Furniture Objects

FIELD OF THE INVENTION

A furniture object is related to flexible foldable furniture components and their advantages in both transportation and installation by using honeycomb technology.

BACKGROUND ART

A honeycomb structure is used to provide flexibility of a structure to open and close, which provides great reduction in volume and weight. The hexagonal shape of the structure proves to be very strong and stable, giving high bearing capacity versus weight. A honeycomb structure is a structure of flaccid materials that may be glued to each other in certain ways that makes them open and close easily. The glue lines' width and the distance between the glue lines affect the flexibility of the structure. The number of layers of the flaccid materials determines the expansion length of the structure. The glued layers can be of any number depending on the design needed. These layers together are being called a block of honeycomb. By cutting a honeycomb block into certain shapes, we can provide different shapes. The block can be cut into the shape of a seat or a bed. By providing the supporting boards, armrests, foam, fiber, and accessories, the final product can be a complete seat or a bed.

SUMMARY

In one example, a bed base comprises a bed frame comprising a plurality of connectable straight and corner pieces. A honeycomb structure is disposable within the plurality of connectable straight and corner pieces when the bed frame is assembled. The honeycomb structure is capable of extending to an extended position and attaching at opposite inner surfaces of the bed frame. Braces are disposed diagonally at each corner of the bed frame to preserve a shape of the bed base

In another example, a bed base comprises housing. A honeycomb structure is disposed within the housing. Head and foot pieces are disposed at either end of the housing to hold the honeycomb structure in an expanded configuration by interlocking with the housing.

In another example, a bed comprises a bed base comprising opposing end pieces. A honeycomb structure is disposed between the end pieces. A mattress is disposed on the bed base. The mattress is attached to the bed base.

In another example, a bed base comprises a housing. The housing comprises a first half comprising a top section, a bottom section, and a side section connecting the top section to the bottom section. A second half of the housing comprises a top section, a bottom section, and a side section connecting the top section to the bottom section. Opposite end pieces are seated against at least an outer edge of the housing. A honeycomb structure is disposed between the opposite end pieces within the housing.

In another example, a shipping assembly comprises a shipping container and a bed base. The bed base is disposed within the shipping container and comprises a bed frame, a housing, and a honeycomb structure. A volume of the shipping container is less than 30% of the bed base when the bed base is fully assembled.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory in nature and are intended to provide an understanding of the present disclosure without limiting the scope of the present disclosure. In that regard, additional aspects, features, and advantages of the present disclosure will be apparent to one skilled in the art from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

These drawings illustrate certain aspects of some of the embodiments of a furniture object and should not be used to limit or define the invention.

FIG. 1 shows a top view of the expanded bed, comprising Headboard (1), flexible hexagonal Structure (2), End Board (3), and Side Board (4), in accordance with some embodiments of the present disclosure.

FIG. 2 shows a cross section A-A Side view of the expanded bed, wherein it shows Headboard (1), flexible hexagonal Structure (2), and End Board (3), in accordance with some embodiments of the present disclosure.

FIG. 3 shows an expanded side view of the expanded bed, wherein it shows Headboard (1), End Board (3), and Side Board (4), in accordance with some embodiments of the present disclosure.

FIGS. 4 and 5 show a top and a side view respectively of the folded bed, wherein it shows Headboard (1), flexible hexagonal Structure (2), End Board (3), in accordance with some embodiments of the present disclosure.

FIG. 6 shows a top view of the expanded sofa, wherein the claimed sofa comprises Flexible hexagonal Structure (5), Side board (6), Extension rods (7), Armrest (8), and Padding (9), in accordance with some embodiments of the present disclosure.

FIG. 7 shows a particular embodiment of a top view of a folded Sofa in order to clarify the flexible hexagonal Structure (5), Side board (6), and Extension rods (7), in accordance with some embodiments of the present disclosure.

FIG. 8 shows a particular embodiment of the foldable sofa a cross section A-A Side View in order to clarify the flexible hexagonal Structure (5), Side board (6), and Extension rods (7), in accordance with some embodiments of the present disclosure.

FIG. 9 shows a particular embodiment of the Side View of a folded sofa in order to clarify the flexible hexagonal Structure (5), Side board (6), and Armrest (8), in accordance with some embodiments of the present disclosure.

FIG. 10 shows a particular embodiment of the expanded front view of the foldable sofa to clarify the flexible hexagonal Structure (5), Side board (6), Extension rods (7), and Padding (9), in accordance with some embodiments of the present disclosure.

FIG. 11 shows cell size dimensions, in accordance with some embodiments of the present disclosure.

FIG. 12 shows honeycomb dimensions, in accordance with some embodiments of the present disclosure.

FIG. 13 shows connector dimensions, in accordance with some embodiments of the present disclosure.

FIG. 14 shows side board dimensions, in accordance with some embodiments of the present disclosure.

FIGS. 15 and 16 show the physical relationship of a metal hinge and beam, in accordance with some embodiments of the present disclosure.

FIG. 17 shows a seat configuration, in accordance with some embodiments of the present disclosure.

FIG. 18 shows an arm rest configuration, in accordance with some embodiments of the present disclosure.

FIG. 19 shows dimensions of an arm rest, in accordance with some embodiments of the present disclosure.

FIG. 20 shows interlocking brackets connected to the honeycomb, in accordance with some embodiments of the present disclosure.

FIG. 21 shows interlocking brackets connected to the honeycomb, in accordance with some embodiments of the present disclosure.

FIG. 22 shows a furniture object's honeycomb arrangement in a seat, in accordance with some embodiments of the present disclosure.

FIG. 23 illustrates a bed base, in accordance with some embodiments of the present disclosure.

FIG. 24 illustrates a bed frame of the bed base of FIG. 23, in accordance with some embodiments of the present disclosure.

FIG. 25 illustrates a corner piece of the bed frame of FIG. 24, in accordance with some embodiments of the present disclosure.

FIG. 26 illustrates a straight piece of the bed frame of FIG. 24, in accordance with some embodiments of the present disclosure.

FIG. 27 illustrates another straight piece of the bed frame of FIG. 24, in accordance with some embodiments of the present disclosure.

FIG. 28 illustrates another straight piece of the bed frame of FIG. 24, in accordance with some embodiments of the present disclosure.

FIG. 29 illustrates a shipping container for the bed base of FIG. 24, in accordance with some embodiments of the present disclosure.

FIG. 30 illustrates a plurality of honeycomb sections to be disposed within the bed frame of FIG. 24 to form the bed base of FIG. 23, in accordance with some embodiments of the present disclosure.

FIG. 31 illustrates the bed frame of FIG. 24, with a plurality of braces for securing the bed frame, in accordance with some embodiments of the present disclosure.

FIG. 32 illustrates another bed base, in accordance with some embodiments of the present disclosure.

FIG. 33 illustrates the housing of FIG. 32 in a disassembled and flat configuration prior to assembly, in accordance with some embodiments of the present disclosure.

FIG. 34 illustrates an exploded view of the head and foot pieces of the bed base of FIG. 10, in accordance with some embodiments of the present disclosure.

FIG. 35 illustrates a plurality of honeycomb sections to be disposed within the housing of FIGS. 32 and 33, in accordance with some embodiments of the present disclosure.

FIG. 36 illustrates a bed base covered by a mattress and padding, in accordance with some embodiments of the present disclosure.

FIG. 37 illustrates a honeycomb structure between opposing end pieces of the bed base, in accordance with some embodiments of the present disclosure.

FIG. 38 illustrates a shipping container for the bed base, mattress, and padding of FIG. 14, in accordance with some embodiments of the present disclosure.

FIG. 39 illustrates an exploded view of an end piece of the bed base of FIG. 36, in accordance with some embodiments of the present disclosure.

FIG. 40 illustrates an exploded view of the mattress and padding of FIG. 36, in accordance with some embodiments of the present disclosure.

FIG. 41 illustrates the bed base, mattress, and padding of FIG. 36 with the end pieces omitted to show connecting features, in accordance with some embodiments of the present disclosure.

FIG. 42 illustrates a bed base covered by covers, in accordance with some embodiments of the present disclosure.

FIG. 43 illustrates a shipping container for the bed base and covers of FIG. 42, in accordance with some embodiments of the present disclosure.

FIG. 44 illustrates opposite end pieces of the bed base of FIG. 42, in accordance with some embodiments of the present disclosure.

FIG. 45 illustrates an exploded view of the bed base of FIG. 20 with the covers omitted to show the central dividers between honeycomb structures, in accordance with some embodiments of the present disclosure.

FIG. 46 illustrates a non-exploded view of the honeycomb structures and central dividers of FIG. 45, disposed between the opposite end pieces of FIG. 44, in accordance with some embodiments of the present disclosure.

FIG. 47 illustrates a housing of the bed base of FIG. 42 in a disassembled and flat configuration prior to assembly, in accordance with some embodiments of the present disclosure.

FIG. 48 illustrates the housing of FIG. 47 in an assembled configuration, in accordance with some embodiments of the present disclosure.

FIG. 49 illustrates two of the housings of FIG. 47 side by side to show how the housings would be assembled within the bed base of FIG. 42, in accordance with some embodiments of the present disclosure.

DETAILED DESCRIPTION

Disclosed herein are methods and apparatuses relating to furniture which includes but are not limited to sofas and beds. More particularly, disclosed herein is furniture including an expandable and collapsible paper honeycomb material.

Advantageously, the furniture may be foldable, collapsible, and/or expandable, in some examples, without significant losses to structural reliability. Further, the honeycomb material may simplify assembly by eliminating or reducing the need for special tools, and may be lightweight and portable. In some examples, instruction manuals may be eliminated entirely or at least simplified due to the elimination of complicated assembly processes. Other advantages may include low shipping costs of the furniture, as well as ergonomic retrieval and storage using a small amount of space.

