BED FRAME

FIELD OF THE INVENTION

The present invention pertains, among other things, to bed frames, components thereof, and methods of producing and/or using any or all of the foregoing.

BACKGROUND

The following discussion concerns certain background information related to the present invention. However, it should be understood that only knowledge clearly, explicitly and specifically described herein as being “conventional” or “prior art” is intended to be characterized as such. Everything else should be understood as knowledge and/or insight originating from the present inventor(s).

Bed frames are commonly used to support and hold a mattress, as well as to elevate it off the floor. A variety of different bed frames exist. However, improvements in such existing bed frames and/or bed frames with different properties than are present in conventional bed frames remain desirable. The present invention is particularly (but not exclusively) focused on providing bed frames that are easy to assemble and configurable for a customer's specific purposes.

SUMMARY OF THE INVENTION

Thus, one embodiment of the invention is directed to a bed frame that includes: a rectangular support structure configured to support a mattress; foot bases, each attached to the rectangular support structure and having a bottom surface, with all of such foot bases collectively capable of supporting the rectangular support structure and the mattress above a floor surface when the bottom surfaces of the foot bases are in contact with the floor surface; and foot extensions, each having a top surface that is configured to form a press-fit attachment with one of the foot bases, in order to further elevate the rectangular support structure above the floor surface.

Another embodiment is directed to a bed frame that includes: a left side-rail component; a right side-rail component; and at least two crossbar components, each extending between the left side-rail component and the right side-rail component. Each of the left side-rail component and the right side-rail component includes a side rail having a side slat and two inwardly extending slats that extend inwardly relative to the side slat.

A still further embodiment is directed to a bed frame that includes: a left side-rail component; a right side-rail component; and a plurality of crossbar components, each extending between the left side-rail component and the right side-rail component and being adjustable in length.

Certain more-specific implementations any of the foregoing embodiments include one or any combination of the following features.

At least one of the foot bases tapers in width, being wider at a higher point, closer to the rectangular support structure, and progressively narrower further down.

At least one of the foot extensions tapers in width, being wider at a higher point, closer to where it press-fit attaches to the one of the foot bases, and progressively narrower further down.

The bottom surface of each of the foot bases includes an indentation, and the top surface of each of the plurality of foot extensions includes a protrusion that can be press fit into the indentation.

The bedframe also includes second foot extensions, each having a top surface that is configured to form a press-fit attachment with a bottom surface of one of the foot extensions, in order to further elevate the rectangular support structure above the floor surface.

Each of the foot extensions has a bottom surface that includes a second indentation, and the top surface of each of the second foot extensions includes a second protrusion that can be press fit into the second indentation.

The rectangular support structure includes a left side-rail component and a right side-rail component.

A first one of the foot bases is fixedly attached to the left side-rail component. A second one of the foot bases is fixedly attached to the right side-rail component.

The first one of the foot bases is attached to the left side-rail component using at least one of a first screw or a first rivet, and the second one of the foot bases is attached to the right side-rail component using at least one of a second screw or a second rivet.

A top portion of the first one of the foot bases has an inner side that is fixedly attached to the left side-rail component and an outer side that is disposed inwardly of the left side-rail component, and a top portion of the second one of the foot bases has an inner side that is fixedly attached to the right side-rail component and an outer side that is disposed inwardly of the right side-rail component.

The inner side of the top portion of each of the first one and the second one of the foot bases has a thinner distal part and a thicker proximal part.

The rectangular support structure further includes a crossbar component extending between the left side-rail component and the right side-rail component and having a first interface pod at its left end and a second interface pod at its right end, with the first interface pod press-fit into a top surface of the first one of the foot bases, and with the second interface pod press-fit into a top surface of the second one of the foot bases.

Each of the first one and the second one of the foot bases includes a lateral channel for accommodating a main structural component of the crossbar component.

The press-fit attachment between the first interface pod and the top surface of the first one of the foot bases extends to a depth of not more than 3 inches, and the press-fit attachment between the second interface pod and the top surface of the second one of the foot bases also extends to a depth of not more than 3 inches.

The crossbar component also has a third interface pod disposed between the first interface pod and the second interface pod.

The bedframe also includes a free-floating foot base having a top surface.

The third interface pod is press-fit into the top surface of the free-floating foot base.

At least one of the first interface pod, second interface pod and third interface pod is comprised of two halves that are attached together so as to clamp to a structural component of the crossbar component.

The rectangular support structure primarily is comprised of steel.

The foot bases primarily are comprised of plastic.

The mattress is one of the following standard sizes: Twin, Twin XL, Full, Queen, King or California King.

The side rail for each of the left side-rail component and the right side-rail component includes two elongated members that have been attached to each other, and each of the elongated members includes two elongated slats that meet each other at a junction line along their lengths.

Each of the two elongated members is made from an elongated rectangular plate that has been bent along the junction line.

The two elongated slats are at approximately right angles to each other.

The left side-rail component is a mirror image of the right side-rail component.

The side rail for each of the left side-rail component and the right side-rail component has a cross-section in the shape of an inverted F.

The bedframe also includes a plurality of foot bases attached to the left side-rail component and the right side-rail component between the inwardly extending slats.

Each of the plurality of foot bases is attached to the inwardly extending slats using at least one of a rivet or a screw extending through mounting holes in the inwardly extending slats.

Each of the plurality of foot bases has a top portion that includes an outer part that fits between the inwardly extending slats and an inner part that is thicker than the distance between the inwardly extending slats.

