BED SYSTEM

Abstract

A bed assembly includes first, second, third, and fourth side rails, first and second slat supports, first and second rail supports, and a slat. The side rails each include an end and a side. The end of the second side rail is coupled to the end of the first side rail. The end of the fourth side rail is coupled to the end of the third side rail such that the sides of the first and second side rails are facing the sides of the third and fourth side rails. The first and second slat supports are configured to engage the first and third side rails, respectively. The first and second rail supports each include a continuous surface coupled to two of the first, second, third, and fourth side rails and configured to inhibit movement of the two of the first, second, third, and fourth side rails.

Description

FIELD

The present disclosure relates to a bed system, including methods of assembling the bed system.

BACKGROUND

This section provides background information related to the present disclosure and is not necessarily prior art.

Bed systems often include various components that must be assembled prior to using the bed. For example, known bed systems often include a pair of side rails, a head board, a footboard, and a plurality of slats or support members. Prior to using the bed system to support a mattress or a box spring, the bed system must be assembled by coupling one end of each side rail to the headboard and the opposite end of each side rail to the footboard, and by engaging each slat with each of the pair of siderails. The components of such a bed system are often very large and involve numerous assembly steps. For example, the side rails are often between six and seven feet long. Accordingly, such systems present challenges during the packaging, shipping, handling, and assembly processes.

While known bed systems and known methods of assembling bed systems have proven useful for their intended purposes, a need for continuous improvement in the pertinent art remains.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

One aspect of the disclosure provides a bed assembly. The bed system may include first, second, third, and fourth side rails, first and second slat supports, first and second rail supports, and a slat. The first, second, third, and fourth side rails may each include an end and a side extending from the end of the respective side rail. The end of the second side rail may be coupled to the end of the first side rail. The end of the fourth side rail may be coupled to the end of the third side rail such that the sides of the first and second side rails are facing the sides of the third and fourth side rails. The first slat support may be configured to engage the first side rail. The second slat support may be configured to engage the third side rail. The slat may be coupled to the first slat support and the second slat support. The first rail support may include a continuous surface coupled to the first side rail and the second side rail and configured to inhibit movement of the first side rail relative to the second side rail. The second rail support may include a continuous surface coupled to the third side rail and the fourth side rail and configured to inhibit movement of the first side rail relative to the second side rail.

Implementations of the disclosure may include one or more of the following optional features. In some implementations, the first rail support includes a dowel having a first end and a second end. The first end of the dowel may be configured to engage the end of the first side rail. The second end of the dowel may be configured to engage the end of the second side rail.

In some implementations, the first rail support includes a leg configured to engage the first side rail and the second side rail.

In some implementations, the first rail support includes a bracket having a base configured to engage the side of the first side rail and the side of the second side rail. The bracket may include an upper flange extending from the base in a first direction and configured to engage a bottom of the first side rail and a bottom of the second side rail. The bracket may also include a lower flange extending from the base in a second direction opposite the first direction.

In some implementations, the first slat support includes a slat-support portion and a rail-support portion. The rail-support portion may include a body portion configured to engage the side of the first side rail. The slat-support portion may include a leg portion and a slat-lock portion. The leg portion may extend from the body portion in a first direction. The slat-lock portion may extend from the leg portion in a second direction transverse to the first direction. The slat-lock portion may be configured to engage the slat.

In some implementations, the rail-support portion includes an arm portion and a catch portion. The arm portion may extend from the body portion in a third direction. The catch portion may extend from the arm portion in a fourth direction transverse to the third direction. The body portion, the arm portion, and the catch portion may collectively define a channel configured to receive the first side rail. The third direction may be parallel to the first direction.

In some implementations, the slat-lock portion includes a lip extending from the leg portion in second direction transverse to the first direction. The slat may include a groove configured to receive the lip. The body portion, the leg portion, and the lip may collectively define a channel configured to receive the slat. The lip may define a notch, a first height extending from the leg portion adjacent the notch, and a second height extending from the leg portion at the notch. The second height may be less than the first height. The groove may extend through a first side and a second side of the slat. The lip may be configured to abut the first side of the slat. The notch may be disposed between the first and second sides of the slat.

