Patent Grant
11659936
The present disclosure relates to furniture and furniture systems. More specifically, the present disclosure relates to furniture spring systems and modular furniture support systems.
Spring systems that provide cushioning to furniture items such as beds, couches, and chairs are generally manufactured to be permanently fixed within a furniture item. For example, a box spring for a mattress includes internal springs that are not removable by a user. Also, S-springs or other springs are often integrated into base members of couches and chairs to provide added cushioning beneath cushions placed thereon.
Spring systems currently utilized in furniture are limited in a number of ways. For example, as noted above, spring systems are not removable or replaceable by a user without significant deconstruction of the furniture item and costly reconstruction. Typically, when a spring in a box spring breaks, it is more economical for the user to throw out the box spring and buy a new one rather than fix the single broken spring. Also, springs built into couches and chairs are integrated into the furniture in such a way that replacement of the spring system is difficult or impossible without damaging the furniture. Thus, as spring systems age and become less firm over time, it is not viable to simply replace the spring system.
Furthermore, the cushioning provided by current spring systems are set such that the user cannot change the degree of flexion, or “firmness,” of the spring system to alter the provided cushioning effect. Rather, the spring system built into a given furniture item, and thus the degree of cushioning provided, is predetermined by the manufacturer and cannot be changed by the user.
However, over time, or as the use of a furniture item changes from one user to another, it may be desirable to change the amount of cushioning provided by a spring system within a furniture item. For example, users often have varying opinions on how firm they like their bed, including a firmness of their box spring. Additionally, a user's preference may change over time. Unfortunately, users need to buy entirely different box springs to alter the firmness of their beds. The same applies to the firmness of spring systems built into couches, chairs, and other furniture items.
Furniture items, such as beds, couches, and chairs, can also include built-in storage spaces. For example, a bed may include space within or underneath the bed frame to store items. Also, couches may include storage spaces within base components or otherwise underneath cushions or within ottomans. However, such furniture storage spaces, which are advantageous to save space and provide extra storage areas within a room, are constructed in a way that while protecting items within the storage spaces from damage limit cushioning or firmness variations. For example, for a storage space disposed underneath a bed or couch, rigid barriers to the storage space, such as lids or drawers, are used to protect items placed inside the storage space. These rigid components are placed underneath furniture cushions or mattresses to support users who sit or lie thereon and can negatively affect the comfort of the furniture item.
Accordingly, there are a number of problems in the prior art that need to be addressed in the field of furniture and furniture spring systems.
The present disclosure relates to furniture and furniture systems. More specifically, the present disclosure relates to furniture spring systems. In one embodiment of the present disclosure, for example, a furniture spring system, includes a lid configured to provide a seating surface. The lid includes a frame comprising two opposing frame members and a retention member disposed on a top surface of at least one of the two opposing frame members. The spring system also includes an elongate slat extending between the two opposing frame members. In such an embodiment, the slat has an elongate body with an upper surface, a lower surface, a first end, a second end, and a flexible middle portion extending between the first end and the second end. The slat also includes a catch disposed at the first or second end. The catch engages the retention member to retain the slat to the frame and is configured to slide back-and-forth relative to the retention member as the middle portion elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
Furniture spring systems described herein solve a number of problems. For example, furniture spring systems of the present disclosure provide support to users sitting or lying thereon while protecting items that may be placed or stored below. In some configurations, spring systems described herein are modular. In some configurations, the spring systems described herein are easily replaceable without requiring deconstruction of other furniture components. In some configurations, spring systems described herein are adjustable so that users can customize the firmness or size of the spring system to suit their preferences or spacing needs. In some embodiments, the slats of the spring system can be extendable or contractable in order to make a furniture system a different size. In some configurations, the spring systems described herein can be at least one of moveable, replaceable, and adjustable. Embodiments of the invention, such as the examples disclosed herein, may be beneficial in a variety of respects.
