Abstract:
A connection system for use in joining structural members of a bed frame together. One of the structural members has a wedge and the other of the structural members has a cavity formed in a receiver. The wedge has a plurality of exterior surfaces that contact with a plurality of interior surfaces formed in the cavity. The wedge may be comprised of a plurality of wedge segments that enter into a plurality of openings in the receiver. The interfitting of the wedge into the receiver make a solid connection that is enhanced by weight of the bedding positioned thereon. The connection resists twisting forces as well as lateral and fore and aft forces.

Description:
REFERENCE TO RELATED CASES 
       [0001]    The present patent application is based upon and hereby claims the benefit of priority to U.S. Provisional application Ser. No. 62/000,754 filed May 20, 2014 and, and the disclosure of that application is herein incorporated by reference in its entirety. Applicant claims the benefits of 35 U.S.C. 119(e) as to such U.S. provisional application. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to a bed frame for supporting a mattress or mattress set and, more particularly, to a bed frame having an improved interconnection system between the side rails and cross members. 
       BACKGROUND OF THE INVENTION 
       [0003]    There are currently in use conventional bed frame assemblies that are used for supporting a mattress or mattress set and such bed frame assemblies are normally made up of two side rails and at least one cross member. The bed frame supports the load of a mattress set by means of multiple support legs. 
         [0004]    Due to the difficulties of actually shipping a completed bed frame, conventional bed frames are delivered to the customer in an unassembled state, and then assembled at the site where the bed frame is intended to be located and used. One difficulty with such bed frames and the assembly thereof, however, is that tools may be required for the on site assembly of the bed frames and, therefore, if the tools are not available, the assembly cannot be done. Further, tool assemblies can be difficult and complicated. 
         [0005]    There has been published, certain three dimensional systems that can be used to carry out the connecting of a cross member and a side rail and a number of such systems are shown and described in U.S. Patent Application of Polevoy et al, U.S. Published Application 2010/0242171 and entitled “Three Dimensional Connection System For Bed Frame” and the specification of that application is hereby incorporated in its entirety into the present patent application. 
         [0006]    In the aforesaid patent application, the components i.e. a wedge and a receiver for the various connections are comprised of a plastic material and the connection is accomplished without the use of tools and therefore the bed frame can be set up readily and conveniently on site. 
         [0007]    While the &#39;171 patent publication discloses certain configurations of connecting components to carry out the assembly of a bed frame, there are addition materials and geometric configurations that can also be used to carry out such assembly. 
         [0008]    Accordingly, it would be advantageous to provide alternative components for connections between cross members and side rails of a bed frame that are comprised of differing materials and geometric configurations that can be used to assemble a bed frame without the need for tools. 
       SUMMARY OF THE INVENTION 
       [0009]    In accordance with the present invention, there is a system to carry out the connection of two structural components of a bed frame, and, as one exemplary embodiment, the connection between a cross member and a side rail of a bed frame. The present system is usable without the need for tools in the assembly of the bed frame at the site where the bed frame is to be used. 
         [0010]    The inventive system creates a robust interconnection between a side rail and a cross member of a bed frame, or other bed frame components by employing a wedge on one of the components and a receiver on the other of the components such that the wedge fits into the receiver. The fit between a wedge and a receiver locks the frame together quickly and securely. The downward pressure of the bedding makes the connection solid and any looseness that might develop is taken away by the automatic and constant resetting of the wedge in the receiver. 
         [0011]    The side rails and the cross members are secured together with a tool-less interlock that uses the weight of the supported load to combined the separate parts into one unit. The system forms the connection between the side rail and cross member and also a support leg. The wedge and receiver may be, respectively, on the side rail or cross member or the reverse. The assembly utilizes a three dimensional wedge at the ends of the cross member or side rail to both connect and stabilize the bed frame components. 
         [0012]    As used herein, the term “wedge” is used to describe the male member and the term “receiver” used to describe the female member of a connection; however, the terms do not necessarily imply that there must be a taper to either the wedge or the receiver. As will be seen, in at least one exemplary embodiment, the wedge and receiver may both be cylindrical in configuration and therefore neither is tapered. It should also be noted that the term “receiver” used with this invention, in many instances, also serves as a leg for the bed frame. 