Another aspect of the disclosure provides a method of assembling a bed. The method may include coupling an end of a first side rail to an end of a second side rail and coupling an end of a third side rail to an end of a fourth side rail. The method may also coupling a first slat support to the first side rail and coupling a second slat support to the third side rail. The metho may further include coupling a continuous surface of a first rail support to the first side rail and the second side rail to inhibit movement of the first side rail relative to the second side rail. The method may also include coupling a continuous surface of a second rail support to the third side rail and the fourth side rail to inhibit movement of the third side rail relative to the fourth side rail. The method may further include coupling a slat to the first slat support and the second slat support.

Implementations of this aspect may include one or more of the following optional features. In some implementations, the first slat support includes a lip and the slat includes a groove. Coupling the slat to the first slat support may include positioning the lip within the groove. In some implementations, the first slat support defines a channel. Coupling the slat to the first slat support may include positioning the slat in the channel. In some implementations, coupling the slat to the first slat support includes abutting the lip with a side of the slat.

In some implementations, coupling a continuous surface of a first rail support to the first side rail and the second side rail includes at least one of (i) positioning a first end of a dowel in the end of the first side rail and positioning a second end of the dowel in the end of the second side rail, (ii) coupling a leg to the first side rail and the second side rail, or (iii) coupling a bracket to the side of the first side rail and to the side of the second side rail.

The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of a bed system in accordance with the principles of the present disclosure;

FIG. 2 is an exploded view of the bed system of FIG. 1;

FIG. 3 is a perspective view of a portion of the bed system of FIG. 1;

FIG. 4 is cross-sectional view of the bed system of FIG. 1 taken along the line 4-4 of FIG. 1;

FIG. 5 is a perspective view of a rail support in accordance with the principles of the present disclosure; and

FIG. 6 is a perspective view of another rail support in accordance with the principles of the present disclosure.

Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.

With reference to FIGS. 1 and 2, a bed assembly or system 10 is provided. While the bed system 10 is generally shown herein as being an assembly, or being in an assembled state, it will be appreciated that, as described in more detail below, the bed system 10 may be provided to a user in an unassembled state within the scope of the present disclosure. For example, the bed system 10 may be packaged, shipped, and provided to the user (e.g., a retail store, a home, a place of lodging, etc.) in an unassembled state with instructions for assembly. In this regard, the bed system 10 may be packaged, shipped, and provided to the user as a kit of components with instructions for transforming the bed system 10 from the unassembled state to the assembled state. Accordingly, references herein to a “bed kit 10” will be understood to be references to the bed system 10 in an unassembled state.

The bed system 10 may include a plurality of side rails 12, a headboard 14, a footboard 16, a plurality of rail supports 18, a plurality of slat supports 20, and a plurality of slats 22. As illustrated in FIG. 2, in some implementations, the bed system 10 includes four side rails 12. For example, the bed system may include a first side rail 12-1, a second side rail 12-2, a third side rail 12-3, and a fourth side rail 12-4. It will be appreciated, however, that the bed system 10 may include more or less than four siderails 12 within the scope of the present disclosure.

The first side rail 12-1 may be substantially similar to the second, third, and fourth side rails 12-2, 12-3, 12-4, apart from any exceptions described below or shown in the Figures. Accordingly, references herein to the side rail 12 will be understood to apply equally to the first, second, third, and fourth side rails 12-1, 12-2, 12-3, 12-4, except as otherwise provided herein.

With reference to FIG. 2, the side rail 12 may include a top 26, a bottom 28, an outer side 30, an inner side 32, a proximal end 34, and a distal end 36. The bottom 28 may be disposed opposite the top 26. The outer side 30 may extend between the top 26 and the bottom 28. For example, in some implementations, the outer side 30 extends from the top 26 to the bottom 28. The inner side 32 may be disposed opposite the outer side 30 and may extend between the top 26 and the bottom 28. For example, in some implementations, the inner side 32 extends from the top 26 to the bottom 28. In this regard, the inner side 32 may be parallel to the outer side 30. The proximal end 34 may extend between the top 26, the bottom 28, the outer side 30, and the inner side 32. For example, in some implementations, the proximal end 34 extends from the top 26 to the bottom 28 and from the outer side 30 to the inner side 32. The distal end 36 may be disposed opposite the proximal end 34 and may extend between the top 26, the bottom 28, the outer side 30, and the inner side 32. For example, in some implementations, the distal end 36 extends from the top 26 to the bottom 28 and from the outer side 30 to the inner side 32. In this regard, the proximal end 34 may be parallel to the distal end 36.

