly from a terminating edge of the top surface  115 . 
     The corner  139  is defined by the intersection of the first corner abutment surface  135  and the second corner abutment surface  136 . It should be appreciated that the first corner abutment surface  135  and the second corner abutment surface  136  are formed at substantially 90° relative to one another. 
     In various exemplary embodiments, as illustrated in  FIGS. 1-6 , one or more recesses  133  are optionally formed in the first abutment surface  131 . Likewise, one or more recesses  134  are optionally formed in the second abutment surface  132 . The one or more recesses  133  and one or more recesses  134  may provide additional strength and/or rigidity to the first abutment surface  131  and the second abutment surface  132 , respectively. 
     In various exemplary embodiments, the corner 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 corner connector element  105  is a design choice based on the desired appearance and functionality of the corner connector element  105 . 
     It should be appreciated that the corner 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 corner connector element  105 . 
     It should be understood that the overall size and shape of the corner connector element  105 , and the various portions thereof, is a design choice based upon the desired functionality and/or appearance of the corner connector element  105 . Additionally, it should be appreciated that the corner connector element  105  is formed such that multiple corner connector elements  105  may be rotated and used as each of the four corners of a mattress foundation assembly  100 . Therefore, multiple corner connector elements do not have to be formed for a specific location at a specific corner of a mattress foundation assembly  100 . 
       FIGS. 7 and 8  illustrate a second exemplary embodiment of a corner connector  205  according to this invention. As shown in  FIGS. 7 and 8 , the corner connector  200  includes at least some of a main body portion, a top surface  215 , one or more attachment apertures  218 , a first side surface  221 , a second side surface  222 , a radiused surface  230 , a first abutment surface  231 , a second abutment surface  232 , a first corner abutment surface  235 , a second corner abutment surface  236 , a corner  239 , and a bottom surface  240 . 
     It should be understood that each of these elements corresponds to and operates similarly to the top surface  115 , one or more attachment apertures  118 , a first side surface  121 , a second side surface  122 , a radiused surface  130 , a first abutment surface  131 , a second abutment surface  132 , a first corner abutment surface  135 , a second corner abutment surface  136 , a corner  139 , and a bottom surface  140 , as described above with reference to the corner connector element  105  of  FIGS. 1-6 . 
     However, as shown in  FIGS. 7 and 8 , the hollow portion  150  of the corner connector element  105  is not included and the main body portion is solid, having a surface  250 . It should be appreciated that the surface  250  may be substantially planar, concave, or convex. 
     Additionally, as illustrated in  FIGS. 7 and 8 , the one or more recesses  133  and one or more recesses  134 , optionally formed in the first abutment surface  131  and the second abutment surface  132  of the corner connector element  105  of  FIGS. 1-6  are not included. 
     As illustrated in  FIGS. 9-14 , the corner connector element  105  may be used to construct a mattress foundation assembly  100 . It should be appreciated that either the corner connector element  105  or the corner connector element  205  (not shown in  FIGS. 9-14 ) may be used to construct the mattress foundation assembly  100 . 
     As illustrated in  FIGS. 9-14 , the mattress foundation assembly  100  comprises at least some of a plurality of corner connector elements  105 , a first header element  161  having a first header element groove  165 , a second header element  162  having a second header element groove  166 , a first side rail element  171  having a first side rail element receiving groove  175 , a second side rail element  172  having a second side rail element receiving groove  176 , a first support rib  181  having a first support rib half-lap joint  185 , a second support rib  182  having a second support rib half-lap joint  186 , a spine element  190  having a spine element half-lap joint  196 , and a top deck panel  198 . 
     In order to construct a mattress foundation assembly  100 , four corner connector elements  105  are positioned at locations proximate the four corners of the finished mattress foundation assembly  100 . Then, as illustrated in  FIG. 11 , the first header element  161 , second header element  162 , first side rail element  171 , and second side rail element  172  are each attached or coupled, at their appropriate ends, to an appropriately corresponding corner connector element  105 . In various exemplary embodiments, the various header and rail elements may be coupled, via fastening elements or means, such as, for example, screws  197 , to the corner connector elements  105 . Alternatively, the various header and rail elements may be secured to the corner connector elements  105  via an adhesive. 