         [0013]    As such, in a first embodiment of the present invention, a wedge is affixed to a cross rail that is either a formed metal wedge of a cast metal wedge In either case, the wedge is affixed to a cross member. 
         [0014]    In a second embodiment, the wedge is comprised of a formed metal or cast metal wedge that is covered by a protective plastic shield. Again, the wedge can be affixed to a cross member. 
         [0015]    In a third embodiment, there is a system where the wedge is cylindrical in geometry and which interfits into a cylindrical shaped opening in a receiver. The wedge is affixed to the cross member. 
         [0016]    In the fourth embodiment, there is a connection system wherein the wedge is cylindrical but that cylindrical wedge is affixed to the side rail and the cylindrical receiver is, in turn, affixed to the cross member such that the side rail is affixed to the cross member by inserting the wedge on the side rail into the receiver on the cross member. 
         [0017]    Lastly, there is an embodiment wherein the wedges comprise a plurality of wedge segments and the receiver has a plurality of openings that receive the wedge segments such that the wedge is basically locked into the receiver as it is inserted therein. In this exemplary embodiment, the receiver is made up of two halves that are affixed together to form the receiver having a plurality of openings. 
         [0018]    These and other features and advantages of the present invention will become more readily apparent during the following detailed description taken in conjunction with the drawings herein. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]      FIGS. 1 and 2  are, respectively, a perspective view and an exploded view, of a bed frame that can utilize the connection system of the present invention; 
           [0020]      FIG. 3A  is an exploded view illustrating the affixation of a formed metal wedge to a cross member and  FIG. 3B  is a perspective view of a cast metal wedge usable with the embodiment; 
           [0021]      FIG. 4A  is an exploded view of a second wedge embodiment of the present invention where the metal wedge is protected by a molded plastic cover and  FIG. 4B  is a cross sectional view of the  FIG. 4A  embodiment; 
           [0022]      FIG. 5  is an exploded view illustrating the interfitting of a cylindrical wedge affixed to a cross member into a cylindrical receiver affixed to a side rail; 
           [0023]      FIG. 6  is an exploded view showing the affixation of the receiver of the  FIG. 5  embodiment to a side rail of a bed frame; 
           [0024]      FIG. 7  is an exploded view illustrating the interfitting of a cylindrical wedge affixed to a side rail into a cylindrical receiver affixed to a cross member; 
           [0025]      FIG. 8  is an exploded view illustrating the affixation of the wedge of the  FIG. 7  embodiment to a side rail of a bed frame; 
           [0026]      FIG. 9  is a perspective view illustrating an alternative receiver to the  FIG. 7  embodiment; 
           [0027]      FIG. 10  is a side view of a still further embodiment wherein a receiver has multiple openings; 
           [0028]      FIG. 11  is a perspective view of a receiver of the  FIG. 10  embodiment; 
           [0029]      FIG. 12  is a top view of the receiver of the  FIG. 10  embodiment; 
           [0030]      FIG. 13  is a perspective view showing the wedge having a plurality of wedge segments of the  FIG. 10  embodiment, 
           [0031]      FIG. 14  is a perspective view illustrating the lower portion of the wedge of the  FIG. 10  embodiment; 
           [0032]      FIG. 15  is a side view of a receiver showing the forces on the saddle formed in the receiver in the  FIG. 10  embodiment; 
           [0033]      FIG. 16  is an exploded view showing the connection of a wedge and receiver carried out with the  FIG. 10 ; 
           [0034]      FIGS. 17A-17C  are side views showing the progressive steps of inserting the wedge into the receiver of the  FIG. 10  embodiment; 
           [0035]      FIG. 18  is a schematic view illustrating the forces exerted along the inner surface of the upper saddle of the receiver in the  FIG. 10  embodiment; 
           [0036]      FIG. 19  is a schematic view illustrating the forces exerted by the wedge against the receiver in the  FIG. 10  embodiment; and 
           [0037]      FIG. 20  is a schematic view illustrating the forces exerted by the receiver against the wedge in the  FIG. 10  embodiment; 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0038]    Turning first to  FIGS. 1 and 2 , there is shown, respectively, a perspective view and an exploded view, of a bed frame  10  and illustrating the three dimensional connection for which the present invention can be utilized. The bed frame  10  of  FIGS. 1 and 2  is shown and described in U.S. Patent Pub. 2010/0242171, published Sep. 30, 2010 and entitled “Three Dimensional Connection System For bed Frame” and the disclosure of that patent application is hereby incorporated herein in its entirety. As will become clear, the present invention is directed to certain alternative embodiments of the three dimensional connection system disclosed in the &#39;171 published application. 