The inner part of the top portion of each of the foot bases abuts the inwardly extending slats.

At least one of the two crossbar components has a first interface pod at its first end that is press-fit attached to one of the foot bases attached to the left side-rail component and a second interface pod at its second end that is press-fit attached to one of the foot bases attached to the right side-rail component.

The two inwardly extending slats extend a same distance inwardly from the side slat.

The side rail for each of the left side-rail component and the right side-rail component primarily is comprised of steel.

The two inwardly extending slats are directly attached to the side slat.

The side slat has a width that is oriented substantially vertically, and each of the two inwardly extending slats has a width that is oriented substantially horizontally.

At least one of the crossbar components includes two outer tubes and a center tube, the center tube being disposed between and telescoping into the two outer tubes.

At least one of the crossbar components includes a first elongated element and a second elongated element that telescopes into the first elongated element.

The crossbar component(s) also include(s) a cam lock component that (a) can be activated to hold the second elongated element at a desired position relative to the first elongated element and (b) can be released to allow the second elongated element to move relative to the first elongated element.

The cam lock component is fixedly attached to the outer surface of the first elongated element.

A portion of the cam lock component extends beyond the end of the first elongated element into which the second elongated element slides.

The cam lock component extends not more than ½ inch beyond the end of the first elongated element into which the second elongated element slides.

The subject portion of the cam lock component includes at least one stop that prevents the cam lock component from sliding too far onto the first elongated element and that protects the second elongated element from the end of the first elongated element into which the second elongated element slides.

An inner surface of the cam lock component includes a ramp that tightens the connection between the first elongated element and the cam lock component as the cam lock component is slid onto the first elongated element.

The cam lock component is fixedly attached to the first elongated element.

An inner surface of the cam lock component includes a soft detent that extends through an opening in the first elongated element.

The second elongated element includes a sequence of openings along its length.

The soft detent engages with the openings as the second elongated element is slid into the first elongated element, thereby providing tactile feedback at different positions of the second elongated element relative to the first elongated element.

The cam lock component includes a lever component having a cam-shaped base that presses a protrusion against the second elongated element when the lever is activated.

The cam lock component includes a spring arm disposed beneath the cam-shaped base of the lever component.

The protrusion is disposed on an inner surface of the spring arm.

The cam lock component is fixedly attached to the first elongated element.

The protrusion extends through an opening in the first elongated element.

The cam lock component includes a second protrusion, on an opposite side of the cam lock component from the lever component and the protrusion, extending through a second opening in the first elongated element.

The second protrusion is disposed on a second spring arm.

The cam lock component primarily is comprised of plastic.

The cam lock component primarily is comprised of a resilient material.

At least one of the foot bases or the foot extensions includes raised ribs for strengthening the press-fit attachment while simultaneously permitting detachment with the application of a reasonable amount of separation force.

Edges of the raised ribs that first engage the press-fit attachment are sloped from a thinner portion upon initial engagement to a thicker portion upon fuller engagement.

The raised ribs are disposed so as to engage only in the final portion of the press-fit attachment.

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 accompanying 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 accompanying drawings.

FIG. 1 is a partially exploded perspective view of a bed frame according to a representative embodiment of the present invention.

FIG. 2 is an exploded perspective view of a left side-rail component according to a representative embodiment of the present invention, with the right side-rail component preferably being the mirror image thereof.

FIG. 3 is a top perspective partial cutaway view of a foot base according to a representative embodiment of the present invention.

FIG. 4 is a bottom perspective view showing a side-rail component and foot extensions, and illustrating how such foot extensions are attached to one of its foot bases, according to a representative embodiment of the present invention.

FIG. 5 is a top perspective view of a lower foot extension according to a representative embodiment of the present invention, with the opposite side preferably being identical, and with the upper foot extension preferably being a similar, but somewhat larger, version thereof.

FIG. 6 is a bottom perspective view of the lower foot extension shown in FIG. 5.

FIG. 7 is a perspective view of an interface pod installed on a crossbar component 25 according to a representative embodiment of the present invention, with the opposite side of the interface pod preferably being identical.

FIG. 8 is an exploded perspective view of a left side rail, according to a representative embodiment of the present invention, with the right side rail preferably being the mirror image thereof.

FIG. 9 is a sectional view of a side rail component, without the optional mounting bracket and plate depicted, according to a representative embodiment of the present invention.

FIG. 10 is an exploded perspective view of a crossbar component according to a representative embodiment of the present invention.

FIG. 11 is an exploded perspective view of a crossbar assembly according to an alternate representative embodiment of the present invention.

FIG. 12 is a perspective view of a cam lock component in the locked position, together with the innermost portion of the outer crossbar tube on which it is installed, with the left side of the cam lock component and the bottom panel of the outer crossbar tube cut away to show relevant interior structure, according to a representative embodiment of the present invention.

FIG. 13 is a bottom perspective view of a cam lock body according to a representative embodiment of the present invention.

FIG. 14 is a top perspective view of the cam lock body shown in FIG. 13.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

For ease of reference, the present disclosure is divided into sections. The general subject matter of each section is indicated by that section's heading. However, such headings are included simply for the purpose of facilitating readability and are not intended to limit the scope of the invention in any manner whatsoever.

Bed Frame Structure.

