BED BASE KIT

Abstract

A bed base kit includes left and right side rails and a head and foot rails. The first end of the left side rail interconnects with the left end of the head rail at a left head joint. The first end of the right side rail interconnects with the right end of the head rail at a right head joint. The second end of the left side rail interconnects with the left end of the foot rail at a left foot joint. The second end of the right side rail interconnects with the right end of the foot rail at a right foot joint. The joints have male and female interconnect elements cooperatively operable to interconnect the respective ends. A center rail may also be provided for supporting a midportion of slats, with the center rail having ends that interconnect with the head and foot rail.

Description

FIELD OF THE INVENTION

The present invention relates to furniture that may be assembled by interconnecting components and, more specifically, a bed base that may be provided as a kit and assembled by an end user.

BACKGROUND OF THE INVENTION

Traditional bed bases often take the form of a box spring or platform that may be preassembled at a factory and has dimensions similar to a mattress. Such bed bases are bulky and difficult to ship. While a bed base could be assembled at the point of use, such as by a homeowner, such assembly typically requires tools and the installation of various connectors, thereby making it difficult for average consumers. There is a need for improved bed bases.

SUMMARY OF THE INVENTION

The present invention provides a bed base kit for assembling a bed base, typically to support a mattress for sleeping. The kit includes a plurality of components that, in some embodiments, may be shipped in a compact configuration. The components may then be assembled into the bed base by interconnecting the components.

In an example, a bed base kit includes a left and a right side rail each having opposed first and second ends. Each side rail has an upper surface, a lower surface, an outer surface and an inner surface. The kit also has a head rail and a foot rail each having opposed left and right ends. The head rail and foot rail each an upper surface, a lower surface, an outer surface and an inner surface. The kit also has a plurality of slats. The first end of the left side rail interconnects with the left end of the head rail at a left head joint. The first end of the right side rail interconnects with the right end of the head rail at a right head joint. The second end of the left side rail interconnects with the left end of the foot rail at a left foot joint. The second end of the right side rail interconnects with the right end of the foot rail at a right foot joint. Each of the joints includes a male and a female interconnect element cooperatively operable to interconnect the respective ends. One of the male or female interconnect elements is provided on the respective side rail and a corresponding other of the male or female interconnect elements is provided on the corresponding head or foot rail. A center rail may also be provided for supporting a midportion of the slats, with the center rail having ends that interconnect with the head and foot rail.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures illustrate an exemplary embodiment of the present invention.

FIG. 1 is a perspective view of a bed base kit with the components shown prior to assembly;

FIG. 2 is a perspective view of side rails, a head and foot rail, and a center rail in an assembled configuration;

FIG. 3 is a perspective view similar to FIG. 2 but showing slats installed;

FIG. 4 is a perspective view similar to FIG. 3 but showing a fabric band installed;

FIG. 5 is a perspective view of a portion of the side and head rail showing male and

female interconnect elements;

FIG. 6 is a perspective view of a portion of the center rail and head rail showing male and female interconnect elements; and

FIG. 7 is a view of dovetail joints showing two positions.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a bed base kit for assembling a bed base, typically to support a mattress for sleeping. The kit includes a plurality of components that, in some embodiments, may be shipped in a compact configuration. The components may then be assembled into the bed base by interconnecting the components.

FIG. 1 provides a view of an exemplary bed base kit 10 with the rails generally arranged in their relative positions and the slats stacked to the side. An optional cosmetic fabric band is also shown to the side. FIG. 2 provides a similar view with the side, head, foot, and center rails interconnected in an assembled configuration to form most of a bed base, but without the slats. FIG. 3 provides a similar view to FIG. 2 but with the slats added to form the complete bed base.

The bed base kit 10 includes a left side rail 100, a right side rail 200, a head rail 300 and a foot rail 400. The left side rail has a first end 102 and an opposed second end 104. An upper surface 106 and an opposed lower surface 108 of the left side rail 100 each extend generally longitudinally between the first end 102 and second end 104 and would typically be generally horizontal when the bed base is assembled. An inner surface 110 and an opposed outer surface 112 of the left side rail 100 each extend generally longitudinally between the first end 102 and second end 104 and vertically between the upper surface 106 and lower surface 108, and would typically be generally vertical when the bed base is assembled.