         [0039]    As can be seen, the bed frame  10  comprises a pair of side rails  12  and a plurality of cross members  14 . As shown, there are three cross members  14 , however a lesser or greater number of cross members  14  can be used in constructing a bed frame. The side rails  12  are comprised of L-shaped angle irons  16  however in U.S. Pat. No. 7,363,664 there is disclosed the use of a T-shaped member that can be used as a structural member of a bed frame, that is, as either a cross member or a side rail. Each side rail  12  may include an end bracket  18  for affixing thereto, a headboard or a footboard (not shown), 
         [0040]    The cross members  14  are L-shaped angle irons  20  that will be later described, however the cross members  14  may be T-shaped elongated members that may be constructed of two L-shaped members affixed together or may be unitary T-shaped metal members. 
         [0041]    Affixed to each of the side rails  12  are receivers  22  having a female cavity  24  formed therein in a configuration to be later explained. Affixed to the ends of the cross members  14  are wedges  26  that are also constructed in a manner to be later explained. 
         [0042]    While the embodiment of  FIGS. 1 and 2  illustrate the receivers  22  affixed to the side rails  12  and the wedges  26  affixed to the cross members  14 , it will be seen that wedges and receivers may be oppositely affixed, that is, the receivers  22  may be affixed to the cross members  14  and the wedges  26  affixed to the side rails  12 . 
         [0043]    Turning then to  FIGS. 3A and 3B , there is shown, respectively, an exploded view illustrating the affixation of a formed metal wedge to a cross member and a perspective view of a cast iron wedge usable with the embodiment. 
         [0044]    As can therefore be seen, in  FIG. 3A , the formed metal wedge  28  is constructed by a forming process of a metal material and is shaped, in the embodiment of  FIG. 3A , to have a rectangular lateral cross section; however, other configurations of the cross section may be used. There is an open interior  30  and the formed metal wedge  28  can be affixed to a cross member  14  by means of rivets  32  or other fastening devices. An inset  34  is provided in the formed metal wedge  28  to receive the vertical flange  36  of the T-shaped cross member  14 . 
         [0045]    In  FIG. 3B , taken along with  FIG. 3A , there is a similarly shaped cast metal wedge  38  comprised of a cast metal and, again, are rivets  40  may be used to affix the cast metal wedge  38  firmly to a cross member  14 . Again, an inset  42  is formed in the cast metal wedge  38  to accommodate the vertical flange  36  of the T-shaped cross member  14 . 
         [0046]    Turning then to  FIGS. 4A  and  FIG. 4B , there is, respectively, an exploded view and a cross sectional view, of a second embodiment of the present invention. In this embodiment, there is a metal wedge  44  that may be comprised of a formed metal or a cast metal material. In this embodiment, again there is an inset  46  formed in the inner surface of the metal wedge  44  for close contact with the vertical flange  36  of the T-shaped cross member  14 . 
         [0047]    An outer surface  48  of the metal wedge  44  is enclosed within a first molded plastic cover  50  such that the outer surface  48  and side surfaces  52  are protected by the first molded plastic cover  48 . In like manner, the other outer surface  54  is enclosed within a second molded plastic cover  56  and the second molded plastic cover  56  includes an inset  58  for accommodating the vertical flange  36  of the cross member  14  so that the vertical flange  36  is sandwiched between the inset  46  of the metal wedge  44  and the inset  58  of the second molded plastic cover  56 . 