FIG. 1 is a partially exploded perspective view of a bed frame 10 according to one representative embodiment of the present invention. In this embodiment, bed frame 10 preferably is provided to a customer as a set of components that can be easily assembled together. Those components include a right side-rail component 15, a left side-rail component 20, a plurality of (three in this specific embodiment) crossbar components 25, and a plurality of foot extensions 28 and 29. Each of the right side-rail component 15 and the left side-rail component 20 preferably has attached to it (or includes) a plurality of foot bases 30 that are fixedly (e.g., permanently) attached along its length—in this embodiment, one at each end and one in the middle. However, in alternate embodiments, such foot bases 30 are provided separately and the customer attaches them to the corresponding right side-rail component 15 and left side-rail component 20.

In any event, the foot bases 30 on the left side-rail component 20 preferably align with the foot bases 30 on the right side-rail component 15, and the top surfaces 31 of the foot bases 30 are configured for a press-fit attachment. At the same time, the crossbar components 25 have interface pods 26 at their ends, and the bottom surfaces or portions 27 of the interface pods 26 are configured for a press-fit attachment to the top surfaces 31 of the foot bases 30. As a result, the customer need only press the interface pods 26 of each crossbar component 25 against the corresponding foot bases 30 to attach the crossbar components 25 to the side-rail components 15 and 20. The result of doing so is a rectangular support structure (e.g., including side-rail components 15 and 20 and a crossbar component 25 at each of the head end 12 and the foot end 14 of the bed frame 10, as well as one additional crossbar component 25 in the center of the rectangular structure) that is capable of supporting a mattress (e.g., a standard-sized mattress such as Twin, Twin XL, Full, Queen, King and/or California King).

In the current embodiment, each of the interface pods 26 has a male insertion member, and each of the foot bases 30 has a female opening. However, in alternate embodiments, each of the interface pods 26 has a female opening, and each of the foot bases 30 has a male insertion member. In still further embodiments, each has both male insertion member(s) and female opening(s). In any event, at least one of such components (i.e., the interface pods 26 or the foot base 30), and more preferably both components (or at least the portion(s) that physically engage with the other), preferably are primarily made of a resilient material, such as plastic, to facilitate the press-fit attachment. As shown, this press-fit attachment preferably is configured such that the engagement depth (e.g., in the current embodiment, the depth to which the male insertion member of an interface pod 26 extends into the opening in a foot base 30) is not more than 2-4 inches.

Once the foregoing step (in which the crossbar components 25 are attached to (and between) the side-rail components 15 and 20) is complete (by press-fit attaching the interface pods 26 at each end of the crossbar component 25 to the foot bases 30 attached to the side-rail components 15 and 20), the bed frame 10 has been fully or almost fully assembled. Prior to or after that step: (1) as discussed in greater detail below, the customer preferably can adjust the lengths of the crossbar components 25 in order to obtain a desired width for the bed frame 10; and/or (2) the customer can attach foot bases 30 to any central interface pods 26 (one for each crossbar component 25 in the current example), i.e., the interface pods 26 that are provided between the interface pods 26 that are at the ends of the crossbar component 25. As to the latter, once again, the components are simply press-fit together in the current embodiment, with the only difference being that, as opposed to the end foot bases 30, these mid-position foot bases 30 (sometimes referred to herein as free-floating foot bases 30) are not permanently attached to either side-rail component 20 or 25 (or any other component for that matter).

In addition, the customer preferably has the option of attaching the upper foot extensions 28 to the foot bases 30 in order to increase the height of the bed frame 10, and then can attach the lower foot extensions 29 to the upper foot extensions 28 in order to further increase the height of the bed frame 10. Although only two such foot extensions 28 and 29 are made available for each foot base 30 in the current embodiment, any other number may be provided in alternate embodiments, e.g., to allow for any desired range and/or degree of granularity of height options. In any event, for this purpose: the bottom surface 32 of each foot base 30 preferably is configured for a press-fit attachment to a mating top surface of a foot extension, the top surface 28A of upper foot extensions 28 is configured for a press-fit attachment to a mating top surface of a foot base 30, the bottom surface 28B of upper foot extensions 28 (and any additional intermediate foot extensions that are provided in alternate embodiments of the invention) are configured for press-fit attachments to the top surface of another foot extension, and at least the top surface 29A of each lower foot extension 29 (or whatever foot extensions is intended as the bottom foot extensions in alternate embodiments of the invention) is configured for a press-fit attachment to the bottom surface of a foot base 30 or another foot extension. As a result, it is a simple matter to press in the desired number of foot extensions to achieve the desired height for the customer's bed frame 10. In the current embodiment, each of the bottom surfaces 28B and 32 have a female opening, and each of the top surfaces 28A and 29A have a male insertion member. However, any other configuration to provide press-fit attachments instead can be used in alternate embodiments.

As will be readily appreciated, the foregoing configuration permits very fast and easy component of bed frame 10. The individual components of bed frame 10 (as well as certain considerations pertaining to them) are now discussed in greater detail.

Side-Rail Components and Legs.