Some embodiments of the present disclosure are directed to honeycomb-based furniture and methods of formation of said furniture. The honeycomb structure can be used to make furniture objects such as a bed frame, sofa, or bed base, for example. The utility of a portable foldable furniture object can be measured according to the following criteria: the weight of a furniture object; the volume of a furniture object when it is folded; the time required to fold/unfold a furniture object; the bearing capacity of a furniture object; the time of assembly and disassembly; and any combination thereof.

In some examples, a furniture object may comprise about 11 kg of honeycomb paper (e.g., without including two side boards). In some examples, a volume of a seat when folded may be 60-110 cm length by 40-90 cm width by 3-10 cm thickness without an armrest. In some examples, the amount of time required to fold/unfold a seat may be 1-2 minutes. In some examples, the bearing capacity of a furniture object may be at least 40 tons/m2.

In some examples, a whole furniture piece can be provided for delivery folded in one or more carton boxes. The structure can be either a seat, love seat, or a sofa, as examples, for one to three people or more. When a furniture object is made to be a sofa for three people, the foldable volume of a furniture object may be at least 50% less than comparable fixed furniture objects (e.g., sofas/flat pack sofas) in the market. The weight of a furniture object may be at least 50% less than the counterpart sofas on the market.

The honeycomb structure of a furniture object can also be used to make a bed frame. In some example, the quality of a portable foldable bed is also measured according to the following criteria: the weight of the bed or bed base; the volume of the bed or bed base when it is folded; the time required to fold/unfold the bed or bed base; the bearing capacity of the bed or bed base. In some examples, the weight of a foldable bed or bed base is 8.5 kg of honeycomb paper (e.g., without including two head boards). In some examples, the volume of a bed or bed base when folded is 80 by 40 by 11 cm. In some example, the time required to fold/unfold the bed or bed base is less than 5 minutes. In some example, the bearing capacity of the bed or bed base is at least 2 tons/m2. In some example, the weight of a foldable bed or bed base of 80 by 200 cm is less than 15 kg depending on the hexagonal cell size and the number of layers. The bearing capacity of the extended structure can carry a weight of more than 1000 kg for a surface of 80 by 200 cm. In example, more layers added in the same area may affect the more bearing capacity a furniture object will carry.

In some example, a furniture object is more than 25% lighter than any foldable bed frame. For example, it may be dressable where covers of the two head and back boards can be changed easily and covered by the customer. In one example, the volume of a folded bed is half the volume of any foldable bed in the market. The bed or bed frame may be made out of cellulose fiber sheets that are made from recyclable materials. In examples, this makes the bed fully green and environmentally friendly. The whole bed or bed frame can be recycled again in a closed loop.

The weight and the dimensions of a furniture object can make it shippable easily by air freight couriers. The shipping of the bed may be, for example, at least 25% lower CO2 footprint than other normal beds in the market. The flexibility of the honeycomb technology in the bed or bed frame makes it versatile and multi-functional. In some examples, a furniture object can be used as a side table, an ottoman, or a seat.

In some examples, the fast operation of expanding and folding the bed or bed base makes the user experience more efficient and hence more convenient than other foldable beds in the market.

The present disclosure may overcome the difficulty of transportation and installation and also add convenience in buying, moving in, and moving out big pieces of furniture like a bed frame or a sofa.

As used herein, a corrugated sheet may comprise, without limiting to any single embodiment, A-flute, B-flute, C-flute, BC-flute, E flute, other standard cardboard sizes, combinations (e.g., layers) thereof, or the like.

In some examples, the structure of a furniture object can be used to make a flexible foldable bed frame, and the components of the bed comprising, with reference to FIGS. 1-10:

A—Head board (1): Head board (1) can be changeable and dressable as well. The dimensions and materials of the head board (1) can be changed to any size based on the bed size. Meanwhile, the side boards can be dressable where the cover can be replaced by any covering materials like fabric, leather, felt or any soft or rigid materials for aesthetics reason.

B—Flexible hexagonal Structure (2): The cell structure is a hexagonal structure that can be uniform or non-uniform. The length between the glue lines and the width of the glue lines affects the shape of the cell. If the lengths and the widths are equal, the widths will be uniform. Any difference between their dimensions makes the honeycomb non-uniform. The non-uniform structure gives higher extension and makes it easier to open and to fold. The glue line has a width and the spacing between the glue lines has another width. If both widths are the same, the cell will be uniform since all the hexagon sides will be the same. If the widths are not equal, the hexagon sides will not be equal and hence the cell shape will not be uniform.

The length of one side of the hexagonal cell can vary from 1 mm to 150 mm. The width of glue lines can be anything from 1 mm to 50 mm.

C—End board (3): The two sides of the honeycomb core are glued to rigid or non-rigid materials. The rigid materials can be any type of wood boards, steel, aluminum or any other rigid materials. The non-rigid boards can be made out of non-woven materials like felt, foam, or any other soft material.

D—Side Boards (4): The side boards can be rigid or soft boards. The board can be one piece or divided into two or more pieces for foldability reason. The side boards can be changeable to give different shape or color. Meanwhile, the side boards can be dressable where the cover can be replaced by any covering materials like fabric, leather, felt or any soft or rigid materials for aesthetics reason.

The structure of a furniture object can also be used to make a flexible foldable sofa, and the components of a furniture object are comprising:

A—Flexible hexagonal Structure (5): The honeycomb cell structure (1) is hexagonal that can be uniform or non-uniform. The non-uniform structure gives a higher extension and makes it easier to open and fold. The length of one side of one hexagonal cell can vary from 1 mm to 150 mm. The width of a glue line can be anything from 1 mm to 50 mm. The structure may take the shape of a furniture object and it can be extended from 6 to more than 1000 cm. For typical seating it can range from 20-300 cm.

B—Side board (6): The side boards (6) are connected to the honeycomb structure. The side boards can be rigid or soft boards. They are used to give support to the honeycomb structure and to attach to connectors. These connectors are used to connect the honeycomb structure, when expanded, to extension rods linearly.

C—Extension rods (7): The extension rods (7) are responsible for extending the honeycomb structure and fixing them in place. Any number from 1 or more can be used for extending the structure. Typically, we use 2 or 4 extension rods. The material of the extension rod can be wood, steel, aluminum, or any rigid material. The rods are connected to the honeycomb structure through the connectors. The length of the rods determines the length of a furniture object. The rods can vary from 30 to 400 cm depending on the length required of a furniture object. The extension rods can be elongated to give variable lengths. The rods can be divided into smaller pieces connected together to give flexible lengths. The extension rods are removable, which gives flexibility to the structure to fold back to its original dimension.

D—Armrest (8): The armrests can be either separate or connected to a furniture object's honeycomb structure. The armrest can be made out of steel, wood, aluminum, or any rigid structure. The armrest can be of any shape and dimension. The armrest can be padded and/or covered by fabric. The armrest can be also made out foldable honeycomb that can be extended and covered by pieces of hard material like MDF sheets, plywood, or others.

E—Padding (9): Padding is a sheet of rigid or soft material that can be laid over the honeycomb structure to give fixation, and protection. It is made out of rigid sheet that can be padded by foam and/or fiber. The padding can be covered by fabric or any rigid/soft material.

In some examples, a goal of a furniture object is to provide foldable furniture using honeycomb technology. Moving/shipping furniture like seats and bed frames is a pain due to the furniture's huge volume. Moving a big piece of furniture requires big spaces in shipping containers, big spaces in trucks and laborers to carry them to the final places. Beside the high shipping cost per piece, the CO2 footprint of transporting the big pieces of furniture is high which adds to both the carbon dioxide emissions and ultimately to climate change in terms of global warming. The honeycomb technology is a structure used in manufacturing aero planes bodies and is now used for furniture. The foldability aspect of such technology allows for reducing the volume, the weight, and the cost of the product considerably, which may lead to a complete disruption in the furniture industry.

A furniture object may relate to a flexible foldable bed made of a core of layers of paper and how it is made. The core shape can be opened and closed manually. The structure is made of honeycomb technology where the layers are glued together with glue. The structure of the hexagonal shape is rigid and can carry heavy weights. The bed is portable and can be carried by one person. The bed is light in weight and is extendable to any length depending on the number of layers. The foldable bed uses extension bars to fix the structure in place using special connections.

A glue may comprise starch with acrylic additives. The glue that can be used includes starch or any other glue like PVA, resins, acrylic or any other glue. The glue can be water based or solvent based. PVA (An aliphatic rubbery synthetic polymer with the formula (C4H6O2)n is preferred due to its elasticity and cost as well. It belongs to the polyvinyl ester family, with the general formula [RCOOCHCH2].

The material used in this structure is preferably paper but can be any flaccid materials like, but not limited to, plastic, non-woven fabric, or synthetic paper. The paper used can be treated to be water resistant and/or fire retardant. The thickness of paper can vary from 10 micron to 15 mm. Other materials can be used to give the hexagonal shapes. Plastic, felt, non-woven fabric can be also used. Any flaccid materials can be used to give the same function.

For paper, paper density can vary from 40 to 500 grams per meter square. Paper also can be engineered to have better edge burst strength of 800 to 900 kPa.

The paper (or other material) used can be treated and sprayed by coloring materials, i.e., with pigments, or dyed in coloring chemicals. Spraying materials can be for any purpose from coloring or adding feature and/or function to the structure like being water proof, or/and fire retardant, changing flexibility, changing color, or changing physical or chemical properties of the paper or other structural material as examples. The honeycomb foldable bed structure of a furniture object comprises A—Headboard (1), B—Flexible hexagonal Structure (2), C—End board (3), and D—Side Boards (4).