         [0048]    Rivets  60  are provided to pass through the holes  62  in the first molded plastic cover  50 , the holes  64  in the vertical flange  36  and the holes  66  in the second molded plastic cover  56  to secure the metal wedge  44  to the cross member  14 . Lastly, another rivet  68  is used to further secure the first and second molded plastic covers  50  and  56  to the metal wedge  44 . 
         [0049]    As thus can be seen, since many of the components of the bed frame  10  ( FIG. 1 ) are covered with protective plastic covers, the metal wedge  44  is itself similarly covered to protect against the presence of sharp edges that could tear the bed coverings. 
         [0050]    In  FIG. 4B , there is a cross sectional view of the  FIG. 4A  embodiment and illustrating the sandwiching of the vertical flange  36  of the cross member  14  between the metal wedge  44  and the second molded plastic cover  56 . 
         [0051]    Turning then to  FIGS. 5 and 6 , there is an exploded view illustrating the connection system of the third embodiment and an exploded view illustrating the connection of a tubular receiver of that third embodiment to a side rail. Taking  FIG. 5 , there is shown a side rail  12  having a plastic protective cover  70 . The tubular receiver  72  is affixed to the side rail  12  in a manner to be later explained. 
         [0052]    The wedge, in this embodiment, is a tubular plug  74  that extends downwardly from the cross member  14  and, as can be seen, the tubular plug  74  has a flange  76  that may be affixed to the vertical flange  36  of the cross member  14  by means such as rivets  78 . The upper surface of the flange  76  is depressed sufficiently from the upper surface  80  of the tubular plug  74  that the upper surface of the horizontal flange  82  is flush and level with the upper surface  80  of the tubular plug  74  to provide a finished appearance to the connection. 
         [0053]    As is shown, the outer cross sectional configuration of the tubular plug  74  is circular, however, other geometric profiles could be used. The cylindrical tubular plug  74  is thus dimensioned to fit snugly into the cylindrical opening  84  of the tubular receiver  72 . 
         [0054]    Turning then to  FIG. 6 , the affixation of the tubular receiver  72  to the side rail  12  is illustrated. As shown, the tubular receiver  72  has a flange  86  extending generally horizontally and that flange  86  has a recessed upper surface  88  that contacts and fits against the horizontal flange  90  of the side rail  12 . Again, rivets  92  can be used to complete the affixation of the tubular receiver  72  to the side rail  12 . 
         [0055]    Turning next to  FIGS. 7 ,  8 , and  9 , there is an exploded view of the connection system of a fourth embodiment, an exploded view showing the affixation of the tube plug of this embodiment to a side rail and an alternative arrangement of a tubular receiver affixed to a cross member. 
         [0056]    Accordingly, taking  FIG. 7 , there is shown a side rail  12  having a plastic cover  94  and a plastic end cap  96 . A wedge in the form of a tube plug  98  extends downwardly from the side rail  12  in a manner to be described. As can be seen, the tube plug  98  is dimensioned so as to fit snugly into an opening  100  in a receiver  102  in order to carry out the connection of the side rail  12  and the receiver  102 . The receiver  102  of this embodiment, is shaped to present a pleasing appearance, that is, rather than having a cylindrical outer shape, the receiver  102  has a specially curved outer surface. 
         [0057]    On the upper surface  104  of the receiver  102 , there is a groove  106  formed to receive the lower surface  108  of the side rail  12 . As also can be seen, the receiver  102  has a rearward flange  110  that can be affixed to the vertical flange  36  of the cross member  14  by rivets  112  to affix the receiver  102  to the cross member  14 . 
         [0058]    In  FIG. 8 , there can be seen the means of affixing the tube plug  98  to the side rail  12  and, as shown, there are corresponding holes  114  in the side rail  12  that mate with holes  116  in the tube plug  98  and rivets  118  can be used to carry out the affixation. 
         [0059]    In  FIG. 9 , there is an alternative receiver  120  where the receiver  120  is tubular in configuration and a recessed area  122  receives the lower surface of the side rail  12  ( FIG. 7 ). Again, the receiver  120  has a flange  124  that can be used to accommodate rivets (not shown) to affix the receiver  120  to a cross member  14 . The outer shape of the receiver  120  is a functional, cylindrical surface. 