FIG. 2 shows left side-rail component 20 in greater detail, with right side-rail component 15 preferably being the mirror image of left side-rail component 20. Side-rail 35 is the main structural component of left side-rail component 20. It preferably is made primarily of steel, although in alternate embodiments any similarly strong natural or synthetic material instead may be used. In the preferred embodiment, side-rail 35: (1) is an elongated component (e.g., at least 68-85 inches long, or in the current embodiment, having a length of approximately 70-75 inches, approximately 72 inches in the current specific embodiment, in order to accommodate the length(s) of one or more of the standard mattress sizes, e.g., Twin, Twin XL, Full, Queen, King and/or California King, typically with some overhang for the longer mattress sizes), (2) having an inverted-F-shaped cross-section along its entire length (or at least a substantial portion thereof). This cross-section is preferred, e.g., because it includes a top horizontal slat 36 and a vertical slat 37 that provide bottom and side support, respectively, for the mattress, and also includes a bottom horizontal slat 38 that, along with top horizontal slat 36 and the lower portion of vertical slat 37, forms a channel for attaching the foot bases 30.

In this latter regard, an inner edge 33 of the top portion of the foot base 30 includes a pair of openings 34 that align with one of the pairs of pre-formed openings 39 in horizontal slats 36 and 38. Rivets 47 (or, in alternate embodiments, screws or other attachment elements) are inserted through such openings 34 and 39 in order to securely and fixedly attach foot bases 30 (or, more precisely, their inner edges 33) to the side-rail 35. Because of this inverted-F-shaped cross-sectional configuration, when a mattress is placed on top of the bed frame 10, its weight also helps to secure the foot bases 30 in place, by essentially causing horizontal slats 36 and 38 to clamp down on their inner edges 33. It is noted that although an inverted-F-shaped cross-section is preferred in the current embodiment, in alternate embodiments, different configurations and/or cross-sections may be used, e.g., also having an elongated side slat (having a width that is substantially vertical) and a pair of elongated inwardly extending slats (each extending inwardly from the side slat and having a width that is substantially horizontal, so that they are at least approximately parallel to each other).

Side-rail cover 57 (discussed in greater detail below) preferably is made of plastic (more preferably, polyvinyl chloride (PVC)), natural or synthetic rubber, or another relatively soft, pliable and/or resilient material, and is slid onto side rail 35 in the current embodiment. Endcap 58, preferably is made of plastic, and is attached (e.g., press-fit onto) the foot end 14 of side-rail 35 in the current embodiment.

The individual components of side-rail components 15 and 20, as well as the associated foot components, are now discussed in greater detail. Initially, as shown in FIG. 3, formed into the top surface 31 of foot base 30 is a female opening 60 for permitting a press-fit attachment. For this purpose, in the current embodiment, foot base 30 is made entirely of plastic or some other pliable and/or resilient material. However, in alternate embodiments, at least the portion of foot base 30 forming opening 60 is made of such a material. In any event, in the current embodiment, opening 60 tapers from a larger cross-section at the very top surface 31 of foot base 30 to a smaller cross-section as opening 60 extends deeper into foot base 30, in order to better facilitate a press-fit attachment.

In addition, a pair of lateral slots 61 and 62 (an upper lateral slot 61 on the top surface of extending portion 63 and a lower lateral slot 62 on the lower surface of such top/extending portion 63) is provided just inwardly of the attachment openings 34. In the current embodiment, slots 61 and 62 also separate the thicker inner (or proximal) part 63A from the thinner outer (or distal) part 63B of extending portion 63, so that extending portion 63 can be simply slid in between top horizontal slat 36 and bottom horizontal slat 38 of side rail 35 until the thicker inner part 63A abuts such slats 36 and 38, and then the foot base 30 can be slid until its attachment openings 34 align with the appropriate pair of attachment openings 39 in the side rail 35. As noted above, the weight of the mattress typically also will cause slats 36 and 38 to clamp down on extending portion 63 (e.g., thinner portion 63B) in order to better secure foot base 30 in position. The provision of slots 61 and 62 can enhance this effect, e.g., with the inner edges of slats 36 and 38 bending into slots 61 and 62, respectively. A lengthwise channel 64 preferably also is provided in the top portion of foot base 30 for facilitating alignment and attachment to a crossbar component 25.

As shown in FIG. 3, opening 60 is surrounded by a ledge 66 to facilitate alignment and attachment of another component (e.g., an interface pod 26). In the depiction of FIG. 3, one side of the ledge 66 is cut away to better reveal the grid-like internal structure of the foot base 30, which provides the required strength while omitting the need for unnecessary material (typically, plastic).

In the current embodiment, foot base 30 is both laterally and longitudinally symmetrical so that inner edge 33 (as shown in FIG. 2) can be selected arbitrarily or, stated differently, the same foot bases 30 can be used for both the right side-rail component 15 and the left side-rail component 20, and it can be attached at either edge that includes the attachment openings 34. However, in alternate embodiments, e.g.: (1) only one of such edges includes openings 34 and slots 61 and 62, or (2) the extending portion 63 exists on only one side (i.e., so that there is only a single extending edge, which is the currently implemented embodiment), and in either case, that edge is designated as the inner edge 33.