In some examples, an advantage of these embodiments is that the structure can be divided into zones with one or more zones having reduced cell size to give more support to the points of stresses of a sleeping person. The cell size can be larger in the areas that will not carry more load.

The structure is also so flexible due to the improvement done herein on the determined cell size and glue size. The cell side is determined by the space between the glue lines in the honeycomb core machine. The width of the glue line is also a factor in giving flexibility to the honeycomb structure. The improvement was done on the machine to increase the length between the glues from 2-3 cm to 7-10 cm. The glue width also was decreased from 10 mm to 2 mm. The glue width can go down to 1 mm. The smaller the glue line and the bigger the width between the glue lines gives higher flexibility.

There are two kinds of foldability for the bed of a furniture object. Horizontal foldability: a furniture object can be folded to be 2 cm and extended to be anything from 2 cm up to 10,000 cm depending on the number of layers glued to each other. Vertical foldability: a furniture object itself can be cut into two or more pieces then be attached to each other vertically with a hinge or any other connector. This allows the structure to be folded into two halves or more.

The honeycomb structure bed can be folded down to be 30×30×30 cm. The box which is used for the folded bed can be any size can have any side length from 20 to 300 cm. The box dimensions are variable to accommodate the required size of the mattresses.

The components of a furniture object may comprise A—Flexible hexagonal Structure (5), B—Side board (6), C—Extension rods (7), D—Armrest (8), and E—Padding (9).

It is worth mentioning that honeycomb structures are natural or man-made structures that have the geometry of a honeycomb to allow the minimization of the amount of used material to reach minimal weight and minimal material cost. The geometry of honeycomb structures can vary widely but the common feature of all such structures is an array of hollow cells formed between thin vertical walls. The cells are often columnar and hexagonal in shape. A honeycomb shaped structure provides a material with minimal density and relative high out-of-plane compression properties and out-of-plane shear properties.

The honeycomb technology in a furniture object uses one or more gluing machines to glue the paper (or analogous flexible materials) in parallel glue lines, in which the lines are laid down ready for the next paper sheet. The glue is done in a staggered way for one paper after another. The paper sheets preferably go through two glue stations. The glue lines are applied on paper layer 1 and layer 2 parallel to each other. When applying the glue lines on paper layer 3, they come in the middle of the distance of the glue lines in layer 1 and 2 (location wise). In layer 4, the glue lines are laid in the same location as in layer 1 and 2. And in layer 5, the glue will laid be on the same location as in layer 3, and so forth. If the glue lines are at the same location in all paper layer, the glues paper will not open (no hexagonal cells would be shaped). Hence, the glue lines must alternate between the layers to provide the hexagonal cell shape.

Sheets one and two are glued together by applying parallel glue lines in the first station. Sheets three and four get the same glue lines at the same station. In glue station number two, sheets one and two get new glue lines on their surfaces in the space between the two glue lines that they had in station one, so they get glued to sheets three and four. So, each single sheet would have parallel glue lines on both surfaces where the glue lines on the surface are not on the same place as the glue lines on the bottom. This staggered way of glue application insures the hexagonal shape of the honeycomb when it gets expanded. The whole stacked paper layer constitutes a block of paper layers. The staggered way of gluing gives us the hexagonal shape constituting the honeycomb structure. Then these layers are cut to the size of the bed by a cutting method. The cut block is attached to the headboard and the end board by glue or any hardware fixture. The hexagonal shape has the property of being expandable manually to the size needed. The length of the expanded honeycomb depends on the number of paper layers. The design of the hexagonal structure, the distance between the glue lines, and the width of the glue lines together makes it easier for the user to expand the bed. Then, the side boards are inserted to keep the structure in place and configured to the designed length ready for the mattress.

The honeycomb material of a furniture object is paper or thin-wood based and/or is preferably formed of cellulose fiber. The cellulose is preferable pure white kraft pulp of high brightness and formed of virgin fibers. This brightness is useful for marketing purposes, to observe the presence of defects, and to increase customers' perception of the products' durability and value. The virgin fibers are pure sourced from tree fibers where no recycled paper fibers are used. This insures the strength and the durability of the honeycomb core. In a preferred embodiment of a furniture object, the material is sourced from one or more Nordic forests, which is preferred because it comes from renewable forests and for being the highest quality in terms of pulp specifications. In the alternative or in addition, the honeycomb material can be formed of additional materials, such as but not limited to aluminum and plastics and/or other papers.

The honeycomb cell size is designed in a way to be folded down and expanded as needed. The cell size of 10 cm vertex to vertex has the dimensions as in FIG. 11.

When paper and/or wood are used, the density is at least 140-170 grams/sq. meter, to assure adequate strength. The paper used should have a weight not less than 140 grams/sq. If less than this weight is used, the honeycomb structure may be affected and hence the durability of the product may be reduced. If less than 140 grams/sq is used in making the honeycomb structure, more layers should be used to compensate for the light weight paper (and hence the structure), which will add unnecessary weight to the product.

For a sofa, the honeycomb structure is cut to the shape of a furniture object that has a preferable distance of 174 cm side to side when expanded. The structure is glued to wooden boards that have connectors to the side armrests. The height of the honeycomb preferably is 60 cm, and the depth is 92.5 cm as in FIG. 12.

In the preferred embodiment, the material is approved by the German Institute for Risk Management (BfR) and the FDA as a safe material for human contact.

One example configuration is a honeycomb structure with a preferable dimension in expanded form of 10 cm from vertex to vertex, with a range of 5 to 20 cm.

Each unit in the honeycomb when expanded forms a hexagonal prism. Except for edges, each side of each hexagonal prism abuts a side of another hexagonal prism, and the sides are attached by glue. That is, each of the six sides are generally attached to a different abutting hexagonal prism along one side using glue. A single glue type is preferably used, with the elastic glue In the preferred embodiment, we use PVA glue of a solid content preferably of 40%+ or −2%, Viscosity of 3000+ or −1000 cps, specific gravity of 1.1, and pH of 5-6.

Each of the individual honeycombs have a thickness of material ranging from 0.5 to 2 mm.

When used to form a sofa or bed, the honeycomb hexagons form hexagonal-prism-based sheets, whereby the honeycomb hexagons are glued together to form a sheet along a common side, and then the sheet is cut to size. In expanded form, the dimension can be as much as 174 cm long and/or wide. It can be longer or shorter based on the design and desired expansion. Another option is 60 cm×92.5 cm when expanded, such as for a sofa.

The next step in the process is to build a stack (three dimensional construction) by attaching sheets to one another. The cells preferably are aligned one on another, but alternatively may be offset from one another; that is, the hexagon sheets may not align exactly one over another.

In one example, the vertexes of the hexagons in a hexagon sheet may be aligned with the center points of the hexagons in the next sheet and so on.

In general, when expanded, each hexagon has a length, thereby each one forms a regular hexagonal prism when expanded.

In attaching the sheets to one another, the honeycomb sheets are each expanded for attachment. In this case, the same glue is preferably used as was used earlier. We ensure glue only goes to the locations we want by glue rollers with protruding glue rings with equal spaces. These spaces differ from one product to another. Up to 300 sheets can be stacked together. The total thickness when done might differ between different types or styles of furniture (e.g., chair, sofa, or bed).

We use a stacking machine that glues certain type of cellulose fiber sheets layer by layer. The machine provides the glue in parallel lines that provides the shape of hexagonal structure. In a preferred embodiment, the distance between the glue lines is 10 cm. We preferably use 80 layers of these sheets to make a furniture object and 100 layers for beds. The stack of these layers is then cut to the shape of the desired furniture piece, such as but not limited to either a sofa, seat, ottoman, bed, or corner unit. The cuts are preferably made manually using a saw machine but could be performed automatically in the alternative. When expanded, the structure gives the look of the honeycomb that can bear vertical load of at least 1 ton/m2.

Cellulose fiber sheets of 140-170 g/m2 are produced from very pure, white kraft pulp of high brightness, and each sheet consists entirely of virgin fibers. The long and strong fibers from the Nordic's slowly growing softwood forests gives the paper its inherent strength.

The cellulose sheets are produced from a mill that preferably is certified in accordance with ISO 9001, ISO 14001, ISO 50001, FSC® CoC (FSC-C020000) and PEFC™ CoC (PEFC/05-33-136).

The honeycomb structure is typically comprised of up to 180 layers of cellulose or hexagon sheets. The sheets are preferably divided into two 90 layer sheet sections. A middle support, typically formed of plywood or another durable light weight material, of a preferable height of 24 cm, may be glued between the two 90 layers of honeycomb sheets. The front panel and back panel are made out of a frame of wood that is laminated with 3 mm MDF board to be covered. Then a layer of 1 cm foam is glued to it. We then add a fabric to cover the foam and staple it to the back side of each panel. We then glue the honeycomb structure to the front panel and back panel preferably using a white or clear glue (such as PVA) and press the panels under a pressing machine for 10-15 minutes.

We prefer to use a white glue Poly Vinyl Acetate (PVA) (commonly known as wood glue or White glue), or equivalent, to glue the sheets together to make the honeycomb structure. An aliphatic rubbery synthetic polymer with the formula (C4H6O2)n, it belongs to the polyvinyl ester family, with the general formula RCOOCHCH2.

If the furniture object is Queen, King, or Cal King size, each panel may be divided into two parts that each has a hollow inside that has a dimension of the rectangular insert, for example.

A wooden, typically plywood, insert is used to connect the two parts together making the panel.