In one embodiment of the present disclosure, a furniture spring system includes a lid configured to provide a seating surface and an elongate slat. The lid includes a frame having two opposing frame members, each frame member having a chamfered top inner edge, and a retention member disposed on at least one of the two opposing frame members. The elongate slat extends between the two opposing frame members and includes an elongate body having an upper surface, a lower surface, a first end, a second end, and a flexible middle portion extending between the first end and the second end. The elongate slat also includes a catch disposed at the first or second end, the catch engaging the retention member to retain the slat to the frame. The chamfered top inner edge of each frame member is configured to allow the slat to flex downward in response to a load applied thereon without the frame members impeding a downward displacement of the lower surface of the slat during use.
In one embodiment of the present disclosure, a furniture assembly includes a transverse member and a base member. The base member includes a base frame member having a bottom panel, side panels, and upper edges on the side panels. The base member also includes a lid configured to be mounted on the base frame member. The lid is mounted such that the lid covers a storage cavity formed within the base frame member. In such an embodiment, the lid includes slats, each slat having an elongate member and one or more catches that engage retention members of the base frame member.
In one embodiment, a furniture spring system of the present invention comprises (i) a lid configured to provide a seating surface, the lid comprising a frame comprising two opposing frame members and a retention member associated with at least one of the two opposing frame members; and (ii) a slat extending between the two opposing frame members, the slat comprising an elongate body having a first end and a second end and a catch disposed at the first end or second end, wherein the catch engages the retention member to retain the slat to the frame and the catch is configured to slide back-and-forth relative to the retention member as a portion of the elongate body between the first end and the second end elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
Another embodiment of a furniture spring system comprises a frame comprising two opposing frame members, and a retention member disposed on at last one of the two opposing frame members, and an elongate slat extending between the two opposing frame members, the slat comprising an elongate body having an upper surface, a lower surface, a first end, a second end, and a flexible middle portion extending between the first end and the second end, and a catch disposed at the first end or the second end, the catch engaging the retention member to retain the slat to the lid frame.
A furniture assembly of the present invention may comprise (i) a transverse member and (ii) a base member, the base member comprising a storage base and a lid configured to be mounted on a top of the storage base, such that the lid covers a storage cavity formed within the storage base, the lid comprising a frame with opposing frame members having one or more retention members, and one or more slats, each slat having an elongate member and one or more catches that engage the one or more retention members of the frame.
In another embodiment, a furniture spring system comprises, (i) a lid configured to be mounted onto (ii) a base frame of a furniture base, the lid configured to provide a seating surface, the lid comprising, a frame comprising two opposing frame members, and a plurality of retention members associated with each of the two opposing frame members, a plurality of slats extending between the two opposing frame members, each of the slats comprising an elongate body having a first end and a second end and first and second catches disposed at the first end and second end, respectively, of the elongate body, wherein each catch engages a retention member to retain the corresponding slat to the frame, and wherein each catch of a slat is configured to slide back-and-forth relative to the corresponding retention member as a portion of the elongate body between the first end and the second end elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
Principles of the present invention can also be applied to mattresses and sleeping systems, making the systems more efficient, useful, and enabling the use of various parts in various different sizes of mattresses and bedding systems.
In one embodiment, a modular mattress system of the present invention comprises a plurality of mattress modules configured to form a first modular mattress of a first selected geometry and being reconfigurable to form a second modular mattress of a second selected geometry, each of the mattress modules having a width (x) and a length (y), wherein the length (y) is substantially equal to two times the width (x); a bed casing (e.g., a rigid bed casing) configured to secure the plurality of mattress modules to form a completed mattress; and a mattress topper sized and shaped to substantially cover the completed mattress and provide additional cushioning to a user.
Further embodiments of the present invention employ slats of the present invention in various different types of modular bed frames. Bed frame systems of the present invention may include such modular bed frames, as well as modular headboard/footboard systems that are coupled to the modular bed frames.
For efficiency of manufacture and assembly, modular bed frames of the present invention can be comprised of a plurality of (i) equally or similarly sized elongate support modules; and (ii) equal or similarly-sized corner modules that are interchangeable between at least two corners of the bed frame e.g., kitty corner (i.e., diagonal across from each other), and may be interchangeable between all four corners of the bed.