As illustrated in FIGS. 3 and 4, at least one of the proximal or distal ends 34, 36 may include one or more apertures 40. For example, in some implementations, the proximal end 34 of the first and third side rails 12-1, 12-3 includes first and second apertures 40-1, 40-2, and the distal end 36 of the second and fourth side rails 12-2, 12-4 includes third and fourth apertures 40-3, 40-4. It will be appreciated, however, that the proximal or distal ends 34, 36 may each include more or less than two apertures 40 within the scope of the present disclosure.

As will be explained in more detail below, in an assembled configuration (e.g., FIG. 1), the apertures 40 of the first and third side rails 12-1, 12-3 may be aligned with the apertures 40 of the second and fourth side rails 12-2, 12-4, respectively, to couple the proximal ends 34 of the first and third side rails 12-1, 12-3 to the distal ends 36 of the second and fourth side rails 12-2, 12-4, respectively. In this regard, the proximal ends 34 of the first and third side rails 12-1, 12-3 may engage the distal ends 36 of the second and fourth side rails 12-2, 12-4, respectively, in the assembled configuration.

With reference to FIG. 2, in some implementations, the bed system 10 includes a plurality of rail supports 18. For example, the bed system may include a first rail support 18-1, a second rail support 18-2, a third rail support 18-3, a fourth rail support 18-4, a fifth rail support 18-5, a sixth rail support 18-6, a seventh rail support 18-7, and an eighth rail support 18-8. It will be appreciated, however, that the bed system 10 may include more or less than eight rail supports 18 within the scope of the present disclosure. In this regard, the bed system 10 may be formed without one or more of the first, second, third, fourth, fifth, sixth, seventh, or eighth rail supports 18-1, 18-2, 18-3, 18-4, 18-5, 18-6, 18-7, 18-8 within the scope of the present disclosure. For example, in one embodiment, the bed system 10 may include the first, second, third, fourth, fifth, and sixth rail supports 18-1, 18-2, 18-3, 18-4, 18-5, 18-6, while in another embodiment, the bed system 10 may include the first, second, third, fourth, seventh, and eighth rail supports 18-1, 18-2, 18-3, 18-4, 18-7, 18-8.

Apart from any exceptions described below or shown in the Figures, (i) the first rail support 18-1 may be substantially similar to the second rail support 18-2, (ii) the third rail support 18-3 may be substantially similar to the fourth rail support 18-4, (iii) the fifth rail support 18-5 may be substantially similar to the sixth rail support 18-6, and (iv) the seventh rail support 18-7 may substantially similar to the eighth rail support 18-8. Accordingly, references herein to the first, third, fifth, and seventh rail supports 18-1, 18-3, 18-5, 18-7 will be understood to apply equally to the second, fourth, sixth, and eighth rail supports 18-2, 18-4, 18-6, 18-8, respectively, except as otherwise provided herein.

With reference to FIGS. 2-4, the first rail support 18-1 may include, or otherwise define, a dowel. In this regard, the first and second rails supports 18-1, 18-2 may be referred to herein as dowels 18-1, 18-2. The dowels 18-1, 18-2 may each include a continuous outer surface 44. As illustrated, in some implementations, at least a portion of the continuous outer surface 44 defines a circular cylindrical shape. It will be appreciated, however, that the continuous outer surface 44 may define other shapes within the scope of the present disclosure. As will be explained in more detail below, in the assembled configuration, the first dowel 18-1 may be coupled to the first and second side rails 12-1, 12-2, and the second dowel 18-2 may be coupled to the third and fourth side rails 12-3, 12-4. For example, the first dowel 18-1 may be disposed within the first aperture 40-1 of the first side rail 12-1 and the third aperture 40-3 of the second side rail 12-2, such that the continuous outer surface 44 of the dowel 18-1 engages and connects the first and second side rails 12-1, 12-2. Similarly, the second dowel 18-2 may be disposed within the first aperture 40-1 of the third side rail 12-3 and the third aperture 40-3 of the fourth side rail 12-4, such that the continuous outer surface 44 engages and connects the third and fourth side rails 12-3, 12-4.