         [0060]    Turning then to  FIGS. 10 and 11 , there is a side view and a perspective view of a receiver  128  that is affixed to a cross member  14 . In this embodiment, the receiver  128  is constructed of two halves, that is, there is a first half  130  and a second half  132  that are bought together to complete the receiver  128 . 
         [0061]    Each of the first and second halves  130 ,  132  has upper flanges and the first upper flange  134  for the first half  130  can be seen in  FIGS. 10 and 11 . The upper flange for the second half  132  cannot be seen, however, the first and second upper flanges sandwich the vertical flange  36  of the cross member  14 . The first and second leg halves  130 ,  132  are held together with rivets, that is, there are two rivets  136  that join the upper first flange  134  and the second upper flange together as well as affix the receiver  128  to the cross member  14  and a third rivet  138  passes through the lower portions  140 ,  142  of the first and second halves  130 ,  132  to retain the first and second halves  130 ,  132  together. 
         [0062]    As can be seen, particularly in  FIG. 11 , when the first and second halves  130 ,  132  of the receiver  128  are joined together, there is formed an upper saddle  144  having an upper surface  146  made up of the combined upper surfaces of the first and second halves  130 ,  132 . Side surfaces  148 ,  150  extend downwardly from the upper surface  146  and are tapered outwardly, that is, away from each other, in the downward direction. 
         [0063]    The geometric configuration of the upper saddle  144  is shown as a shape having surfaces defining multiple functional sides, similar to a truncated trapezoid, however, the shape of the upper saddle  144  may also be other shapes such as a cylindrical shape or other multi-surfaced shape. The shape of the upper saddle  144  could also be formed by as series of ribs to take the place of the solid surfaces. 
         [0064]    As also can be seen in  FIG. 11 , there are two triangular openings formed in each half of the receiver  128 . As such there is a first opening  152  and a second opening  154  formed in the first and second halves  130 ,  132  and the purpose of the first and second openings  152  and  154  will be later explained. 
         [0065]    As a further feature of the present receiver  128 , there is a slight inset  156  formed in the uppermost surface  160  and that inset  156  is dimensioned so that the upper horizontal flange  82  of the cross member  14  can sit flush with the uppermost surface  160  of the receiver  128 . 
         [0066]    Turning then to  FIG. 12 , there is a top view of receiver  128  affixed to a cross member  14 . As can be seen, the first and second openings  152 ,  154  are spaced apart with the upper saddle  144  sandwiched therebetween. The slight outward taper of the side surfaces  148 ,  150  can be observed. The first and second openings  152 ,  154  are triangular in the illustrated embodiment, however, it can be seen that the openings could be cylindrical, triangular, rectangular or multi-sided in shape. 
         [0067]    The first and second openings  152 ,  154  are formed so as to be wider at the top and narrower at the bottom, forming openings that are tapered inwardly in the downward direction. 
         [0068]    Turning next to  FIG. 13 , taken along with  FIG. 11 , there is a perspective view of the wedge  162  that is useable with this embodiment. As can be seen, the wedge  162  has multiple wedge segments. There is a first wedge segment  164  and a second wedge segment  166  depending downwardly from a base portion  168  of the wedge  162 . In the exemplary embodiment, two wedge segments are depicted, though more segments could also be used consistent with the intent of the present invention. The wedge  162  is riveted through its base portion  168  to a vertical flange  170  of a side rail  12 . 
         [0069]    The first and second segments  164 ,  166  are tapered inwardly in the downward direction with each segment being widest near the base portion  168  and tapering inwardly toward their distal ends  172 ,  174 . This taper of the first and second wedge segments  164 ,  166 , corresponds to the shape of the upper saddle  144  and tapers from a space equal to the distance D 1  across the gap between the side surfaces  148 ,  150 , at the top to less than a greater distance D 2  across the gap at the bottom of the first and second openings  152 ,  154 . The first and second openings  152 ,  154  are designed to interact with, align to, and tightly fit to the tapered first and second wedge segments  164 ,  166  when the wedge  162  is inserted into the receiver  128 . 