For example, in one embodiment, in order to provide for efficiency and standardization in manufacturing and assembly, each of the corner modules of the modular bed frame have substantially the same footprint dimensions and each of the uniform-length support modules of the modular bed frame have substantially the same footprint dimensions, specifically the same length. In one embodiment, for efficiency in manufacture and assembly, each of the corner modules are telescoping modules and have the same footprint dimensions and each of the support modules comprise elongate blocks that are of equal length.
These uniformities in geometries and size of the modules of the present invention enable the manufacturer to manufacture certain standardized pieces and enable the user assembling the pieces to work with certain standardized pieces, making the manufacturing and assembling process more simple, reliable, and efficient. To the extent that customization is required when moving from one selected size of bed frame to another selected size, the gaps may be filled in using telescoping members, filler modules, and/or elongate end modules that span the entire length between the corner modules, for example. Thus, the modular, adjustable bed frame systems of the present invention artfully allow for both standardization of certain components (e.g., uniform-length support modules and corner modules) as well as customization when customization is desired (e.g., filler modules, telescoping members, and/or elongate end modules).
For example, one embodiment of the modular bed frame comprises: a plurality of bed frame modules configured to form a first modular bed frame of a first selected geometry and being reconfigurable to form a second modular bed frame of a second selected geometry, the bed frame modules comprising, a plurality of uniform-length support modules, and a plurality of corner modules, wherein at least one of the uniform-length support modules or corner modules is reconfigurable such that the second selected geometry of the second modular bed frame is selectively formed.
In another embodiment of a modular bed frame, the bed frame comprises: a plurality of bed frame modules configured to form a first modular bed frame of a first selected geometry and being reconfigurable to form a second modular bed frame of a second selected geometry, the bed frame modules comprising, a plurality of uniform-length support modules (e.g., keystone blocks), and a plurality of corner modules, wherein at least one of the uniform-length support modules or corner modules is reconfigurable such that the second selected geometry of the second modular bed frame is selectively formed, wherein at least one of the bed frame modules is a telescoping module that is reconfigurable such that the second geometry of the second modular bed frame is selectively formed, wherein the telescoping module is a corner module. In one embodiment, the telescoping corner module telescopes from one or both of plurality of ends of the corner module. One or more additional modules are selectively added to the plurality of uniform-length support modules and the plurality of corner modules, the one or more additional modules being selected from the group consisting of: (1) filler modules (e.g., filler blocks) that each have a different configuration from the plurality of uniform-length support modules and the plurality of corner modules; (2) additional uniform-length support modules having the same length as the plurality of uniform-length support modules; and (3) elongate end modules (e.g., elongate end blocks) that each have a different configuration from the plurality of uniform-length support modules and the plurality of corner modules and that span the entire length between corner modules without any gaps.
The one or more gaps are selectively filled by telescoping members, filler blocks, or elongate end blocks, wherein a gap distance of the one or more gaps is calculated according to the following formula:
where,
In one embodiment, each of the support modules of the plurality of uniform-length support modules comprise elongate blocks that are of equal size and configuration.
In yet another embodiment, a modular bed frame comprises a plurality of bed frame modules configured to form a first modular bed frame of a first selected geometry and being reconfigurable to form a second modular bed frame of a second selected geometry, the bed frame modules comprising, one or more rails, and a plurality of corner modules, wherein each of the corner modules are configured to be selectively repositionable, from a long configuration to a short configuration, wherein in the long configuration the length of the corner module is substantially aligned with a longitudinal axis of the rail, and wherein in the short configuration the length of the corner module is substantially perpendicular to the longitudinal axis of the rail.
Another embodiment of the bed frame system employs a modular end board, e.g., a module headboard or footboard, that selectively adjusts to correspond to the adjustable dimensions, e.g., the width, of a modular bed frame. In such an embodiment, a modular end board is configured to be selectively coupled to a modular bed frame to form an adjustable bed frame system comprising an adjustable frame and an adjustable headboard and/or footboard. This is system is very useful because it allows the headboard, footboard and bed frame to be adjusted as desired for use by a user.