With reference to FIGS. 2 and 3, the third rail support 18-3 may include a plurality of cams 48 and a dowel 50. The dowel 50 may include a continuous outer surface 52. As illustrated, in some implementations, at least a portion of the continuous outer surface 52 defines a circular cylindrical shape. It will be appreciated, however, that the continuous outer surface 52 may define other shapes within the scope of the present disclosure.

As will be explained in more detail below, in the assembled configuration, the dowel 50 of the third rail support 18-3 may be coupled to the first and second side rails 12-1, 12-2, and the dowel 50 of the fourth rail support 18-4 may be coupled to the third and fourth side rails 12-3, 12-4. For example, the dowel 50 of the third rail support 18-3 may be disposed within the second aperture 40-2 of the first side rail 12-1 and the fourth aperture 40-4 of the second side rail 12-2, such that the continuous outer surface 52 of the dowel 50 of the third rail support 18-3 engages the first and second side rails 12-1, 12-2. Similarly, the dowel 50 of the fourth rail support 18-4 may be disposed within the second aperture 40-2 of the third side rail 12-3 and the fourth aperture 40-4 of the fourth side rail 12-4, such that the continuous outer surface 52 of the dowel 50 of the fourth rail support 18-4 engages the third and fourth side rails 12-3, 12-4. The cam 48 may be disposed within one of the first, second, third or fourth side rails 12-1, 12-2, 12-3, 12-4. During assembly, the user may rotate the cam 48 to lock the cam 48 to the dowel 50 and thereby secure a location of the first side rail 12-1 relative to the second side rail 12-2, or secure a location of the third side rail 12-3 relative to the fourth side rail 12-4. In some implementations, four cams 48 are used. For example, one cam 48 may be used in each of the first, second, third, and fourth side rails 12-1, 12-2, 12-3, 12-4.

With reference to FIGS. 3 and 4, the fifth rail support 18-5 may include, or otherwise define, a bracket. In this regard, the fifth rail support 18-5 may be referred to herein as the bracket 18-5. The bracket 18-5 may include a base 56, an upper flange 58, and a lower flange 60. The base 56 may include a proximal end 62, a distal end 64, an upper end 66, a lower end 68, a continuous inner surface 70, and a continuous outer surface 72 opposite the continuous inner surface 70. The continuous inner and outer surfaces 70, 72 may extend between the proximal and distal ends 62, 64 and between the upper and lower ends 66, 68. For example, the continuous inner and outer surfaces 70, 72 may extend from the proximal end 62 to the distal end 64 and from the upper end 66 to the lower end 68.

The upper flange 58 may extend from and along the upper end 66 of the base 56 in a first direction and may include a continuous upper flange surface 76. The lower flange 60 may extend from and along the lower end 68 of the base 56 in a second direction and may include a continuous lower flange surface 78. The second direction may be opposite the first direction. In some implementations, the continuous upper and lower flange surfaces 76, 78 extend from the continuous inner and outer surfaces 70, 72, respectively, of the base 56, such that the continuous upper flange surface 76 is substantially parallel to the continuous lower flange surface 78.

As will be explained in more detail below, in the assembled configuration, the fifth rail support 18-5 may be coupled to the first and second side rails 12-1, 12-2, and the sixth rail support 18-6 may be coupled to the third and fourth side rails 12-3, 12-4. For example, the fifth rail support 18-5 may be coupled to the first and second side rails 12-1, 12-2 such that the continuous inner surface 70 or the continuous lower flange surface 78 engage the inner side 32 or the bottom 28, respectively, of the first and second side rails 12-1, 12-2, and the sixth rail support 18-6 may be coupled to the third and fourth side rails 12-3, 12-4 such that the continuous outer surface 72 or the continuous upper flange surface 76 engage the inner side 32 or the bottom 28, respectively, of the third and fourth side rails 12-3, 12-4. In this regard, it will be appreciated that the fifth and sixth rail supports 18-5, 18-6 may be reversible, or otherwise interchangeable, relative to assembly to and with (i) the first and second side rails 12-1, 12-2 and (ii) the third and fourth side rails 12-3, 12-4.