In the illustrated embodiment, the left side rail 100 is formed as an open truss with an elongated upper element 114 defining the upper surface 112 and a parallel elongated lower element 116 defining the lower surface 108 and being spaced from the upper element 114. Connecting elements extend between the upper element 114 and lower element 116 to define the overall rail. In this example, a first end block 118 and a second end block 120 are disposed at the first end 102 and second end 104, respectively, and serve as connecting elements. Additionally, three center connecting elements 122 are spaced apart along the length of the left side rail 100 and interconnect the upper element 114 and lower element 116. The open truss may reduce the use of materials and make for a lighter structure.

In the illustrated embodiment, the right side rail 200 is substantially a mirror image of the left side rail 100, and includes the same ends, surfaces, and elements, and therefore will not be described in detail. In some examples the left rail and right rail are substantially identical, such that the same part (and constituent elements) may be used for both. As used herein, the term “substantially identical” means that the rails are sufficiently similar that they may be used interchangeably without impacting the overall structure and function of the bed base, but may have minor differences such as markings, cosmetic features and/or features or elements that do not prevent interchangeability.

In the illustrated embodiment, the head rail 300 has a left end 302 and an opposed right end 304. An upper surface 306 and an opposed lower surface 308 of the head rail 300 each extend generally longitudinally between the left end 302 and right end 304 and would typically be generally horizontal when the bed base is assembled. An inner surface 310 and an opposed outer surface 312 of the head rail 300 each extend generally longitudinally between the left end 302 and right end 304 and vertically between the upper surface 306 and lower surface 308, and would typically be generally vertical when the bed base is assembled. As with the left side and right side rails, the head rail may be formed as open trusses, using similar components.

In the illustrated embodiment, the foot rail 400 is substantially a mirror image of the head rail 300 and includes the same ends, surfaces, and elements, and therefore will not be described in detail. In some examples the head rail and foot rail are identical, such that the same part (and constituent elements) may be used for both.

In the illustrated embodiment, the side rails and foot and head rail each have the same vertical height; the upper surfaces are each at substantially the same vertical distance from the respective lower surfaces.

In the illustrated embodiment, the bed base kit 100 also includes a center rail 500 that is disposed generally parallel to and halfway between the left side rail 100 and right side rail 200. The center rail 500 may be included or omitted depending on the width of the bed base and the stiffness and strength of the slats 600. Referring to FIG. 3, each slat 600 has a left end 602 and an opposed right end 604. Each slat has an upper surface 606 and an opposed lower surface 608, separated by a slat thickness ST. Each slat also has a slat width SW.

Referring again to FIG. 1, certain embodiments of the side rails 100 and 200 have upper surfaces with inwardly facing slat recesses defined therein. A slat recess in the upper surface 106 of the left side rail 100 is shown at 130 and a corresponding slat recess in the upper surface of the right side rail 200 is shown at 230. As shown in FIG. 3, a left end 602 of one of the slats is received in the recess 130 and a right end 604 of the same slat is received in the recess 230. As shown, a plurality of spaced apart recesses are provided in the upper surfaces of both side rails to receive ends of the slats, such that the slats are generally parallel to each other and spaced generally evenly along the length of the bed base 10.

Referring again to FIG. 1, the illustrated embodiment of the recess 130 has an outermost or terminal surface 132 that faces towards the other side of the bed base. The recess 130 further has a first side end 134 and a second side edge 136. The recesses in the right side rail 200 are a mirror image. The side edges that are spaced apart by a recess width RW (labeled on the right side rail 200) and the recess has a height or depth RD (also labeled on the right side rail 200). In the illustrated embodiment, the recess depth RD is substantially the same as the slat thickness ST so that the upper surfaces 606 of the slats 600 are generally coplanar with the upper surfaces of the side, head and foot rails. The recess width RW is approximately the same, or slightly larger, than the slat width SW to accept the ends of the slats.

In the illustrated embodiment, the slats 600 are configured to each extend continuously side to side with the ends in the recesses and a midportion 610 of each slat being supported on the center rail 500. The center rail 500 has a first end 502 and an opposed second end 504. An upper surface 506 and an opposed lower surface 508 of the center rail 500 each extend generally longitudinally between the first end 502 and second end 504 and would typically be generally horizontal when the bed base is assembled. A left surface 510 and an opposed right surface 512 of the center rail 500 each extend generally longitudinally between the first end 502 and second end 504 and vertically between the upper surface 506 and lower surface 508, and would typically be generally vertical when the bed base is assembled.