Thus, one adjustable bed frame system of the present invention comprises: (1) a modular end board comprising: (A) a frame assembly, the frame assembly comprising: (i) first and second upright members; and (ii) a moveable connecting system for connecting the first and second upright members to each other such that the distance between the first and second upright members can be selectively adjusted; and (iii) one or more panels that are selectively mounted onto the frame assembly, wherein the end board is an adjustable headboard or an adjustable footboard; and (2) a modular bed frame selectively coupled to the modular end board, the modular bed frame configured such that the modular bed frame can be reconfigurable from a first geometry to form a second modular bed frame of a second selected geometry, the end board and the bed frame each being configured such that they can be adjusted to each have a corresponding dimension (e.g., width) in the first geometry and a corresponding dimension (e.g., width) in the second geometry.
Manufactured components of the present invention may include base members, and/or transverse members, e.g., for use in assembling a chair, couch, or the like, or other furniture components, methods, or technology, such as those disclosed in U.S. Pat. No. 7,213,885 entitled MODULAR FURNITURE ASSEMBLY, incorporated herein by reference in its entirety. The modular furniture components and methods disclosed in the present application may also be used in connection with numerous furniture assemblies, e.g., such as, but not limited to, any similar to those disclosed in (i) U.S. Pat. No. 9,277,826, entitled MOUNTING PLATFORM FOR MODULAR FURNITURE ASSEMBLY, (ii) U.S. Pat. No. 8,783,778, entitled MOUNTING PLATFORM FOR MODULAR FURNITURE ASSEMBLY, (iii) U.S. Pat. No. 7,963,612 entitled MODULAR FURNITURE ASSEMBLY, (iv) U.S. Pat. No. 7,547,073, entitled MODULAR FURNITURE ASSEMBLY, (v) U.S. Pat. No. 7,213,885 entitled MODULAR FURNITURE ASSEMBLY, (vi) U.S. Publication No. 2017/0367486 entitled MODULAR FURNITURE ASSEMBLY CORNER SEATING SYSTEM, (vii) U.S. Pat. No. 10,212,519 entitled ELECTRONIC FURNITURE SYSTEMS WITH INTEGRATED INTERNAL SPEAKERS, (viii) U.S. Pat. No. 10,236,643 entitled ELECTRICAL HUB FOR FURNITURE ASSEMBLIES, (ix) U.S. Pat. No. 10,143,307 entitled FURNITURE SYSTEM WITH RECLINER ASSEMBLY, and (x) U.S. Pat. No. 10,123,621 entitled FURNITURE SYSTEM RECLINER ASSEMBLY WITH SLED RAILS, each of which is incorporated herein by reference in its entirety.
These and other objects and features of the present invention will become more fully apparent from the following description and appended claims or may be learned by the practice of the invention as set forth hereinafter.
To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
The present disclosure relates to furniture and furniture systems. More specifically, the present disclosure relates to furniture spring systems. For example, in at least one embodiment of the present disclosure, a furniture spring system includes a lid configured to provide a seating surface. The lid includes a frame having two opposing frame members and a retention member disposed on a top surface of at least one of the two opposing frame members. The spring system also includes an elongate slat extending between the two opposing frame members. The slat has an elongate body with an upper surface, a lower surface, a first end, a second end, and a flexible middle portion extending between the first end and the second end. The slat also includes a catch disposed at the first or second end. The catch engages the retention member to retain the slat to the frame and is configured to slide back-and-forth relative to the retention member as the middle portion elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
Furniture spring systems described herein solve a number of problems. For example, furniture spring systems of the present disclosure provide support to users sitting or lying thereon while protecting items that may be placed or stored below. In some configurations, spring systems described herein are modular. In some configurations, spring system described herein are easily replaceable without requiring deconstruction of other furniture components. In some configurations, spring systems described herein are adjustable so that users can customize the firmness of the spring system to suit their preferences. In some embodiments, the slats of the spring system can be extendable. In some configurations, the spring systems described herein can be at least one of moveable, replaceable, and adjustable.