As shown in FIG. 4, in the current embodiment, foot extensions 28 and 29 can be simply press-fit into the bottoms 32 of the foot bases 30 of the side-rail component (left side-rail component 20 depicted). For this purpose, the bottom surface 32 of each foot base 30 has a female opening 70, and the top surface 28A of upper foot extension 28 has a male insertion member 72 that fits securely into opening 70. Similarly, the bottom surface 28B of the upper foot extension 28 includes a female opening 76, and the top surface 29A of lower foot extension 29 has a male insertion member 78 (e.g., as shown more clearly in FIG. 5) that fits securely into opening 76. In the current embodiment, the bottom surface 29B of lower foot extension 29 includes just a partial opening, revealing an internal grid-like structure 79 throughout (e.g., as shown more clearly in FIG. 6). This is because, if used at all, in the current embodiment, lower foot extension 29 is intended to be the very bottom foot component, so no larger opening is required and the grid structure can be used throughout, providing additional strength. However, in alternate embodiments, a portion of the grid-like structure 79 is omitted to provide a female opening and thereby allow another foot extension to be press-fit into it. More generally, any number of similar foot extensions may be used in alternate embodiments of the invention. In the currently preferred embodiment, the foot extension that is intended to be used as the very bottom foot extension does not include any such opening, and even the limited opening to reveal the internal grid-like structure 79 is omitted in alternate embodiments. However, in still further alternate embodiments, particularly embodiments where all the foot extensions are identical to each other, each foot extension includes a press-fit opening in its bottom surface. Except as otherwise desirable, e.g., in order to provide a press-fit female opening, grid-like structure 79 preferably is used throughout the interior of each foot extension, again to provide strength while minimizing the amount of material used.

Also, it is noted that in the current embodiment, primarily for aesthetic purposes, the foot base 30 and each foot extension (e.g., foot extensions 28 and 29) are tapered so that the main body portion of each is wider at the top and becomes progressively narrower toward its bottom, with each additional (lower) foot extension being narrower than the foot extension (or foot base 30) that is immediately above it, so that, regardless of how many foot extensions (e.g., 28 and 29) are installed, the overall foot structure tapers (preferably continuously) from wider at the top two narrower at the bottom. However, in alternate embodiments, other configurations are used. For example, in one alternate embodiment, all of the foot extensions are identical to each other (e.g., having purely vertical sides), thereby reducing the number of different components to be manufactured.

Referring back to FIG. 5, in the preferred embodiments, any or all of the surfaces of the components that are used in the press-fit attachments (e.g., the surfaces of the male insertion members avoid the female openings) discussed herein are provided with raised ribs 40 for strengthening the press-fit attachment while simultaneously permitting detachment with the application of a reasonable amount of separation force (e.g., approximately 1-10 pounds of force). In the current embodiment, such ribs 40 are provided only on the male insertion members. More specifically, three pairs of such ribs 40 are provided on each of the two opposite sides of the male insertion member (e.g., the longer side of male insertion member 78 shown in FIG. 5 as well as the opposite longer side). However, any other number and/or configuration of ribs 40 instead may be used, and, in alternate embodiments, such ribs 40 instead (or also) are provided on the inner surface of the corresponding female opening. In any event, ribs 40 preferably: (1) have a fairly short engagement portion (e.g., not more than 3 centimeters (cm) in length); (2) have a collective width of less than 5-15% of the circumference of the surface on which they are provided; (3) have a maximum height or thickness that is sufficient to provide a desired tightness of fit (which typically will be related to the widths of such ribs 40, relative to the overall circumference of the surface on which they are provided, but often preferably are in the range of 0.5-3.0 mm (millimeters) maximum thickness); (4) have sloped edges where they initially engage the mating attachment surface, sloping from a thinner portion upon initial engagement to a thicker portion upon fuller engagement until reaching its maximum thickness; and/or (5) are provided only in the final portion of the press-fit attachment (e.g., in the segment of male insertion member 78 that is closest to surface 29A, which functions as a stop).

As shown in FIG. 7, similar ribs 40 (again, preferably with the same properties noted above) also are provided on the male insertion member (e.g., bottom portion 27) of interface pod 26. Specifically, in this particular embodiment, three pairs of such ribs 40 are provided in each of the two longer sides of male insertion member 27 (the side depicted in FIG. 7 in the opposite side which is not visible). It is noted that in this embodiment, interface pod 26 is comprised of two lateral halves that are attached together using screws, rivets or other attachment members 42.

In the current embodiment, side rail 35 primarily is comprised of two angle irons 80 and 85 (each preferably formed from a single rectangular piece of steel by being bent along its entire length so as to have an L-shaped, at least approximately right-angle cross-section). More preferably, angle irons 80 and 85 preferably are welded together as shown in FIG. 8 such that slat 89 of smaller angle iron 85 is welded to the bottom portion of slat 37 of the larger angle iron 80, so that the bottom edge 86 of smaller angle iron 85 abuts the junction edge 81 of larger angle iron 80. Here, each of angle irons 80 and 85 is 70 inches long (in alternate embodiments, e.g., at least 65 inches long), slat 37 is approximately 3 inches wide, each of slats 36, 38 and 39 is approximately 1.5 inches wide, and each of angle irons 80 and 85 is approximately 0.1 inch thick. With this configuration: (1) one of the slats forming smaller angle iron 85 provides the top horizontal slat 36 of side rail 35 (with its attachment openings 39); (2) the narrower slat of larger angle iron 80 provides the bottom horizontal slat 38 of side rail 35 (with its aligned attachment openings 39); and (3) the other slat of larger angle iron 80 provides the vertical slat 37, all integrated into an inherently strong and supportive structure 35. Preferably, the inner edge 82 of bottom horizontal slat 38 at least approximately aligns with (i.e., extends the same distance inwardly as) the inner edge 87 of top horizontal slat 36, and horizontal slats 36 and 38 are at least approximately parallel to each other.