     Each of the first header element  161 , the second header element  162 , the first side rail element  171 , and the second side rail element  172  has at least one groove formed on an interior side of the element, perpendicular to the longitudinal axis of the element. These one or more grooves are formed so as to accept at least a portion of a support rib or spine element, as described below. 
     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 first header element  161  and the second header element  162  are of an equal length and the first side rail element  171  and the second side rail element  172  are of an equal length, and so long as each of the elements  161 ,  162 ,  171 , and  172  has a terminating end that is parallel and perpendicular to the longitudinal axis of the element and a planar portion, on an interior side of the element, proximate the terminating end of the element, which 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 corner connector element  105  and the terminating end is positioned against a corresponding first abutment surface  131  or second abutment surface  132 , the first header element  161  and the second header element  162  will be parallel to one another and the first side rail element  171  and the second side rail element  172  will be parallel to one another. 
       FIG. 10  shows a cross-sectional view of an exemplary side rail element or header element according to this invention. As illustrated most clearly in  FIG. 10 , each of the first header element  161 , the second header element  162 , the first side rail element  171 , and the second side rail element  172  includes a recessed notch  173  to accommodate a flush-mounted top deck panel  198 . 
     Once each of the first header element  161 , the second header element  162 , the first side rail element  171 , and the second side rail element  172  are attached, coupled, or secured to an appropriate corner connector element  105 , as illustrated in  FIG. 11 , the first support rib  181  and the second support rib  182  can be positioned between the first side rail element  171  and the second side rail element  172 , within corresponding first side rail element receiving grooves  175  and second side rail element receiving grooves  176 , as illustrated in  FIG. 12 . 
     In various exemplary embodiments, the first support rib  181  and the second support rib  182  can be coupled, via fastening elements or means, such as, for example, screws  197 , within the corresponding first side rail element receiving grooves  175  and second side rail element receiving grooves  176 . Alternatively, the support ribs may be secured within receiving grooves via an adhesive. 
     Once each of the first support rib  181  and the second support rib  182  are attached, coupled, or secured within the corresponding receiving grooves  175  and  176 , as illustrated in  FIG. 12 , the spine element  190  can be positioned between the first header element  161  and the second header element  162 , within corresponding first header element groove  165  and second header element groove  166 , as illustrated in  FIG. 13 . 
     As further illustrated in  FIG. 13 , because the first support rib half-lap joint  185  and the second support rib half-lap joint  186  are formed to mate with the spine element half-lap joints  196 , when the spine element  190  is positioned between the first header element  161  and the second header element  162 , the first support rib half-lap joint  185  and the second support rib half-lap joint  186  align with the spine element half-lap joints  196  to allow a top surface of the spine element  190  to be flush with a top surface of the first header element  161  and the second header element  162 . 
     In various exemplary embodiments, the spine element  190  can be coupled, via fastening elements or means, such as, for example, screws (not shown), within the corresponding grooves  165  and  166 . Alternatively, the support ribs may be secured within the grooves via an adhesive. 
     It should be appreciated that the number of spine elements  190 , first support ribs  181 , and second support ribs  182  is a design choice based upon the desired functionality, rigidity, and/or strength of the mattress foundation is simply  100 . 
     Finally, as illustrated in  FIG. 14 , the top deck panel  198  can be placed atop the spine element  190 , the first support rib  181  and the second support rib  182 , within the recessed notch  173  of the first header element  161 , the second header element  162 , the first side rail element  171 , and the second side rail element  172 , so as to be flush-mounted with a top surface of the header elements  161  and  162  and the rail elements  171  and  172 . 
     Once assembled, the mattress 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 embodiment(s) outlined above, it is evident that this invention is not limited to particular variation(s) set forth and many alternatives, adaptations, modifications, and 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. 
     Such alternatives, adaptations, modifications, and variations should and are intended to be and are comprehended within the meaning and range of equivalents of the disclosed exemplary embodiment(s) and may be substituted without departing from the true spirit and scope of the invention. It is to be understood that the phraseology of terminology employed herein is for the purpose of description and not of limitation. Accordingly, the foregoing description of the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting and the fundamental design should not be considered to be necessarily so constrained. Various changes, modifications, and/or adaptations may be made without departing from the spirit and scope of this invention.