With reference to FIGS. 1 and 2, the seventh rail support 18-7 may include a leg. In this regard, the seventh rail support 18-7 may be referred to herein as the leg 18-7. In the assembled configuration, the seventh rail support 18-7 may be coupled to the first and second side rails 12-1, 12-2, and the eighth rail support 18-8 may be coupled to the third and fourth side rails 12-3, 12-4. In this regard, the seventh and eighth rail supports 18-7, 18-8 may extend away from the first and second side rails 12-1, 12-2 and the third and fourth side rails 12-3, 12-4, respectively, to support the side rails 12 relative to a floor or ground surface.

In the assembled configuration, the first, second, third, fourth, fifth, sixth, seventh, or eighth rail supports 18-1, 18-2, 18-3, 18-4, 18-5, 18-6, 18-7, 18-8 may inhibit movement of the first and third side rails 12-1, 12-3 relative to the second and fourth side rails 12-2, 12-4. In particular, the rail supports 18 help to prevent the proximal ends 34 of the first and third side rails 12-1, 12-3 from moving relative to the distal ends 36 of the second and fourth side rails 12-2, 12-4.

With reference to FIGS. 1 and 2, in some implementations, the bed system 10 includes six slat supports 20. For example, the bed system may include a first slat support 20-1, a second slat support 20-2, a third slat support 20-3, a fourth slat support 20-4, a fifth slat support 20-5 and a sixth slat support 20-6. It will be appreciated, however, that the bed system 10 may include more or less than six slat supports 20 within the scope of the present disclosure.

The first slat support 20-1 may be substantially similar to the second, third, fourth, fifth, and sixth slat supports 20-2, 20-3, 20-4, 20-5, 20-6, apart from any exceptions described below or shown in the Figures. Accordingly, references herein to the slat support 20 will be understood to apply equally to the first, second, third, fourth, fifth, and sixth slat supports 20-1, 20-2, 20-3, 20-4, 20-5, 20-6, except as otherwise provided herein.

With reference to FIGS. 4 and 5, the slat support 20 may include a rail-support portion 80 and a slat-support portion 82. In some implementations, the rail-support portion 80 is integrally formed with the slat-support portion 82 such that the rail-support portion and slat-support portion 80, 82 define a monolithic or unitary construct. As will be explained in more detail below, in the assembled configuration, the rail- and slat-support portions 80, 82 may be coupled to one or more of the first, second, third, or fourth side rails 12-1, 12-2, 12-3, 12-4 to secure the location of the slats 20 relative to the first, second, third, or fourth side rails 12-1, 12-2, 12-3, 12-4.

The rail-support portion 80 may include a body portion 88, an arm portion 90, and a catch portion 92. The arm portion 90 may extend between the body portion 88 and the catch portion 92. In particular, the arm portion 90 may extend in a first lateral direction from the body portion 88 to the catch portion 92. In some implementations, the arm portion 90 extends in a direction substantially perpendicular to the body portion 88, and the catch portion 92 extends in a direction substantially parallel to the body portion 88. As illustrated, the body portion 88, the arm portion 90, and the catch portion 92 may define a substantially J-shaped construct, such that the body portion 88, the arm portion 90, and the catch portion 92 collectively define a channel 94. The size and shape of the body portion 88, the arm portion 90, and the catch portion 92 may be such that the size and shape of the channel 94 is substantially the same as, or equal to, the size and shape defined by the top 26, the outer side 30, and the inner side 32 of the side rails 12. Accordingly, as illustrated in FIG. 4, the channel 94 may receive the side rails 12 in the assembled configuration. In this regard, in the assembled configuration, the body portion 88 may engage the inner side 32 of the side rails 12, the arm portion 90 may engage the top 26 of the side rails 12, and the catch portion 92 may engage the outer side 30 of the side rails 12.