         [0070]    In  FIG. 14 , taken along with  FIG. 11 , there is a bottom perspective view of the wedge  162  wherein the triangular first and second wedge segments  164 ,  166  are illustrated extending from the base portion  168 . Thus the gap  176  or space between the first and second wedge segments  164 ,  166  receives the upper saddle  144  and the taper of the side surfaces  148 ,  150  ( FIG. 11 ) cause the first and second wedge segments  164 ,  166  to press inwardly against the first and second halves  130 ,  132  to force the first and second halves  130 ,  132  together as the connection is completed. As also can be seen in  FIG. 14 , there are enlarged upper raised portions  178 ,  180  that are ultimately positioned just below the cross member  14  ( FIG. 11 ) to create a smooth appearance to the connection. 
         [0071]    Turning now to  FIG. 15 , there is a side view of receiver  128  of this exemplary embodiment and showing the upper saddle  144 . The formation of the upper saddle  144  requires the presence of open slots  182 ,  184  in the face of each of the first and second halves  130 ,  132  and the enlarged upper raised portions  178 ,  180  ( FIG. 14 ) aesthetically fill in these open slots to provide a smooth, contiguous appearing leg surface when the first and second wedge segments  164 ,  166  are assembled together in forming the receiver  128   
         [0072]    Turning next to  FIG. 16 , there is an exploded view illustrating the beginning of a connection between the wedge  162  and the receiver  128  in the exemplary embodiment. Accordingly, the side rail  14  is oriented directly above the cross member  14  so that the wedge  162  and the receiver  128  are in alignment. As the side rail  12  is then lowered, the first and second wedge segments  164 ,  166  can enter into the first and second openings  152 ,  154  in the receiver  128 , bridging the upper saddle  144  to assemble the side rail  12  to the cross member  14 . 
         [0073]    The progression of that assembly of the side rail  12  and the cross member (not shown) can further be seen in  FIGS. 17A-17C  where there are schematic views illustrating the steps of assembly. As such, in  FIG. 17A , the side rail  12  having the wedge  162  affixed thereto is spaced above the receiver  128  and the side rail  12  is, in order to carry out a connection, lowered in the direction of the arrows A toward the receiver  128 . 
         [0074]    In  FIG. 17B , the side rail  12  has been lowered in the direction of the arrows A such that the first and second wedge segments  164 ,  166  are entering into the first and second openings  152 ,  154 , thereby creating forces in the direction of the arrows F inwardly against the upper saddle  144  to force and hold the first and second wedge segments  164 ,  166  forcefully together. 
         [0075]    Finally, in  FIG. 17C , the first and second wedge segments  164 ,  166  have fully entered into the first and second openings  152 ,  154  so that the side rail  12  is fully attached to the cross member resulting in a tight, friction fit between the side rail  12  and the cross member where the first and second wedge segments  164 ,  166  are forced tightly together. 
         [0076]    Turning then to  FIG. 18 , there is a schematic view illustrating the forces between the first and second wedge segments  164 ,  166  and the upper saddle  144  since the first and second wedge segments  164 ,  166  exerts an inward force F in  and the upper saddle  144  creates outer forces F out . 
         [0077]    In  FIG. 19 , there is shown the forces F o  exerted against the first and second wedge segments  164 ,  166  against the inner surfaces of the first and second openings  152 , 154 . 
         [0078]    Lastly, in  FIG. 20 , there is shown the forces F h  exerted by the first and second wedge segments  164 ,  166  against the inner surfaces of the first and second openings  52 ,  154  creating a self-aligning, secure, tight fitting, and tool-less friction-fit assembly of a bed side rail  12  to a cross member  14 . 
         [0079]    While the present invention has been set forth in terms of a specific embodiment or embodiments, it will be understood that the present three dimensional connection system for a bed frame herein disclosed may be modified or altered by those skilled in the art to other configurations. Accordingly, the invention is to be broadly construed and limited only by the scope and spirit of the claims appended hereto.