Also in the current embodiment, each of side-rail components 15 and 20 includes a headboard mounting bracket 48 (which is L-shaped in the current embodiment) and a mounting plate 49, although both components can be omitted in alternate embodiments of the invention. Specifically, attached to (e.g., welded onto) the head end 12 of side rail 35 (i.e., the combination of angle irons 80 and 85 in the current embodiment) is headboard mounting bracket 48, and the distal end 88 of headboard mounting bracket 48, in turn, is attached (e.g., welded) to headboard mounting plate 49. Specifically, as indicated in FIG. 8, in the current embodiment, the distal end 88 of headboard mounting bracket 48 is inserted through a slot 90 (vertically oriented in the current embodiment) or other opening in headboard mounting plate 49, where the two components are welded together. As shown, headboard mounting plate 49 includes four mounting slots 91-94 (horizontally oriented in the current embodiment) or other openings or attachment components at different (e.g., equally spaced) vertical positions, for attaching (e.g., bolting on) a headboard (not shown). This configuration, e.g., allows the bed frame 10 to accommodate attachment of a headboard at different vertical positions, e.g., for situations where the rectangular support structure (e.g., including side-rail components 15 and 20 and a crossbar component 25 at each of the head end 12 and the foot end 14 of the bed frame 10) is at different heights above the floor's surface. It is noted that, in the current embodiment, by appropriately rotating side rail 35 prior to attachment (if any) of the headboard mounting bracket 48 and plate 49, the same structure also can be used for the right side rail.

FIG. 9 illustrates the engagement between side-rail cover 57 and side rail 35 after the side-rail cover 57 has been installed (e.g., slid onto side rail 35). As shown, in the current embodiment, side-rail cover 57 has a bottom channels 95A&B, and the inner contour of side-rail cover 57 closely matches the cross-section of side rail 35. At the same time, side-rail cover 57 includes a number of inwardly extending, preferably resilient, fingers or strips 96 for providing a secure attachment while simultaneously accommodating manufacturing variations in the components and making it easier to slide side-rail cover 57 onto side rail 35.

Preferably, bottom channel 95A (or another attachment surface in alternate embodiments) of side-rail cover 57 is used for attaching a lighting strip 99. In the current embodiment, lighting strip 99 is attached to side-rail cover 57 using an adhesive material (e.g., lighting strip 99 has an adhesive backing, or it is attached using a separate adhesive material). However, in alternate embodiments, lighting strip 99 is attached using other means (e.g., screws, rivets, or any combination of attachment means) in addition or instead of adhesive material. In the various embodiments, a lighting strip 99: (1) runs along the entire length of each side-rail component 15 and 20, (2) is powered by an external power supply, (3) is a strip of light-emitting diodes (LEDs), (4) is electrically connected to the lighting strip 99 on the other side-rail component 15 or 20, so that the two can be switched on and off together (or separately, if desired), and/or (5) can be turned on and off using a remote control and/or automatically via a motion sensor (e.g., part of lighting strip 99 or separately installed on the subject side-rail component 15 or 20).

As a result of lighting strip 99, e.g., underbed lighting can be provided, various aesthetics can be achieved, and/or if a person gets out of bed in the middle of the night, the motion sensor can automatically turn on the lighting in order to illuminate the floor. For this latter purpose, in certain embodiments, as shown in FIG. 9, the light from lighting strip 99 is directed outwardly (i.e., away from the footprint occupied by the bed frame 10), e.g., by directing the LEDs within lighting strip 99, using mirrors and/or lenses, and/or attaching lighting strip 99 in and angled manner (such as by making bottom channel 95A angled). In the current embodiment, side-rail cover 57 also is provided with a narrower bottom channel 95B, e.g., for running wires or for use as an additional attachment surface for lighting strip 99.

The foregoing discussion concerns one specific embodiment in which lighting strip 99 is used. However, in alternate embodiments: (1) lighting strip 99 is provided on another part of side-rail cover 57 (e.g., its side surface, rather than its bottom surface), (2) lighting strip 99 is provided on another portion of the side-rail assembly 15 or 20 (e.g., for embodiments in which side-rail cover 57 is not used, (3) lighting is provided on side-rail components 15 and/or 20 in a configuration other than a strip (and references herein to strip 99 can be replaced with references to other lighting configurations), and/or (4) the light from lighting strip 99 is directed downwardly (rather than outwardly), or lighting strip 99 has a rotatable (e.g., bottom) portion (e.g., rotatable on a base portion that is fixedly attached to the side-rail cover 57 or other component), so that such light can be directed as desired by the customer (e.g., outwardly by default, downwardly for a more muted or decorative lighting effect, or inwardly for situations in which the customer wants to look underneath the bed).

Crossbar Components.

FIG. 10 illustrates the structure of a representative crossbar component 25. In the present embodiment, each crossbar component 25 is adjustable-length, e.g., so that bed frame 10 (or more precisely, its rectangular support structure, e.g., including side-rail components 15 and 20 and a crossbar component 25 at each of the head end 12 and the foot end 14 of the bed frame 10), is adjustable-width and, therefore, capable of supporting (e.g., and closely matching the width of) any of the standard mattress sizes, such as Twin, Twin XL, Full, Queen, King and/or California King.