The next step in construction is the side boards (such as for a sofa or chair). See FIGS. 13 and 14, with connectors added. Typically, the connectors are metal but may be made of other materials, such as wood. The connectors attach the honeycomb to the frame. Eight metal connectors are screwed on the side edges of the front and back panel. The upper four connectors are 2×8×2 cm where the bottom ones are 2×4×2 cm. Each connector is screwed to accept the thumbscrews that are provided separately.

The side boards of the honeycomb are preferably made from wood and covered with fabric. To keep the expanded distance in place, 8 metal connectors are provided to be connected by the expanded wooden beams. The connector preferably is done in a U shape with a bent steel support under it. The connector has two holes: a circular hole of 8 mm and a screw hole of 6 mm that accept a thumb screw of 6 mm as in FIG. 13. The U connectors are fixed by two screws to the wooden side boards as in FIG. 14.

These side boards are formed of wood, usually plywood, medium density fiberboard (MDF), or particle board, and covered with fabric. The invention may include “expanded wooden beams”. For a bed, four wooden beams made out of beech wood or equivalent are provided to expand the honeycomb bed and fix it in place to the dimension of 195 cm. Each beam has two halves. The upper two beams have the dimension of 2×8×9 8 cm. The lower beams have the dimension of 2×4×98 cm. Each half is connected to the second half by a hinge of a 2.5 cm (for the bottom beams and 6 cm for the upper ones).

Wooden beams are used to expand the honeycomb structure of a furniture object. Each beam is folded into two halves. The dimension of each half is 2×4×85 cm. The two halves are connected by a hinge typically 2.5 cm. A metal slide bar of 16 cm is intended to slide over the two expansion beams to support them when expanded. The slide bar is closed from all dimensions except for one dimension that is sliding in the same face of the hinge, where the sliding connector is bent on the wooden beam as per FIG. 15.

Expansion beams are also used and preferably are made of wood and include a metal hinge which is encased in a pair of “metal sliding connectors” (per FIG. 15). The expansion beams may be on two sides or four sides of the frame. The purpose of the metal hinge is to allow for folding up a furniture object, but the sliding connector locks it in place. Wooden beams are used to expand the honeycomb structure of a furniture object. Each beam is folded into two halves. The dimension of each half is 2×4×85 cm. The two halves are connected by a hinge of 2.5 cm. A metal slide bar of 16 cm is intended to slide over the two expansion beams to support them when expanded. The slide bar is closed from all dimensions except for one dimension that is sliding in the same face of the hinge, where the sliding connector is bent on the wooden beam as per FIG. 15.

A sliding connector is provided to slide over the beam to be placed exactly in the middle of the beam to give it the support it needs. The sliding connector is stopped from sliding by a metal pin or screw as shown in FIG. 16.

A furniture object has 4 wooden beams. All of them are the same except for the two lower beams where a hook-and-loop fastener is provided to be connected to the back padding.

The lower beams have hook-and-loop fastener stapled to the bottom part along the beam. The hook-and-loop fastener is intended to connect the final cover of the bed.

The beams have holes in their edges. The beams are attached to the connectors and then a thumbscrew is screwed inside the hole to connect each beam to each of the front and back panels (total eight screws).

A foldable sleeping pad is laid on the expanded bed. It preferably is shipped in 6 cardboard sheets of 2000 grams/m2 of a dimension of 33.3 cm×76 cm (for queen) or 33.3 cm×90 cm for the king size. The six sheets are connected by a fabric hinge and then all covered by fabric.

A final bed upholstery cover may be put to complete the bed. The cover may have a hook-and-loop fastener underneath that is connected to the hook-and-loop fastener on the lower beams. An upholstery cover may have 1 cm foam around to provide a cushioning effect to the 4 sides of the bed.

In one back padding example, two paddings are provided. Each back padding has three plywood boards that are connected by fabric hinge. A layer of foam is provided on one or more boards. The middle part has a foam layer of 4 cm and then all the three parts are covered by one layer of 1 cm foam. The whole back padding is then covered by a fabric cover. The two ends of the padding each have hook-and-loop fastener tape to be connected—one with the lower wooden beam and one with a furniture object padding hook-and-loop fastener.

In one front padding example, two plywood pieces (each has a nominal dimension of 87×26×6 cm) are connected with a fabric hinge. Then the whole structure may be covered by a fabric cover that has two hook-and-loop fastener tapes—one on the top and one on the bottom. Both hook-and-loop fastener tapes are intended to be connected—one to a furniture object padding and the other to the bottom wooden beam.

A furniture object padding may be foldable and may have four plywood pieces (each has a nominal dimension of 70×34×6 cm) that are connected with fabric hinge. The upper surface of a furniture object padding has two hook-and-loop fastener tapes on the upper and the lower ends. These hook-and-loop fastener tapes are intended to be connected with both the back paddings and the front padding. FIG. 17 shows a furniture object (adding in the hook-and-loop fastener).

A furniture object may have two armrests. Each armrest may have a nominal dimension of 95×19.5×66 cm. The armrests are preferably hollow and covered with fabric from inside. The hollow armrests are intended to act as compartments for a furniture object components (padding, cushions, pillows, and expansion beams. The armrest structure is made out of wood that is covered from the top by foam of 4 cm and with a layer of 0.5 cm foam covering the whole armrest. Each armrest has a metal connector to be connected to the honeycomb sides as in FIG. 18. FIG. 18 shows the interlocking for the armrest. Arm rest dimensions are shown in FIG. 19. Each armrest has three metal interlocking brackets to be connected to the honeycomb wooden sides as in FIG. 20. The detail of the metal interlocking bracket is shown in FIG. 21.

In examples, the honeycomb structure is supported by a plywood support that is glued in the middle layers of the honeycomb. The support acts as a carrier for the upper wooden beams. The preferred shape of the wooden support is shown in FIG. 22.

FIG. 23 illustrates a bed base 100 in accordance with some embodiments of the present disclosure. As illustrated, a bed base 100 may comprise one or more of the honeycomb structures 102 disposed within a bed frame 200. This example shows multiple honeycomb structures 102 tightly packed together within the bed frame 200 so that the inner volume of the bed frame 200 is substantially filled by the honeycomb structures 102 when the honeycomb structures 102 are in an expanded configuration. This example shows the honeycomb structures 102 extended laterally across the bed base 100 between left and right sides 110, 112, however bed base 100 may alternatively be configured such that the honeycomb structures 102 extend longitudinally between ends 114 and 116 of the bed base 100. Similarly, while this example shows only a single honeycomb structure 102, any suitable number of the honeycomb structures 102, or sections thereof, may be used, for example, two, four, five, ten, etc., or any ranges therebetween.

Bed frame 200 comprises a rigid structure (e.g., plywood, wooden slats, plastic slats, etc.) in this example which contains the honeycomb structures 102 within an area of the bed base 100 so that honeycomb structures 102 are sufficiently weight bearing to support the weight of, for example, a heavy person disposed on a mattress on the bed frame 200, without warping or damaging the honeycomb structures 102. In the example shown, bed frame 200 comprises interconnected corner and straight pieces 106, 108 spanning the perimeter of the bed base 100. These interconnected panels may comprise corner pieces 106 and straight pieces 108, which may be various types, to be discussed in later Figures. Interconnected panels used to form bed frame 200 may be coupled together such as with or without fasteners, such as screws or nails. For example, corner and straight pieces 106, 108 may be joined together by interlocking features such as snap fit, tongue and groove, etc., or any other interlocking method. As alluded to previously, the expandable honeycomb structures 102 may expand and collapse between extended and nonextended configurations during assembly or disassembly of bed base 100. The honeycomb structures 102 may be functionally attached (e.g., permanently, or temporarily) to the bed frame 200, such as at interface 118.

Moreover, bed frame 200 may have any suitable dimension that allows it to support a person, or person disposed on a mattress. Each honeycomb structure 102 in this example may have a length equal to width 124 in the expanded configuration, and a width 126 equal to one third of length 120. Alternatively, a height 122 from about 10 cm to about 100 cm, a width from about 50 cm to about 500 cm, a length 120 from about 50 cm to about 500 cm, or any respective ranges therebetween. In one example, bed frame 200 has a length 120 of about 203 centimeters (cm), a height 122 of about 20 cm, and a width 124 of about 125 cm. In another example the honeycomb structure 102 may be configured such that width 126 does not vary significantly (e.g., less than 10%, or less than 5%) between expanded and collapsed configurations.

FIG. 24 illustrates the bed frame 200 of the bed base 100 of FIG. 23 formed from interconnected panels of corner pieces 106 and straight pieces 108, in accordance with some embodiments of the present disclosure. This example shows bed frame 200 having a connector 202 which, referring to FIG. 23, would be disposed between honeycomb structure 102 and bed frame 200. Connector 202 may be, for example, a hook-and-loop fastener strip that extends linearly across a substantial width 124 (and/or length 120, e.g., referring to FIG. 23) of bed frame 200. Alternatively, various temporary attachment devices such as clips, fasteners, tie-ups, buckles, snaps, buttons, hook-and-loop, combinations thereof, or the like. Yet alternatively, connector 202 may comprise a more permanent attachment such as an adhesive, glue, stitches, or the like.

In examples, connector 202 may comprise a single, or multiple, connectors. Where connector 202 comprises multiple connectors, these may be disposed on an interior surface of bed frame 200, such as on one or more individual panels, for example. Likewise, connector 202 may extend across a substantial portion of (e.g., the entirety of) one or more inner sides of a bed frame 200, such as along at least 5%, at least 10%, at least 20%, at least 50%, at least 80%, or any ranges therebetween.