Embodiments of the invention, such as the examples disclosed herein, may be beneficial in a variety of respects. For example, and as will be apparent from the present disclosure, one or more embodiments of the invention can provide one or more advantageous and unexpected effects, in any combination, some examples of which are set forth below. It should be noted that such effects are neither intended, nor should be construed, to limit the scope of the claimed invention in any way. It should further be noted that nothing herein should be construed as constituting an essential or indispensable element of any invention or embodiment. Rather, various aspects of the disclosed embodiments may be combined in a variety of ways so as to define yet further embodiments. Such further embodiments are considered as being within the scope of this disclosure. As well, none of the embodiments embraced within the scope of this disclosure should be construed as resolving, or being limited to the resolution of, any particular problem(s). Nor should any such embodiments be construed to implement, or be limited to implementation of, any particular technical effect(s) or solution(s). Finally, it is not required that any embodiment implement any of the advantageous and unexpected effects disclosed herein.
Turning now to the Figures,
One or more of the bases 12 of the furniture system 10 can include a storage cavity or space to store items, such as blankets, books, electronics, or other items within the base 12. As such, in the description, base and storage base can be used interchangeably to refer to the bases of the various furniture systems. In at least one embodiment, the storage bases can be visually indistinguishable from non-storage bases and often improve the aesthetic appearance of the furniture systems over the non-storage bases. Because the bases 12 can be rearranged and reconfigured within the furniture system 10, the storage spaces provided by such bases 12 can be repositioned within a footprint of the furniture system 10 without changing, repositioning, or otherwise reconfiguring the overall footprint of the furniture system 10. Stated another way, the location of particular storage spaces within a furniture system 10 can be changed while maintaining a particular footprint or combination modules forming the furniture system 10.
Turning now to
The furniture system 10b includes a storage base 12 having a lid 22 with a spring system 24, and a cushion 16. A plurality of couplers 18 hold the various transverse members 14 to the storage base 12 as they are disposed within complementary slots 26 formed in the storage base 12 and the transverse members 14. For instance, the transverse members 14 and the storage base 12 include the slots 26 into which opposing arms of the couplers 18 are inserted to secure the storage base 12 to the various transverse members 14. The couplers 18 are removable such that the storage base 12 and the transverse members 14 can be separated, rearranged, and re-secured together. Alternatively, the base 12 and the traverse members 14 may be coupled via magnets embedded in one or both of base 12 and/or traverse members 14, optional with complementary iron-based coupling plates or connectors. The magnetic coupling assembly of U.S. Pat. No. 9,277,813 is incorporated herein by reference. In other configurations, other structures can be used to connect the storage bases 12, such as hook and loop fasteners, spring clamps, belts, or other mechanical fasteners or couplers. Additional details for a base or storage base useable with the spring system 24 can be found in U.S. patent application entitled “Furniture Storage Base” bearing, filed the same day as the present application, the entire disclosure of which is incorporated herein by this reference.
In at least one embodiment, the lid 22 is configured to be removable from the storage base 12 independently of the transverse members 14, as illustrated in
To allow the lid 22 to be easily removed from the storage base 12, the lid 22 may not be secured in any way to the storage base 12. Rather, the lid 22 can rest on top of the storage base 12 and can easily be lifted off. However, in at least one embodiment, the lid 22 can be partially or removably secured to the storage base 12. For example, in at least one embodiment, the lid 22 can be removably secured to the storage base 12 via one or more clips, clamps, or other securement means along one or multiple edges of lid 22. In such an embodiment, the lid 22 can be removably secured to storage base 12 to prevent the lid 22 from inadvertently lifting, sliding off, or otherwise disengaging from storage base 12.