In the illustrated embodiment, the center rail 500 is formed as an open truss in a manner similar to the other rails. The center rail may have a vertical height that is less than the vertical heights of the other rails, such that the upper surface 506 sits lower than the upper surfaces of the other rails. The difference in height is substantially the same as a thickness ST of each the plurality of slats 600. Therefore, the upper surfaces 606 of the slats are generally coplanar with the upper surfaces of the side, head and foot rails and the lower surface of the center rail is generally coplanar with the lower surfaces of the side, head and foot rails.

In certain embodiments, the rails interconnect with joints. The first end 102 of the left side rail 100 interconnects with the left end 302 of the head rail 300 at a left head joint 702 (FIGS. 2 and 5). The first end of the right side rail 200 interconnects with the right end of the head rail 300 at a right head joint 704 (FIG. 2). The second end 104 of the left side rail 100 interconnects with the left end of the foot rail 400 at a left foot joint 706. The second end of the right side rail 200 interconnects with the right end of the foot rail 400 at a right foot joint 708. Each of the joints may take a similar form, and may include a male and a female interconnect element cooperatively operable to interconnect the respective ends. One of the male or female interconnect elements is provided on the respective side rail and a corresponding other of the male or female interconnect elements is provided on the corresponding head or foot rail.

In certain embodiments, the male and female interconnect elements allow assembly of the kit without fasteners or tools. FIG. 5 illustrates assembly of the left head joint 702 and will be described in more detail. The other joints between side rails and head or foot rails take the same form. In this example, two male interconnect elements 140 extend from the first end 102 of the left side rail 100 and two female interconnect elements are defined as receiving slots in the left end 302 of the head rail 300. The interconnect elements cooperatively interconnect the rails when the male interconnect elements 140 are engaged with the female interconnect elements. In this example, the resulting joint is a dovetail-type joint. The male interconnect elements 140 are “tail-shaped” with an outer portion that is wider than where the element joins the remainder of the rail. Side surfaces taper inwardly. The female interconnect elements are slots that are wider at the inward surface and narrower at the outward area, shaped as an “inverse-tail” to receive the male tail. The male interconnect elements 140 engage the female interconnect elements 340 when the left side rail moves outwardly relative to the centerline of the bed base and head rail. The male elements 140 have a curved nose end and a wider base end. The female elements are cooperatively shaped such that the male elements bottom out in the female elements when the joint is in an interconnected position. In one example, the elements 140 and 340 are non-symmetrical top to bottom. Referring to FIG. 7, the position of the female element is illustrated. As shown in solid lines, the female element 340 is a slot with a lower edge 342 that is generally horizontal, in a lateral direction, and an upper edge 344 that is angled upwardly away from the lower edge 342 in the lateral direction. The male elements are similarly configured. The generally horizontal lower edges help provide for a stable connection. Downward pressure on the side rail will not cause the dovetail joint to try to separate. As an alternative, as shown in dash-dot lines, the entire female element 340 may be angled downwardly, such as by the illustrated 15 degrees. In this version, upper and lower edges still diverge but both angle upwardly. This may result in a more stable configuration. In examples, the lower edge may angle downwardly by at least 5 degrees, by 5 to 25 degrees, by 10 to 20 degrees, or by approximately 15 degrees. In each case, the mail elements are similarly angled.

The center rail may interconnect in a similar way, but with dovetail elements that vertically engage, as shown in FIG. 6.

When the slats are added, the bed base becomes a stable and complete base. The ends of the slats engage the terminal surfaces of the recesses in the upper surfaces of the side rails, thereby preventing inward movement of the side rails. The slats also prevent upward movement of the center rail. The center rail maintains the spacing between the head and foot rails. As such, no fasteners may be required.

As will be clear to those of skill in the art, different sizes of bed bases may be provided by providing different lengths of head, foot and side rails. A narrower bed base may not require a center rail.

Referring now to FIGS. 1 and 4, a stretchable fabric band is shown at 800. The band is configured to be stretched around the perimeter of the assembled bed base so as to cover the outer surfaces of the side, head and foot rails. It may be wide enough to also wrap onto the upper and/or lower surfaces. This may be a merely cosmetic feature that covers the bed base. When the rails have an open truss configuration, the band helps to hide the openings and to provide the appearance of a solid base.