FIG. 25 illustrates a corner piece 300 of the bed frame 200 of FIG. 24, in accordance with some embodiments of the present disclosure. Corner piece 300 in this Figure is an example of corner piece 106 in FIGS. 23 and 24. As shown, corner piece 300 may have perpendicularly oriented pieces 302 and 304 joined at a corner 308. The ends of the perpendicularly oriented pieces 302, 304 may have reduced width portions 310 characterized by a step change 312 from a larger width 314 to a narrow width 316, wherein respective borcholes 318 may be disposed for attaching to neighboring panels (e.g., straight pieces 400, 500, 600, etc. of FIGS. 27, 28, and 29). Step change 312 may alternatively be a gradual change. A groove 306 is also shown across the longer of the two pieces 302, 304, wherein a connector strip (e.g., hook-and-loop strip clips, fasteners, tie-ups, buckles, snaps, buttons, etc.) may be deposited in or adhered thereto. A connector deposited in groove 306 may connect to a corresponding connector adhered to, disposed on, or otherwise attached to, honeycomb structure 102 (e.g., referring to FIG. 23) to keep it in an extended configuration when honeycomb structure 102 is disposed within the bed frame 200.

In examples, the longer of the two perpendicularly oriented pieces 302, 304 may have a length of about 22.2 cm. Alternatively, from about 10 cm to about 40 cm, or any ranges therebetween. The shorter of the two may have a length of about 10.6 cm. Alternatively, from about 5 cm to about 15 cm, or any ranges therebetween. The portions of the pieces 302, 304 having a narrow width 316 may extend out beyond the step change 312 by about 3 cm. Alternatively, from about 1 cm to about 8 cm, or any ranges therebetween. A plurality of fasteners, e.g., screws, dowels, nuts, washers, or the like, may be used in borcholes 318 to secure reduced width portions 310 to neighboring pieces (e.g., straight pieces 400, 500, or 600 of FIGS. 26-28).

FIG. 26 illustrates a straight piece 400 of the bed frame 200 of FIG. 24, in accordance with some embodiments of the present disclosure. Straight piece 400 is an example of a straight piece 108 shown in FIGS. 23 and 24. As shown, straight piece 400 may be a single laterally oriented piece 402 having ends with reduced width portions 404, 406 bilaterally disposed at either end, characterized by respective step changes 408, for mating to respective ends of corner piece 300 and/or other straight pieces (e.g., straight pieces 500 or 600, referring to FIGS. 27 and 28). This Figure also shows groove 410 which, like groove 306 of FIG. 25, may adhere or attach (e.g., stitch) to a connector strip or other suitable connector to keep honeycomb structure 102 (e.g., referring to FIG. 23) in an extended configuration in bed frame 200. As with FIG. 25, borcholes 412 may also be used, as shown, to connect to neighboring panels.

In examples, straight piece 400 may have a length of about 40 cm, measured from end to end. Alternatively, from about 10 cm to about 80 cm, or any ranges therebetween. Straight piece 400 may have a height of about 20 cm, measured from bottom 414 to top 416. Alternatively, from about 5 cm to about 40 cm, or any ranges therebetween. Each reduced width portion 404 may have a narrow width which may likewise extend out beyond respective step change 408 by any of the dimensions and/or ranges disclosed with respect to reduced width portion 310 relative to step change 312 (e.g., referring to FIG. 25).

FIG. 27 illustrates another straight piece 500 of the bed frame 200 of FIG. 24, in accordance with some embodiments of the present disclosure. Straight piece 400 is an example of a straight piece 108 shown in FIGS. 23 and 24. As shown, straight piece 500 may be a single laterally oriented piece 502 having ends with reduced width portions 504, 506 bilaterally disposed at either end as in FIG. 26, except that respective step changes 508 are disposed in this example at side 512 of laterally oriented piece 502. In examples, the length and/or width of straight piece 500, as well as reduced width portions 504, 506, may correspond to or include any of the dimensions or ranges disclosed herein with respect to straight piece 400 (e.g., FIG. 26). Also visible in this Figure are boreholes 510 for connecting to neighboring panels.

FIG. 28 illustrates another straight piece 600 of the bed frame of FIG. 24, in accordance with some embodiments of the present disclosure. Straight piece 400 is an example of a straight piece 108 shown in FIGS. 23 and 24. In this example, rather than both reduced width portions 602, 604 being disposed on side 606, these are staggered. In examples, this may allow for a complete bed frame 200 (e.g., referring to FIG. 23) by allowing straight piece 600 to connect between pieces where respective reduced width portions (e.g., 504 and 310) would otherwise be unable to connect to each other. The dimensions of straight piece 600 may share in common any of those herein disclosed for straight pieces 400 and/or 500 (e.g., referring to FIGS. 26 and 27). Any of the corner or straight pieces 300, 400, 500, or 600 may have a thickness of about 16 mm to about 25 mm. Alternatively, from about 10 mm to about 45 mm, or any ranges therebetween.

FIG. 29 illustrates a shipping container 700 for the bed base 100 of FIG. 23, in accordance with some embodiments of the present disclosure. Shipping container 700 may have one or more surfaces 708 configured to house the honeycomb structure 102 (e.g., referring to FIG. 23) in a non-expanded configuration and bed frame 200, disassembled. Thus, in examples, shipping container 700 may house sixteen straight pieces and four corner pieces, without limiting to any specific embodiment. In examples, shipping container 700 may have a length and/or width of about 48 cm, and a height of about 43 cm. Alternatively, a length, width, and/or height from about 20 cm to about 80 cm, or any ranges therebetween. In one example, the volume occupied by shipping container 700 is less than 20% of the volume occupied by fully assembled bed base 100 (e.g., referring to FIG. 23). Alternatively, less than 30%, less than 40%, less than 50%, less than 60%, less than 70%, or any ranges therebetween. This may allow bed base 100 to be easily shipped at a low cost, as well as stored within a small storage space.

FIG. 30 illustrates a plurality of honeycomb sections 802 to form a honeycomb structure 102 of FIG. 23, to be disposed within the bed frame 200 to form the bed base 100 of FIG. 23, in accordance with some embodiments of the present disclosure. As illustrated, honeycomb structure 102 may comprise one or more honeycomb sections 802, such as the four shown by this Figure. Each may have the honeycomb material disposed between respective ends which may comprise, in some examples, end pieces 804, 806. As discussed, the honeycomb material may collapse/expand between extended and nonextended configurations, such as by a single assembler, or two assemblers standing at either end of bed frame 200 (e.g., referring to FIG. 23).

End pieces 804 and 806 may comprise, for example, one or more corrugated sheets. The function of end pieces 804, 806 is to provide a rigid or semi-rigid structure capable of holding each honeycomb section 802 in an expanded configuration with connector 808. As an alternative to corrugated sheets, end pieces 804, 806 may comprise, for example, cardboard, plastic, wood, heavy weight fabric, canvas, honeycomb boards, engineered wood, or any other suitable solid material that adds substantial rigidity to each honeycomb section 802 and prevents collapse of the honeycomb structure 102 back to a non-expanded configuration. Where a plurality of the honeycomb sections 802 is disposed within a bed frame 200 (e.g., referring to FIGS. 23, 24), there may exist a gap 810 between sections. Gap 810 may be between 0 cm to about 10 cm, or any ranges therebetween, for example. In examples, gap 810 may further reduce the total weight of bed base 100 (and total material cost) by allowing for less than the whole volume of (e.g., a fraction of) the bed frame 200 to be filled by the honeycomb structure 102. This may be achieved without any significant reduction in the bed base's 100 ability to support the weight of a mattress pad, pad, or person, for example.

FIG. 31 illustrates the bed frame 200 of FIG. 24, with a plurality of braces 900 for securing the bed frame 200, in accordance with some embodiments of the present disclosure. Braces 900 may add structure and support to bed frame 200 to ensure, for example, that the shape of bed frame 200 is preserved as a rectangle and does not become trapezoidal-shaped or parallelogram-shaped over time. Braces 900 may also increase durability and longevity of bed base 100 (e.g., referring to FIG. 23) by ensuring that corner pieces 300 are not overly strained at the corner 308 or at respective interfaces 902, 904 with neighboring panels. Braces 900 may comprise, for example, steel rods, and may have a thickness from about 3 mm to about 8 mm. Alternatively, from about 1 mm to about 15 mm, or any ranges therebetween. A fabric or material cover may be positioned over at least a portion (e.g., the entirety of) bed frame 200 after braces 900 are used to secure the structure. While this figure shows braces 900 disposed above bed frame 200, they may be alternatively disposed below bed frame 200, in some examples.

With respect to FIGS. 23-31, assembly of a bed base 100 in accordance with some embodiments will now be described. An assembler may assemble a bed frame 200 from corner pieces 300 and straight pieces 400, 500, 600. This may involve placing fasteners in respective boreholes 318, 412, 510, etc. One or more honeycomb sections 802 may be expanded between ends 114, 116 or sides 110, 112 of bed frame 200. Connectors 808 at either end of each section 802 may be mated to a corresponding connector 202 adhered to an inner surface of bed frame 200 at an interface 118, for example. Braces 900 may be then installed to secure the shape of bed base 100. Optionally, fabric, padding, or other material cover may be placed over bed base 100 before placing a mattress, pad, or other bed object on top of bed base 100.

FIG. 32 illustrates a bed base 100, in accordance with some embodiments of the present disclosure. In this example, bed base 100 may be fully sustainable, meaning that it may consist of 100% recyclable materials, in some examples. Bed base 100 may, in some examples, consist of, or essentially consist of, paper pulp and the remainder adhesives, coatings, and additives (e.g., cardboard, paperboard, etc.).