The slat-support portion 82 may include a leg portion 98 and a slat-lock portion 100. As will be explained in more detail below, in the assembled configuration, the slat-lock portion 100 may engage, and secure the position of, the slats 22. In this regard, the leg portion 98 may extend between the slat-lock portion 100 of the rail-support portion 80 and the body portion 88 of the rail-support portion 80. The slat-lock portion 100 may include a lip 102 extending from the leg portion 98. In some implementations, the leg portion 98 may extend in a second lateral direction from the body portion 88 to the lip 102. In particular, the leg portion 98 slat-support portion 82 may extend in a direction substantially perpendicular to the body portion 88, and the lip 102 slat-support portion 82 may extend in a direction substantially parallel to the body portion 88. In this regard, the leg portion 98 may extend in a direction substantially opposite, and parallel to, the arm portion 90 of the rail-support portion 80, and the lip 102 may extend in a direction substantially opposite, and parallel to, the catch portion 92 of the rail-support portion 80. As illustrated, the body portion 88, the leg portion 98, and the lip 102 may define a substantially J-shaped construct, such that the body portion 88, the leg portion 98, and the lip 102 collectively define a channel 104.

With reference to FIG. 5, the lip 102 may define a plurality of notches 106. In this regard, as illustrated in FIGS. 4 and 5, the lip 102 may define (i) a first height H1 extending from the leg portion 98 adjacent to, and in a location extending between, each of the notches 106, and (ii) a second height H2, less than the first height H1, extending from the leg portion 98 at each notch 106. Accordingly, the notches 106 may each be defined in part by opposing sidewalls 107, 109 of the lip 102.

With reference to FIGS. 2 and 4, the slats 22 may extend from a proximal end 108 to a distal end 110 opposite the proximal end 108, from a first side 112 to a second side 114 opposite the first side 112, and from a top 116 to a bottom 118 opposite the top 116. The first and second sides 112, 114 and the top and bottom 116, 118 may each extend from the proximal end 108 to the distal end 110. As illustrated in FIG. 2, the slats 22 may define a first groove 120 and a second groove 122. In particular, the bottom 118 may define the first and second grooves 120, 122. As illustrated, in some implementations, the first groove 120 is disposed proximate the proximal end 108 and extends across the bottom 118 and through a portion of the first and second sides 112, 114, and the second groove 122 is disposed proximate the distal end 110 and extends across the bottom 118 and through a portion of the first and second sides 112, 114.

As previously described, in the assembled configuration, the slats 22 may be coupled to the slat-lock portion 100 of the slat support 20. In particular, the lip 102 of the first, second, or third slat support 20-1, 20-2, 20-3 may be disposed within the first groove 120 of the slats 22, and the lip 102 of the fourth, fifth, or sixth slat support 20-4, 20-5, 20-6 may be disposed within the second groove 122 of the slats 22. In this regard, the lip 102 of the first slat support 20-1 may be disposed within the first groove 120 such that (i) the notch 106 is aligned with the first groove 120 and (ii) the lip 102 abuts the first or second sides 112, 114 of the slat 22 at the second height H2. For example, the side 107 of the lip 102 of the first slat support 20-1 or the side 109 of the lip 102 of the first slat support 20-1 may abut, or otherwise face, the first or second sides 112, 114, respectively, of the slat 22. Similarly, the lip 102 of the fourth slat support 20-4 may be disposed within the second groove 122 such that (i) the notch 106 is aligned with the second groove 122 and (ii) the lip 102 abuts the first or second sides 112, 114 of the slat 22 at the second height H2. For example, the side 107 of the lip 102 of the fourth slat support 20-4 or the side 109 of the lip 102 of the fourth slat support 20-4 may abut, or otherwise face, the first or second sides 112, 114, respectively, of the slat 22. In this way, the slat-lock portion 100 is able to secure the location of each slat 22 relative to the other slats 22 in a spaced-apart (e.g., equally spaced) configuration and to evenly support a mattress or box spring.

In some implementations, the bed kit 10, including the plurality of side rails 12, the headboard 14, the footboard 16, the plurality of rail supports 18, the plurality of slat supports 20, and the plurality of slats 22, may be disposed within a package (e.g., a box, carton, container, etc.) having a length between three feet and five feet, a width between one half foot and two feet, and a depth between one half foot and one foot. In this regard, the bed kit 10 may be disposed within a package that can be lifted and otherwise handled by a single person.

With reference to FIG. 6, an alternate slat support 20a for use with the bed system 10 is shown. The structure and function of the slat support 20a may be substantially similar to that of the slat support 20, apart from any exceptions described below and/or shown in the Figures. Accordingly, the structure and/or function of similar features will not be described again in detail. In addition, like reference numerals are used hereinafter and in the drawings to identify like features, while like reference numerals containing letter extensions (i.e., “a”) are used to identify those features that have been modified.