For this purpose, the crossbar component 25 is comprised of telescoping components. More specifically, in the current embodiment, crossbar component 25 includes two outer crossbar tubes 97 and a center (or inner) crossbar tube 98 that is narrower than (preferably having outer dimensions that are just a little smaller than the corresponding inner dimensions of) each of the two outer crossbar tubes 97. In the current embodiment, each of the two outer crossbar tubes 97 has a 1.5-inch-width square cross-section and a length of 18.6 inches, and the center crossbar tube 98 has a 1.38-inch-width square cross-section and a length of 49 inches. This particular configuration allows center crossbar tube 98 to slide into each of the outer crossbar tubes 97, allowing the bed frame 10 to have an adjustable width, e.g., from 54-76 inches, so that it is capable of accommodating Full, Queen, California King or King mattress widths. In addition, in the current embodiment, a cam lock component 100 is fixedly attached to the inner end of each of the outer crossbar tubes 97 and is used to fix the position of its respective outer crossbar tube 97 to the center crossbar tube 98 at the desired position. Preferably, cam lock component 100 is comprised entirely or substantially entirely of plastic.

As shown in FIG. 10, interface pods 26 are attached to the outer crossbar tube 97 using two halves 26A&B that are joined together so as to clamp onto the corresponding outer crossbar tube 97 using a pair of rivets 128 (or, in alternate embodiments, screws or other attachment elements). In this embodiment, in order to use a single size for all interface pods 26, a spacer 130 (e.g., 11-12 inches long, made of plastic, and provided from two attached halves 130A&B) is first installed on the center crossbar tube 98 to increase the proportions of the center crossbar tube 98 at that location, prior to attaching the interface pods 26 there. However, in alternate embodiments (such as the currently implemented embodiment shown in FIG. 11), a different interface pod (with a modified configuration in order to properly fit the smaller proportions) is attached to the center crossbar tube 98, and the spacer 130 is omitted. Finally, end caps 132 (made of plastic in the current embodiment) are attached (e.g., press-fit onto) to the outer ends of the outer crossbar tubes 97.

In this latter regard, an alternate configuration for the center portion of the crossbar component 25 is shown in FIG. 11. In this configuration, unlike the interface pods 26 attached to the ends of the crossbar component 25, which are assembled from two lateral halves 26A&B, the interface pod 26 at the center of the crossbar component 25 is assembled from a top portion 26C and a bottom portion 26D, again using screws, rivets or other attachment elements 128.

FIGS. 10 and 12 collectively illustrate the structure of a cam lock component 100 and its structural relationship with an outer crossbar tube 97 and (particularly with respect to FIG. 10) a center crossbar tube 98. In the current embodiment, cam lock component 100 consists of three main components: a body 102, a lever component 103 and a pin 104. The lever component 103 has a cam (or base) portion 105 that includes a lateral opening for accepting the pin 104 and an elongated arm 106 that extends from the base portion 105 and is curved in the current embodiment to facilitate use.

The body 102 of the cam lock component 100 (shown most clearly in FIGS. 13 and 14) has an internal cross-section that mainly matches the external cross-section of the outer crossbar tube 97 (square in the present embodiment), so that it can be slid onto the end of outer crossbar tube 97. In addition, cam lock body 102 preferably includes one or more of the following additional features: (1) stop(s) 112 (implemented as protruding strips in the current embodiment) that, among other things, limit how far cam lock body 102 can be slid onto outer crossbar tube 97; (2) spring arm(s) 113, two in the present embodiment, one on the top surface just beneath the cam or base portion 105 of the lever arm component 103 and one on the bottom surface just opposite the one on the top surface, each of which being attached on just one side to the rest of the cam lock body 102 (leaving the other three sides unattached); (3) protruding element(s) 114 on the spring arm(s) 113, preferably matching the size and shape of corresponding mounting openings 115 (both substantially rectangular with rounded ends and corners in the current embodiment) in the portion of the outer crossbar tube 97 where the cam lock component 100 attaches (close to the inner end of outer crossbar tube 97, in the current embodiment); (4) an additional protrusion or soft detent 116 (dome-shaped in the current embodiment) on top of one of the protruding elements 114; (5) ramp strip(s) 117; and (6) a pair of support structures 118, each having a lateral opening 119 that is aligned with the other, with the support structures 118 being separated from each other a sufficient distance to accommodate the width of the lever 103's base portion 105, and with the lateral openings 119 being configured to accept the pin 104.

Accordingly, cam lock component 100 can be assembled by inserting the cam or base portion 105 of lever component 103 between the support structures 118 and then inserting the pin 104 first through the lateral opening 119 in one of the support structures 118, then through the lateral opening in the cam or base portion 105, and finally through the opening 119 in the other support structure 118. Once assembled, cam lock component 100 can be installed onto an outer crossbar tube 97 by simply sliding it (e.g., with the lever component 103 in the unlocked position) onto the end of outer crossbar tube 97 that includes the mounting openings 115, with the lever component of the cam lock component 100 on the same side is one of such openings 115, until the protruding element(s) 114 engage with such openings 115, at which point the end of the outer crossbar tube 97 will contact (or, e.g., at least be close to contacting) stop(s) 112. Also, as the cam lock component 100 is slid onto the outer crossbar tube 97, the ramp strip(s) 117 provide increasing tension, further helping to hold it in place.