Honeycomb material may be positioned in a housing 1002. Housing 1002 may be configured to bend at parallel folds 1004 extending end-to-end lengthwise along the length of housing 1002. The purpose of housing 1002 is to protect the honeycomb material and to provide shape and structure to bed base 100. A scam 1006 may be disposed parallel to folds 1004, such as at or near a central axis 1014 of bed base 100. Seam 1006 may comprise adjacently disposed flaps, to be discussed in greater detail in FIG. 33.

Head and foot pieces 1008, 1010 may be disposed at either end of bed base 100. These may include interlocking features for securing housing 1002 in place. Locking features may include, for example, one or more tabs 1012 configured to mate with housing 1002, such as at corresponding apertures 1106 (e.g. referring to FIG. 33). Tabs 1012 are rigid and not foldable in this example. However, suitable alternative interlocking features may include, for example, foldable tabs.

Tabs 1012 are shown in this Figure as being disposed bilaterally on either side of central axis 1014, extending out beyond sides 1016, 1018 of head and foot pieces 1008. While each piece is shown as having four tabs 1012, these may alternatively comprise any suitable number of tabs, for example, two, three, five, eight, ten, etc. Each tab 1012 may have a width equal to, or slightly greater than, a corresponding aperture 1106 (e.g., referring to FIG. 33) to allow the tabs 1012 to frictionally engage the walls of the apertures 1106, thereby ensuring that the housing 1002 is tightly secured about the honeycomb material following assembly.

In one example, bed base 100 has a height of 23 cm. Alternatively, from about 18 cm to about 35 cm, or any ranges therebetween, for example. Each tab 1012 may extend out beyond sides 1016, 1018 by 1 cm. Alternatively, about 1 millimeter (mm) to about 5 cm, or any ranges therebetween. The length of head and foot pieces 1008 may be 153 cm, which may match a corresponding width of bed base 100. Alternatively, from about 50 cm to about 300 cm, or any ranges therebetween. The length of bed base 100 may be 203 cm. Alternatively, from about 50 cm to about 400 cm, or any ranges therebetween. In some examples, bed base 100 may be queen sized, and may thus have dimensions configured to accommodate/support the weight of a queen-sized mattress or mattress pad. In other examples, bed base 100 may be twin sized, twin XL, full XL, king, or California king sized.

FIG. 33 illustrates the housing 1002 of FIG. 32 in a disassembled and flat configuration prior to assembly, in accordance with some embodiments of the present disclosure. As illustrated, housing 1002 comprises a central section 1100 and two bilateral halves 1102 connected by side sections 1104. Housing 1002 may be foldable at parallel folds 1004, as well as at the seam 1006 where bilateral halves 1102 attach to flaps 1108.

Central section 1100 may be unitarily formed of a single non-folded sheet, for example, having one surface facing downward towards the ground, and another surface 1118 for holding the honeycomb structure 102 (e.g., referring to FIG. 35). As discussed, apertures 1106 for receiving tabs 1012 are punched through central section 1100 near the outer edges 1120, 1122.

Bilateral halves 1102 may each be unitarily formed of a single sheet folded at various locations which, when pressed together at flaps 1108, may form an opposite section effectively mirroring central section 1100 at the seam 1006. One or more apertures 1106 may also be punched through these sections near the respective outer edges, as illustrated.

Side sections 1104 may connect bilateral halves 1102 to central section 1100. This example and outer edge 1124 of side sections 1104 recessed with respect to outer edge 1120 such that a rounded corner 1116 extends down from the outer edge 1120 of central section 1100 to each side section 1104. In examples, this may allow for head and foot pieces 1008, 1010 to seat against outer edge 1124 and thus fit easily between apertures 1106 when bed base 100 is assembled. Rounded corner 1116 may serve to frictionally engage corresponding rounded corners 1206 of inner section 1202 of head and foot pieces 1008, 1010 (e.g., referring to FIG. 34), in some examples.

Flaps 1108 may extend out from bilateral halves 1102. In examples, flaps 1108 of either bilateral half 1102 may be symmetrical about central axis 1014, which may allow the surface 1110a of each flap 1108 to seat against a respective surface 110b of an opposite flap on the other side of central axis 1014. There may be one or more gaps 1112 between flaps 1108, which may facilitate the assembly process. Gap 1112 may be between 0 cm and 200 cm, or any ranges therebetween, for example, depending on the number of flaps 1108.

FIG. 34 illustrates an exploded view of head and foot pieces 1008, 1010 of the bed base 100 of FIG. 10, in accordance with some embodiments of the present disclosure. As illustrated, head and foot pieces 1008, 1010 may each comprise a inner section 1202 and an outer section 1204. Inner section 1202 may have rounded corners 1206 which may conform to the outer edges 1124 of side section 1104 (e.g., referring to FIG. 33). Second section 1204 may have a straight edge 1208, e.g., without any rounded corners. Inner and outer sections 1202, 1204 may be attached together (e.g., glued, adhered, etc.) in any suitable fashion to form a single piece, or may comprise two separate pieces separately attachable to bed base 100 (e.g., referring to FIG. 32). In alternative examples, head and foot pieces 1008, 1010 each comprise only a single sheet, or a single section (e.g., of corrugated sheets). This Figure also shows tabs 1012 which may be disposed at the sides 1016 and 1018 of inner section 1202, for example.

FIG. 35 illustrates an exploded view of a honeycomb structure 102 comprising a plurality of honeycomb sections 1300 to be disposed within the housing of FIGS. 10 and 11, in accordance with some embodiments of the present disclosure. As illustrated, a honeycomb structure 102 may comprise a plurality of honeycomb sections 1300. In this example, each of the plurality may be disposed horizontally, i.e., perpendicular to central axis 1014 of FIGS. 32, 33 and parallel to inner and outer sections 1202, 1204 of head and foot pieces 1008, 1010 of FIG. 35. Other configurations are possible, however, such as one or more honeycomb sections 1300 disposed lengthwise within housing 1002, i.e., parallel to central axis 1014. This Figure also shows a divider 1302 disposed between individual honeycomb sections 1300. Divider 1302 may be, for example, corrugated sheets glued to the different honeycomb sections 1300 to ensure even and uniform distribution of the expansion of the honeycomb of honeycomb structure 102. In this example, the honeycomb sections 1300 collapses/expands perpendicular to the orientation of divider 1302.

This Figure also shows a portion removed from the honeycomb structure 102 to form a groove 1304 to accommodate insertion of flaps 1110 when bed base 100 is assembled. Flaps 1110 may fit neatly within groove 1304 upon assembly. Where honeycomb structure 102 comprises multiple sections 1300, the removed groove 1304 may be oriented perpendicular to gaps 1306 formed between sections 1300 of the honeycomb structure 102. Gaps 1306 may function to reduce the total amount of weight of the bed base 100.

With respect to FIGS. 32-35, assembly of bed base 100 of FIGS. 32-35 will now be described. During assembly, an assembler may lay the housing 1002 on the ground in the flat configuration of FIG. 32. Honeycomb structure 102 is then expanded and positioned on surface 1118. The assembler then positions the tabs 1012 (e.g., referring to FIG. 32) of the inner sections 1202 of the head and foot pieces 1008, 1010 within respective apertures 1106 (e.g., referring to FIG. 33) of central section 1100 and also folds side sections 1104 at folds 1004 to allow bilateral halves 1102 to lay across the top of honeycomb structure 102. The assembler may then insert the last tabs 1012 into the respective apertures 1106 of the bilateral halves 1102 and fold flaps 1108 inward so that they insert into groove 1304 (e.g., referring to FIG. 35) of honeycomb structure 102, with edges (i.e., at seam 1006) and surfaces 1110a, 1110b of the respective flaps 1108 (e.g., referring to FIG. 33) pressed up against each other. In some examples, housing 1002 may also serve to maintain honeycomb structure 102 from collapsing, such as when head and foot pieces 1008 are permanently attached (e.g., glued) to honeycomb structure 102.

In examples where inner and outer sections 1202, 1204 (e.g., referring to FIG. 34) are not a single piece, assembly may further comprise separately positioning outer section 1204 at the edges of bed base 100 (e.g., referring to FIG. 32), such as on or between the outer edges 1120, 1122 (e.g., referring to FIG. 33).

FIG. 36 illustrates a bed base 100 covered by a mattress 1400 and padding 1402, in accordance with some embodiments of the present disclosure. Mattress 1400 may be, for example, any suitable mattress, mattress pad, cushion, fabric, etc., for cushioning the weight of a person laying on bed base 100. Mattress 1400 may serve to redistribute a person's weight across the top 1408 of bed base 100. Mattress 1400 may be foldable along horizontal folds 1410, in some examples. Mattress 1400 may attach to honeycomb structure (e.g., honeycomb structure 102 of FIG. 37) by a temporary or permanent connector, such as a hook-and-loop fastener. In examples, unfolding of mattress 1400 may impart the movement needed to expand the honeycomb to the extended configuration, or may provide structure needed to keep the honeycomb from collapsing once fully expanded. For example, unboxing of bed base 100 may be what triggers expansion of a compressed mattress 1400 which may thereby linearly expand the honeycomb. Specifically, in some examples, the elasticity of mattress 1400 tightly packed within a shipping container may, as mattress 1400 intakes air and returns to its natural shape, force the honeycomb to expand until it reaches its full length. Thus, mattress 1400 may be permanently secured to honeycomb structure or to a device (e.g., end pieces 1500, 1502 of FIG. 37) affixed thereto, in some examples.