As will be clear to those of skill in the art, the embodiments disclosed herein may be altered in various ways without departing from the scope or teaching of the present invention. It is the following claims, including all equivalents, which define the scope of the present invention.

Claims

1. A bed base kit for assembling a bed base, the kit comprising: a left and a right side rail each having opposed first and second ends, each side rail having an upper surface, a lower surface, an outer surface and an inner surface;a head rail and a foot rail each having opposed left and right ends, the head rail and foot rail each having an upper surface, a lower surface, an outer surface and an inner surface;a plurality of slats;wherein;the first end of the left side rail interconnects with the left end of the head rail at a left head joint;the first end of the right side rail interconnects with the right end of the head rail at a right head joint;the second end of the left side rail interconnects with the left end of the foot rail at a left foot joint;the second end of the right side rail interconnects with the right end of the foot rail at a right foot joint;thereby forming a bed base perimeter;each of the joints comprising a male and a female interconnect element cooperatively operable to interconnect the respective ends, one of the male and female interconnect elements provided on the respective side rail and a corresponding other of the male and female interconnect elements provide on the corresponding head or foot rail.

2. The bed base kit according to claim 1, wherein each of the joints cooperatively interconnects by the respective side rail moving outwardly relative to a centerline of the head and foot rails, into an interconnected position, and disconnects by the respective side rail moving inwardly relative to the centerline.

3. The bed base according to claim 2, wherein the slats have ends that engage the side rails and maintain the side rails in the outwardly moved interconnected position.

4. The bed base kit according to claim 2, wherein the joints are dovetail joints with the respective male interconnect elements moving outwardly into the respective female interconnect elements.

5. The bed base kit according to claim 4, wherein the dovetail joints each have lower sides that are generally horizontal in a lateral direction and upper sides that are angled upwardly in the lateral direction.

6. The bed base kit according to claim 4, wherein the dovetail joints each have lower sides and upper sides that both are angled upwardly in the lateral direction.

7. The bed base kit according to claim 1, wherein the upper surfaces of the side rails have a plurality of inwardly facing slat recesses extending downwardly therein for receiving ends of the slats, each recess having a vertical depth approximately equal to a vertical height of the slats so that an upper surface of each slat disposed in one of the recesses is generally coplanar with the upper surface of the side rails adjacent the recesses.

8. The bed base kit according to claim 7, wherein each recess has a terminal surface that faces inwardly, each slat having length dimension such that ends of the slats engage the terminal surface to maintain the side rails in their outwardly moved interconnected positions.

9. The bed base kit according to claim 1, further comprising: a center rail having opposed first and second ends, the center rail having an upper surface and a lower surface, the first end of the center rail interconnecting with a midportion of the head rail at a center head joint and the second end of the center rail interconnecting with a midportion of the foot rail at a center foot joint, each of the center joints comprising a male and a female interconnect element cooperatively operable to interconnect the respective end with the respective head or foot rail, one of the male and female interconnect elements provided on the center rail and a corresponding other of the male and female interconnect elements provide on the corresponding head or foot rail.

10. The bed base kit according to claim 9, wherein the center joints are dovetail joints with the male and female engagement elements moving vertically into an interconnected position.

11. The bed base kit according to claim 9, wherein the upper surface of the center rail in the interconnected position is lower than the upper surfaces of the side, head and foot rails, such that the slats are disposed on top of the center rail and have an upper surface that is generally coplanar with the upper surfaces of the side, head and foot rails.

12. The bed base kit according to claim 9, further comprising a stretchable fabric band configured to be stretched around the bed base perimeter and to cover the outer surfaces of the side, head and foot rails in an assembled configuration.

13. The bed base kit according to claim 1, further comprising a stretchable fabric band configured to be stretched around the bed base perimeter and to cover the outer surfaces of the side, head and foot rails in an assembled configuration.

14. The bed base kit according to claim 1, wherein the side rails and head and foot rails are open trusses, each having a upper element, a lower element, and connecting elements extending between the upper and lower elements.

15. The bed base kit according to claim 1, wherein the left side rail and right side rail are substantially identical.

16. The bed base kit according to claim 15, wherein the head rail and foot rail are substantially identical.