The slat support 20a may include the body portion 88 of the rail-support portion 80 and the leg portion 98 and the slat-lock portion 100 of the slat-support portion 82. In this regard, the slat support 20a may be formed without the arm portion 90 and the catch portion 92 of the rail-support portion 80. Accordingly, the slat support 20a (e.g., the body portion 88) may be coupled to the side rails 12 (e.g., the inner side 32) using a mechanical fastener 126 (e.g., a screw, a bolt, a nail, a pin, etc.), an adhesive, or another suitable fastening technique.

A method of assembling the bed system 10 may include removing (i) the plurality of side rails 12, (ii) the headboard 14, (iii) the footboard 16, (iv) the plurality of rail supports 18, (v) the plurality of slat supports 20, 20a and (vi) the plurality of slats 22 from the package.

The method of assembling the bed system 10 may include coupling the distal end 36 of the first and third side rails 12-1, 12-3 to the headboard 14 and coupling the proximal end 34 of the first and third side rails 12-1, 12-3 to the distal end 36 of the second and fourth side rails 12-2, 12-4, respectively. The method may also including coupling the proximal end 34 of the second and fourth side rails 12-2, 12-4 to the footboard 16.

The method of assembling the bed system 10 may also include coupling one or more of the rail supports 18 to (i) the first and second side rails 12-1, 12-2 and (ii) the third and fourth side rails 12-3, 12-4. For example, the method may include coupling the rail supports 18-1, 18-2, 18-3, 18-4, 18-5, 18-6, 18-7, 18-8 to (i) the first and second side rails 12-1, 12-2 or (ii) the third and fourth side rails 12-3, 12-4.

The method of assembling the bed system 10 may further include coupling one or more of the slat supports 20, 20a to one or more of the side rails 12. For example, the method may include coupling the slat supports 20-1, 20-2, 20-3, 20-4, or 20a to one or more of the side rails 12-1, 12-2, 12-3, or 12-4. In particular, the method may include positioning one or more of the side rails 12 within the channel 94 of the rail-support portion 80 of the slat support 20, or otherwise fastening the slat support 20a to one or more of the side rails 12 using a mechanical fastener or other fastening technique, as previously described.

The method of assembling the bed system 10 may also include coupling a slat 22 to a plurality of the slat supports 20, 20a. For example, the method may include positioning the lip 102 of a slat support 20, 20a within a first groove 120 of the slat 22 such that (i) the notch 106 is aligned with the first groove 120 and (ii) the lip 102 abuts the first and second sides 112, 114 of the slat 22. For example, the slat 22 may be positioned within the notch 106 of a first of the slat supports 20, 20a such that the sides 107, 109 of the lip 102 abut, or otherwise face, the first or second sides 112, 114, respectively, of the slat 22. Similarly, the method may include positioning the lip 102 of another slat support 20, 20a within the second groove 122 such that (i) the notch 106 is aligned with the second groove 122 and (ii) the lip 102 abuts the first and second sides 112, 114 of the slat 22. For example, the slat 22 may be positioned within the notch 106 of a second of the slat supports 20, 20a such that the sides 107, 109 of the lip 102 abut, or otherwise face, the first or second sides 112, 114, respectively, of the slat 22. The first and second of the slat supports 20, 20a may be positioned on opposite sides of the bed system 10 (e.g., on bed side rails 12-1, 12-3) such that a slat 22 extends between and connects side rails 12-1 and 12-2. Multiple slats 22 may be positioned between slat supports 20-1, 20-2, 20-3 on bed rails 12-1, 12-2 and slat supports 20-4, 20-5, 20-6 on bed rails 12-3, 12-4, in the same manner.

The configuration of, and related methods of assembling, the bed system 10 described herein, including, for example, the method of securing the proximal end 34 of a side rail 12 to a distal end 36 of another side rail 12, and the method of securing the rail supports 18, slat supports 20, 20a, and slats 22 to the side rails 12, can allow a user to easily and efficiently assemble a bed system having superior strength and durability.