At this point, the center crossbar tube 98 can be slid into the outer crossbar tube 97 until a desired position is reached, and then the lever component 103 is pushed down into the locked (or activated) position, which rotates the cam or base portion 105, forcing the underlying spring arm 113 further down and pressing its protruding element 114 firmly against center crossbar tube 98, thereby holding it in place. To facilitate this width adjustment, the center crossbar tube 98 preferably is provided with a pair of alignment openings 122 (rounded the current embodiment), one on each side of, and equidistant from, its center point, that indicate the appropriate positions for each of different standard-sized mattresses (e.g., Full, Queen, California King or King). In addition, in the preferred embodiments, a pair of preferably labeled lines or other marks also is provided, one on each side of the center point of the center crossbar tube 98 and equidistant from such center point, showing where the inner edge of the cam lock body 102 should be positioned for that particular mattress size. As the center crossbar tube 98 is slid into outer crossbar tube 97, the detent 116 softly engages such openings, providing the customer with tactile feedback, so that the customer knows precisely where to lock the lever component 103 for his or her mattress size. However, the customer is not limited to the standard mattress sizes and can instead choose to lock the cam lock assembly 100 at any desired relative positioning of the center crossbar tube 98 to the outer crossbar tube 97.

It is noted that in the current embodiment, cam lock component 100 extends a little past the end of the outer crossbar tube 97. This configuration, particularly in combination with the fact that such extension portion has narrower interior dimensions (e.g., stops 112 and a generally narrower cross-section), helps to protect the center crossbar tube 98 from potentially being scratched or otherwise damaged as it enters the corresponding outer crossbar tube 97 from any potential rough edges or other manufacturing imperfections at that and of the outer crossbar tube. Due to the preferred configuration of cam lock component 100, even this extension can be fairly minimal (e.g., not more than ½ inch). However, in alternate embodiments, such extension can be reduced even further or even eliminated.

Additional Considerations.

Certain components discussed above are described as preferably being made of plastic. More preferably, unless specifically stated otherwise, such components are made of a thermoplastic, such as acrylonitrile butadiene styrene (ABS), Polycarbonate (PC) or a blend thereof (all the foregoing being collectively referred to herein as ABS/PC). However, in alternate embodiments, another similarly strong but flexible and/or resilient material instead is used, and references above to plastic may be replaced with references to such other materials.

Similarly, certain components discussed above are described as preferably being made of steel. More preferably, such components are made of a low-carbon steel (e.g., where the carbon content is in the 0.04-0.3% range), sometimes referred to as mild steel. However, in alternate embodiments, another material with similar or better properties (e.g., in terms of cost, strength and/or strength-to-weight ratio) instead is used, and references above to steel may be replaced with references to such other materials.

In the discussion above, when a particular cross-section is identified (e.g., F-shaped or L-shaped), it should be understood that the referenced component can have that cross-section or its mirror image (i.e., rotated 180° left-right). Also, when the discussion above refers to an “inverted” shape that term is intended to mean that the shape is flipped vertically (i.e., rotated 180° top-bottom and, optionally, rotated 180° left-right).

In the discussion above, various references are made to press-fit attachments. In each such case, preferably: (1) at least one of the male or the female components forming such an attachment (and more preferably both) are made of plastic or another resilient material, and (2) the male component engages more tightly the further it is inserted into the female component, e.g., by making the female opening taper in size, from wider near the top to narrower as the depth increases. Although in each case, a specific configuration is described (e.g., with a first component including the male member and a second component including the female opening), it should be understood that equivalent configurations instead may be used (e.g., with the subject first component including the female opening in the subject second component including the male member).

As used herein, the term “component” without further qualification is intended to mean a single unitary component or an assembly of different subcomponents. As used herein, the term “attached”, or any other form of the word, without further modification, is intended to mean directly attached, attached through one or more other intermediate elements or components, or integrally formed together. In the drawings and/or the discussion, where two individual components or elements are shown and/or discussed as being directly attached to each other, such attachments should be understood as being merely exemplary, and in alternate embodiments the attachment instead may include additional components or elements between such two components. Similarly, method steps discussed and/or claimed herein are not intended to be exclusive; rather, intermediate steps may be performed between any two steps expressly discussed or claimed herein.

Unless otherwise clearly stated herein, all relative directions (e.g., left, right, top, bottom, above, below) mentioned herein in relation to an article are from the perspective of the article itself and, therefore, are consistent across different views.

Whenever a specific value is mentioned herein, such a reference is intended to include that specific value or substantially or approximately that value. In this regard, the foregoing use of the word “substantially” is intended to encompass values that are not substantially different from the stated value, i.e., permitting deviations that would not have substantial impact within the identified context. For example, the identification of a single length, width, depth, thickness, etc. should be understood to include values within a range around such specifically stated value that produce substantially the same effect as the specifically stated value. As used herein, except to the extent expressly and specifically stated otherwise, the term “approximately” can mean, e.g.: within +10% of the stated value or within ±20% of the stated value.

In the event of any conflict or inconsistency between the disclosure explicitly set forth herein or in the accompanying drawings, on the one hand, and any materials incorporated by reference herein (whether explicitly or by operation of any applicable law, regulation or rule), 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 disclosure most recently added or changed shall take precedence.

Unless clearly indicated to the contrary, words such as “optimal”, “optimize”, “maximize”, “minimize”, “best”, as well as similar words and other words and suffixes denoting comparison, in the above discussion are not used in their absolute sense. Instead, such terms ordinarily are intended to be understood in light of any other potential constraints, such as user-specified constraints and objectives, as well as cost and processing or manufacturing constraints.

As used herein, 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 and/or in any documents incorporated by reference herein, 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 intent 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 intent of the invention are to be considered as within the scope thereof, as limited solely by the claims appended hereto.

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