Padding 1402 may likewise by any suitable sheet, pad, material, cushion, etc., or other cover to drape over and/or around at least a portion of bed base 100. Padding 1402 may also be foldable, in some examples. While this Figure shows padding 1402 simply being disposed at the sides 1404 and ends 1406 of bed base 100, padding 1402 may also be disposed over the top 1408 of bed base 100, such as between the bed base 100 and mattress 1400. In some examples, mattress may comprise one or more layers of cushion, such as a spongy layer surrounded by one or more layers of fabric.

In examples, bed base 100 may be 27 cm by 191 cm by 96.5 cm. Other ranges are possible, for example, between 10 cm and 40 cm by between 100 cm and 300 cm by 50 cm and 200 cm, or any respective ranges therebetween. In some examples, bed base 100 may be characterized as a “twin bed,” being able to accommodate a standard twin sized mattress. In some examples, the length of bed base 100 is between 180 cm and 220 cm. In some examples, the width of bed base is between 60 cm and 160 cm. In some examples, the height of bed base is between 10 cm and 35 cm.

FIG. 37 illustrates a honeycomb structure 102 between opposing end pieces 1500, 1502 of the bed base 100, in accordance with some embodiments of the present disclosure. End pieces 1500, 1502 are panels, structure, or pieces (e.g., corrugated sheets) that lay at opposite ends of bed base 100. End pieces 1500, 1502 may comprise, for example, one or more layers of corrugated sheets. Alternatively, one or more layers of wood, plastic, plywood, medium density fiber board (MDF), etc., or any of the other materials herein disclosed (e.g., with respect to end pieces 804 and 806 of FIG. 30). End pieces 1500, 1502 may also serve a structurally supportive function, in some examples, and may be temporarily or permanently attached (e.g., glued, stitched, etc.) to honeycomb (e.g., honeycomb structure 102 of FIG. 37).

Bed wings 1504 may provide a structure or fabric to which padding 1402 (e.g., referring to FIG. 36) may attach. Bed wings 1504 may extend lengthwise along a side 1506 of honeycomb structure 102. In some examples, bed wings 1504 may serve to keep the end pieces 1500, 1502 in place by preventing them from rotating down. Bed wings 1504 may comprise one or more connectors (e.g., hook-and-loop fasteners) or fabric attached to one or more connectors, for example. Corresponding connectors may be disposed on padding 1402 and/or honeycomb structure 102 to temporarily attach to bed wings 1504.

FIG. 38 illustrates a shipping container for the bed base 100, mattress 1400, and padding 1402 of FIG. 36, in accordance with some embodiments of the present disclosure. In some examples, a shipping container 1600 may encompass the honeycomb structure 102, end pieces 1500, 1502, mattress 1400, and padding 1402 (e.g., referring to FIGS. 36, 37). In some examples, shipping container 1600 is 32 cm by 32 cm by 15 cm. In some examples, the volume of shipping container may be less than 15% the volume of bed base 100. Alternatively, less than 20%, less than 30%, less than 40%, less than 50%, less than 60%, less than 70%, or any ranges therebetween. Shipping container 1600 may be used to ship bed base 100, mattress 1400, and padding 1402 or otherwise store these items for convenient retrieval.

FIG. 39 illustrates an exploded view of an end piece 1500 of the bed base of FIGS. 36, 37, in accordance with some embodiments of the present disclosure. As shown by the Figure, end piece 1500 may comprise a plurality of layers 1700. While this Figure shows three layers 1700, end piece 1500 may alternatively comprise any suitable number of layers, for example, one, two, four, ten, etc., and any ranges therebetween. Layers 1700 may comprise any suitable material, for example, corrugated sheets. Layers 1700 may be stacked on top each other, adhered, or attached in any suitable fashion to form the end piece 1500. End piece may also comprise a connector 1704 which may connect to padding 1402 and/or mattress 1400 disposed atop bed base 100 (e.g., referring to FIGS. 37, 40). Connector 1704 may be any suitable connector, such as any of those disclosed with respect to connector 202 (e.g., referring to FIG. 24). Another connector 1702 (e.g., L-bracket) may be attachable to end piece 1500 and a respective bed wing 1504, as illustrated. Connector 1702 may provide a secure connection between the surface 1706 of the innermost layer 1700 of the end piece 1500 and bed wing 1504.

FIG. 40 illustrates an exploded view of the mattress and padding of FIG. 14, in accordance with some embodiments of the present disclosure. As mentioned previously, padding 1402 may be disposed between mattress 1400 and bed base 100 (e.g., referring to FIG. 37). Mattress 1400 and/or padding 1402 may also comprise one or more folds 1800 to allow for easy compaction and storage within a shipping container. In this FIG. 1402, the section of padding 1402 between mattress 1400 is one or more corrugated sheets. In examples, this may protect the honeycomb structure 102 (e.g., referring to FIG. 37).

FIG. 41 illustrates the bed base 100, mattress 1400 of FIG. 14 with the end pieces and some of the padding 1402 omitted to show bed sides 1900 disposed over mattress 1400 and some of the padding 1402, in accordance with some embodiments of the present disclosure. As illustrated, bed sides 1900 may extend vertically across one or more layers of padding 1402 and at least a portion of mattress 1400. Bed side 1900 may be, for example, a layer of fabric (e.g., fabric, corrugated sheets, panels, etc.) attachable to a corresponding fabric (e.g., including hook fasteners) on or attached to the part of the padding 1402 (e.g., referring to FIG. 36) omitted in this Figure. In some examples, bed side 1900 may provide structure to bed base 100 and hold the honeycomb structure in an extended position. In other examples, bed side 1900 only forms part of the padding 1402 or else serves as a cover to bed base 100 to hide or protect the honeycomb structure. In some examples, padding 1402 may additionally, or alternatively, provide structure to bed base 100 to hold the honeycomb structure in the extended position. However, as mentioned, an inherent outwardly biased shape of the unboxed mattress 1400 may be what ultimately causes the honeycomb to remain in the extended position, in some examples. In other examples, an assembler may be required to pull apart the honeycomb into the extended position.

Bed side 1902, which may be attached to or be the same as bed side 1900, may be configured to extend over the bed base 100 (e.g., referring again to FIG. 36) horizontally between padding 1402 and bed base 100, for example. Bed side 1902 may comprise another layer of fabric (e.g., loop fasteners) attachable to a corresponding fabric (e.g., hook fasteners) on or attached to an underside of padding 1402. Fabric may include, for example, cotton, satin, wool, polyamide, elastane, lace, etc., (e.g., Evana fabric), or the like. As mentioned previously, the lower most layer of padding 1402 may comprise one or more corrugated sheets, for example. While various examples of suitable attachment devices/fabrics/materials are herein provided, it should be understood that various alternative attachment methods may be used to connect any of the bed base 100, mattress 1400, padding 1402, bed sides 1900, and bed wings 1504.

With respect to FIGS. 36-41, assembly of bed base 100 of FIGS. 36-41 will now be described. During assembly, an assembler may unbox bed base 100 and mattress 1400. As mattress 1400 expands to its full shape, this may open honeycomb structure 102 so that it is in an extended position. An assembler may facilitate this natural process by pulling apart the opposing end pieces 1500, 1502 to thereby elongate the honeycomb. Once honeycomb structure 102 has been extended to the desired length, padding 1402 and bed sides 1900 may be placed on or along respective planar surfaces of honeycomb structure 102, such as by connecting these to bilateral bed wings 1504 at the opposing end pieces 1500, 1502. In alternative examples, bed base 100 may already be dressed in the padding 1402 and/or bed sides 1900. One advantage of the bed base 100 of FIGS. 36-41 is that, like the unboxing, re-boxing bed base 100 and mattress 1400 within shipping container 1600 may be a relatively simple process of recompressing the mattress 1400 and honeycomb structure 102 without the need for special tools, removing screws or fasteners, etc. Thus, assembly and/or disassembly of this example of bed base 100 may be performed in less than 1 minute in some examples, as measured from the moment of unboxing to when bed base 100 and mattress 1400 are fully assembled. Alternatively, less than 2 minutes, less than 5 minutes, or less than 7 minutes.

FIG. 42 illustrates a bed base 100 covered by a complete housing 2702 and end pieces 2000a, 2000b, in accordance with some embodiments of the present disclosure. As shown in this Figure, end pieces 2000a, 2000b may be disposed at either end of bed base 100. A plurality of connectors 2004 may connect end pieces 2000a, 2000b to bed base 100 (e.g., directly to honeycomb structure 102 of FIG. 46. A scam 2006 between two bilateral halves 2500a, 2500b of complete housing 2702 may be disposed along the central axis 2008 of bed base 100, to be discussed in later Figures. In some examples, bed base 100 may be free of, or essentially free of screws, metal, and wood. In some examples, bed base 100 may consist of, or consist essentially of, recyclable materials, or else any of the materials herein disclosed with respect to FIGS. 32-35.

End pieces 2000a, 2000b may be, for example, rigid panels (e.g., fiber, corrugated sheet, wood, plastic, cardboard, etc.) covered by fabric. End pieces 2000a, 2000b may hide bed base 100 so that the honeycomb structure 102 disposed inside (e.g., referring to FIGS. 35, 36) is protected and hidden. End pieces 2000a, 2000b may also help house the honeycomb structure and to provide structure to bed base 100. This may prevent honeycomb structure 102 from being damaged as well as facilitate ergonomic assembly/disassembly.

Connectors 2004 may comprise any suitable connector or connector. In this example, connectors 2004 comprise hook-and-loop fasteners that connect end pieces 2000a, 2000b together and to or around the bed base 100. The purpose of connectors 2004 is to securely fasten end pieces 2000a, 2000b to the bed base 100 prevent them from becoming dislodged following assembly, while still allowing the bed base 100 to be easily disassembled or reassembled. In some examples, however, connectors 2004 may comprise one or more permanent and/or temporary connectors such as any of the permanent or temporary fasteners herein disclosed (e.g., glue, stitches, adhesives, clips, fasteners, tie-ups, buckles, snaps, buttons, hook-and-loop fasteners, etc.).