The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A bed assembly comprising: a first side rail having an end and a side extending from the end;a second side rail having an end and a side extending from the end of the second side rail, wherein the end of the second side rail is coupled to the end of the first side rail;a third side rail having an end and a side extending from the end of the third side rail;a fourth side rail having an end and a side extending from the end of the fourth side rail, wherein the end of the fourth side rail is coupled to the end of the third side rail, and wherein the sides of the first and second side rails are facing the sides of the third and fourth side rails;a first slat support configured to engage the first side rail;a second slat support configured to engage the third side rail;a slat coupled to the first slat support and the second slat support;a first rail support having a continuous surface coupled to the first side rail and the second side rail and configured to inhibit movement of the first side rail relative to the second side rail; anda second rail support having a continuous surface coupled to the third side rail and the fourth side rail and configured to inhibit movement of the first side rail relative to the second side rail.

2. The bed assembly of claim 1, wherein the first rail support includes a dowel having a first end and a second end, the first end of the dowel configured to engage the end of the first side rail, the second end of the dowel configured to engage the end of the second side rail.

3. The bed assembly of claim 1, wherein the first rail support includes a leg configured to engage the first side rail and the second side rail.

4. The bed assembly of claim 1, wherein the first rail support includes a bracket having a base configured to engage the side of the first side rail and the side of the second side rail.

5. The bed assembly of claim 4, wherein the bracket includes an upper flange extending from the base in a first direction and configured to engage a bottom of the first side rail and a bottom of the second side rail.

6. The bed assembly of claim 5, wherein the bracket includes a lower flange extending from the base in a second direction opposite the first direction.

7. The bed assembly of claim 1, wherein: the first slat support includes a slat-support portion and a rail-support portion, the rail-support portion including a body portion configured to engage the side of the first side rail, the slat-support portion including a leg portion and a slat-lock portion, the leg portion extending from the body portion in a first direction, the slat-lock portion extending from the leg portion in a second direction transverse to the first direction and configured to engage the slat.

8. The bed assembly of claim 7, wherein the rail-support portion includes an arm portion and a catch portion, the arm portion extending from the body portion in a third direction, and the catch portion extending from the arm portion in a fourth direction transverse to the third direction.

9. The bed assembly of claim 8, wherein the body portion, the arm portion, and the catch portion collectively define a channel configured to receive the first side rail.

10. The bed assembly of claim 8, wherein the third direction is parallel to the first direction.

11. The bed assembly of claim 7, wherein the slat-lock portion includes a lip extending from the leg portion in second direction transverse to the first direction, and wherein the slat includes a groove configured to receive the lip.

12. The bed assembly of claim 11, wherein the body portion, the leg portion, and the lip collectively define a channel configured to receive the slat.

13. The bed assembly of claim 11, wherein the lip defines a notch, a first height extending from the leg portion adjacent the notch, and a second height extending from the leg portion at the notch, the second height being less than the first height.

14. The bed assembly of claim 13, wherein the groove extends through a first side and a second side of the slat, and wherein the lip is configured to abut the first side of the slat.

15. The bed assembly of claim 14, wherein the notch is disposed between the first and second sides of the slat.

16. A method of assembling a bed, the method comprising: coupling an end of a first side rail to an end of a second side rail;coupling an end of a third side rail to an end of a fourth side rail;coupling a first slat support to the first side rail;coupling a second slat support to the third side rail;coupling a continuous surface of a first rail support to the first side rail and the second side rail to inhibit movement of the first side rail relative to the second side rail;coupling a continuous surface of a second rail support to the third side rail and the fourth side rail to inhibit movement of the third side rail relative to the fourth side rail; andcoupling a slat to the first slat support and the second slat support.

17. The method of claim 16, wherein the first slat support includes a lip and the slat includes a groove, and wherein coupling the slat to the first slat support includes positioning the lip within the groove.

18. The method of claim 17, wherein the first slat support defines a channel, and wherein coupling the slat to the first slat support includes positioning the slat in the channel.

19. The method of claim 18, wherein coupling the slat to the first slat support includes abutting the lip with a side of the slat.

20. The method of claim 16, wherein coupling a continuous surface of a first rail support to the first side rail and the second side rail includes at least one of (i) positioning a first end of a dowel in the end of the first side rail and positioning a second end of the dowel in the end of the second side rail, (ii) coupling a leg to the first side rail and the second side rail, or (iii) coupling a bracket to the side of the first side rail and to the side of the second side rail.