In some examples, bed base 100 may be 23 cm by 203.2 cm by 153 cm. However, other dimensions are possible. For example, between 10 cm and 50 cm by between 100 cm and 300 cm by between 50 cm and 250 cm, or any respective ranges therebetween. In some examples, the bed base 100 of FIGS. 20-27 may be characterized as queen size, and thus may be able to accommodate a queen size mattress.

FIG. 43 illustrates a shipping container 2100 for the bed base 100 of FIGS. 42-49 including end pieces 2000a, 2000b of FIGS. 20, in accordance with some embodiments of the present disclosure. In examples, shipping container 2100 houses bed base 100 (e.g., referring to FIG. 20) and end pieces 2000a, 2000b. Shipping container 2100 may be 154 cm by 42 cm by 32 cm, however other dimensions are possible. In examples, shipping container 2100 may be less than 30% the volume of bed base 100 and end pieces 2000a, 2000b shown by FIG. 20. Alternatively, less than 35%, less than 40%, less than 45%, less than 50%, less than 70%, or any ranges therebetween. In some examples, bed base 100 (e.g., including complete housing 2702 of FIG. 49) may be folded down to a smaller size to align with the honeycomb (e.g., honeycomb structure 102 of FIGS. 35, 36) to fit within the shipping container 2100.

FIG. 44 illustrates an end piece 2000 shown by FIG. 42, in accordance with some embodiments of the present disclosure. This Figure shows connectors 2004 attached at a surface 2200 of end piece 2000 such that ends 2202 extend beyond respective edges 2206, 2208 of end piece 2000. In some examples, ends 2202 are fasteners (e.g., the hook side of a hook-and-loop) configured to attach directly to an outer fabric of complete housing 2702 or else a corresponding fastener (e.g., loop side of a hook-and-loop) attached to complete housing 2702 or its outer fabric.

FIG. 45 illustrates the bed base 100 of FIGS. 42-49, with complete housing 2702 omitted to show the separate sections 2304a, 2304b of the honeycomb structure 102 as well as dividers 2300 disposed between the end pieces 2000a, 2000b, in accordance with some embodiments of the present disclosure. As illustrated, a groove 2302 may extend lengthwise from end piece 2000a to end piece 2000b. Groove 2302 may simply comprise a gap between sections 2304a and 2304b of the honeycomb, or else an indentation in honeycomb structure 102 (e.g., when honeycomb structure 102 comprises a single or odd number of sections). As will be discussed in FIG. 47-49, groove 2302 and divider groove 2306 may accommodate reception of flaps 2502a, 2502b, etc. (E.g., referring to FIG. 47).

End pieces 2000a and 2000b may extend slightly beyond the outermost edges 2310a and 2310b. This allows overhanging surfaces (e.g., surfaces 2308a, 2308b) to seat against respective surfaces 2700a, 2700b, 2700c, and 2700d of complete housing 2702 (e.g., referring to FIG. 49) when the honeycomb structure 102 is fully extended in the expanded configuration, thereby preventing the honeycomb structure 102 from retracting back to its non-expanded configuration.

FIG. 46 illustrates an exploded view of the honeycomb structure 102 of FIG. 45 with some of the end pieces 2000a, 2000b omitted to show the dividers 2300 between honeycomb structures, in accordance with some embodiments of the present disclosure. Visible in this Figure are the divider grooves 2306 of each divider 2300. Each divider 2300 may be permanently (or temporarily) sealed to (e.g., glued, adhered, etc.) neighboring surfaces of the honeycomb. Dividers 2300 ensure honeycomb structure 102 expands evenly, thereby preventing some regions of the honeycomb being over expanded while some are under expanded. Dividers 2300 may also provide additional structure to the bed base 100. Dividers 2300 may comprise, for example, one or more layers of corrugated sheets. In some examples, dividers 2300 may be 151.6 cm by 21.6 cm. For example, between 50 cm and 300 cm by between 10 cm and 50 cm, or any respective ranges therebetween. However, other dimensions are possible. The depth of each divider groove 2306 may be about 4.3 cm. Alternatively, from about 1 mm to about 7 cm, or any ranges therebetween.

FIG. 47 illustrates one half 2500 of a complete housing 2702 of the bed base 100 (e.g., referring to FIGS. 42, 49) in a disassembled and flat configuration prior to assembly, in accordance with some embodiments of the present disclosure. This Figure shows top and bottom sections 2504a, 2504b connected by a side section 2506. Each of the top and bottom sections 2504a and 2504b have respective flaps 2502a and 2502b. Flaps 2502a may be spaced apart by any suitable distance, to form one or more gaps 2516 between the flaps 2502a. As with housing 1002 of FIG. 33, a half 2500 of a complete housing 2702 may include any suitable number of flaps 2502a (e.g., two, three, four, five, eight, ten, etc.). The top and bottom sections 2504a and 2504b may be folded along top outer fold 2508, bottom outer fold 2510, top inner fold 2512, and bottom inner fold 2514 to form the folded configuration of FIG. 48. These may fit within the groove provided by divider grooves 2306 and groove 2302.

FIG. 48 illustrates the half 2500 of the complete housing 2702 in an assembled and folded configuration, with the honeycomb structure 102 omitted for reference, in accordance with some embodiments of the present disclosure. This Figure shows the gaps 2516 between the various flaps 2502a, 2502b to form a plurality of “X” or “T” shapes. When fully assembled, the respective outer surfaces of flaps 2502a, 2502b may seat against corresponding surfaces of flaps of an identical half 2500 to form the complete housing 2702. Also visible in this Figure are the folds 2508, 2510, 2512, and 2514 so that the top section 2504a is disposed above the bottom section 2504b and connected by side section 2506.

FIG. 49 illustrates two of the halves 2500a and 2500b to form a complete housing 2702 of the bed base 100 of FIGS. 42-49, in accordance with some embodiments of the present disclosure. This Figure also shows the surfaces 2700a-d which may seat against respective inner surfaces 2308a-d of end piece 2000 (e.g., referring to FIG. 45) to thereby hold the honeycomb structure 102 (e.g., referring to FIG. 45) in an open and extended configuration. Also visible in this Figure is the seam 2006 corresponding to the adjacency between the two halves 2500a, 2500b, as well as the adjacency between flaps 2502a and 2502b.

In some examples, a width of half 2500a may be 76.5 cm, with a width of side section 2506 (e.g., referring to FIG. 48) being 23 cm. Alternatively, width of half 2500a may be from about 50 cm to about 150 cm, or any ranges therebetween, and width of side section 2506 may be from about 15 cm to about 50 cm, or any ranges therebetween. The length from an outer edge of flap 2502a to that of 2502b in the flat and unassembled configuration may be 200 cm. However, other dimensions are possible. For example, from about 150 cm to about 300 cm, or any ranges therebetween.

With respect to FIGS. 42-49, assembly of bed base 100 of FIGS. 42-49 will now be described. During assembly, two of the halves 2500 of the housing may be laid on the floor by an assembler in a flat configuration. Some of the flaps 2502 of the two halves 2500 may be pushed together, e.g., so that a surface of flap 2502a of one half 2500 meets a corresponding surface of flap 2502b of another half 2500. Optionally, clips may be used to attach flaps 2502 of the two halves 2500 together. End pieces 2000a, 2000ba, 2000b may be pulled apart by an assembler to expand the honeycomb structure 102 (e.g., one or more sections 2304 laid side-by-side) to the appropriate length. The length of the halves 2500 may provide a reference for the assembler to avoid overextension. Honeycomb structure 102 may be slightly overextended past surfaces 2700a-d during the assembly process to allow the halves 2500 to be separately folded along folds 2510, 2508, 2512 to form parallel structures that together form the complete housing 2702 of the bed base 100. Remaining flaps 2502 may be positioned together within bed base 100 to achieve a complete housing 2702. Surfaces 2308a, 2308b, etc., may then be seated against corresponding surfaces 2700a-d by the assembler so that the honeycomb structure 102 is in the desired extended position. Connectors 2004 of end pieces 2000a, 2000b may then be securely fastened to complete housing 2702 to complete the bed base 100. A mattress or mattress pad may be then disposed on top of the assembled bed base 100.

Although specific embodiments have been described above, these embodiments are not intended to limit the scope of the present disclosure, even where only a single embodiment is described with respect to a particular feature. Examples of features provided in the disclosure are intended to be illustrative rather than restrictive unless stated otherwise. The above description is intended to cover such alternatives, modifications, and equivalents as would be apparent to a person skilled in the art having the benefit of this disclosure. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an”, and “the” include singular and plural referents unless the content clearly dictates otherwise. Furthermore, the word “may” is used throughout this application in a permissive sense (i.e., having the potential to, being able to), not in a mandatory sense (i.e., must). The term “include,” and derivations thereof, mean “including, but not limited to.” The term “coupled” means directly or indirectly connected. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted for the purposes of understanding this invention.

For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

The scope of the present disclosure includes any feature or combination of features disclosed herein (either explicitly or implicitly), or any generalization thereof, whether or not it mitigates any or all of the problems addressed herein. Various advantages of the present disclosure have been described herein, but embodiments may provide some, all, or none of such advantages, or may provide other advantages.

	Number	Date	Country
Parent	17591541	Feb 2022	US
Child	18583645		US
Parent	17049659	Oct 2020	US
Child	17591541		US

Furniture Objects

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