Alternatively, in at least one embodiment, the lid 22 is fixed on top of the storage base 12 to allow the lid 22 to be pivoted or tilted from the storage base 12 like a door. For instance, as illustrated in
In still other embodiments, the storage base 12 can be a base member that does not provide storage space. Rather, the storage base 12 can be configured as a typical furniture base member having springs, such as the spring system 24. Whether the lid 22 is removable or permanently fixed to the storage base 12, the lid 22 can still be utilized and function as described herein.
In the illustrated embodiments of
Turning to
The recessed member 32 includes an internal chamfered edge 42 that extends at least partially around a perimeter of the base frame 30 and from a surface 44. The internal chamfered edge 42 and the surface 44 accommodate the lid 22. The surface 44, and optionally a portion of the internal chamfered edge 42, includes the slots 26 that receive the couplers 18 (
As mentioned previously, the storage cavity 20 or the interior space 34 can be defined by the walls 36, the base 38, and the lid 22. The base 38 can have an interior-facing surface 70 configured to come into contact with items stored within the storage base 12 when no fabric 80 is provided and an exterior-facing surface 72 which can come into contact with the floor or other surface where the storage base 12 is located. For instance, the base 38 includes feet 74 formed with the base 38. Webs 76 extend between the interior-facing surface 70 and the exterior-facing surface 72 and form venting holes 78 to provide airflow and decrease the weight of the base 38. As illustrated, the webs 76 form concentric rings and straight members emanating from a common central point, thereby including the venting holes 78 of different sizes. While this is one illustrative pattern of the webs, the base 38 can have different patterns of webs where the spacing between adjacent webs can be uniform or non-uniform, with sizes optionally being dependent on the size of the items to be stored within the storage base 12, and the desired weight or material usage to form the base 38. For example, toddler toys may include large blocks which can be stored in a storage base have a base with a large grid pattern or larger spacing between adjacent webs, while older children might have small toys requiring the base to having a smaller or finer-sized grid pattern.
The base 38 can be formed as monolithic structure with the feet 74 and the webs 76 formed as one-piece structure. Alternatively, the feet 74 can be separate structures from a remainder of base 38, the feet 74 being permanently or removably attached to a reminder of the base 38. In other configurations, less than all of the spaces between adjacent the webs 76 include the venting holes 76. In still other configurations, the base 38 may be solid, without the venting holes 78, so as to create a sealed compartment without any apertures. In still other configurations, the base 38 can include cross-hatching, patterning, groove formation, or other patterns, with or without venting holes, apertures, etc. In still other configurations, the Generally, the parts of storage base 12 can be formed as a single monolithic structure, i.e., as a one-piece structure, or alternatively, the parts of storage base 12 may separate pieces and assembled together to form storage base 12 as illustrated and described herein. Storage base 12 can be fabricated from a polymer, wood, metal, alloys, composites, combinations thereof, or the like.
Returning to
As illustrated, the frame 52 has an exterior support 84 and an interior support 86 separated by an upper support 88 and a transition support 90. Both the exterior support 84 and the interior support 86 extend around a perimeter of the frame 52, with the interior support 86 vertically displaced relative to the exterior support 84. Upper support 88 extends from the exterior support 84 towards an intermediate support 92 from which the transition support 90 extends to the interior support 86. The transition support 90 extends at an angle that approximates the internal chamfered edge 42 of recessed member 32 so the frame 52 can rest within the interior space 34.
To reduce overall weight of the frame 52, while maintaining strength and rigidity, the frame 52 includes a number of walls or webs forming spaces or compartments. This allows the frame 52 to be formed as a single monolithic structure, i.e., as a one-piece structure, or alternatively as a number of parts assembled together to form the frame 52. Additionally, the frame 52 can be fabricated from a polymer, wood, metal, alloys, composites, combinations thereof, or the like.
As illustrated in
Transition support 90 also includes a plurality of webs 104 with spaces 106. An upper surface of the webs 98 lie in the same plane, while upper surfaces of the webs 102 lie in another plane transverse to the upper support 88. It is understood, however, that the upper surfaces of the webs 98 need not lie in the same plane and the upper surfaces of the webs 102 need not lie in the same plane and that plane need not be transverse to the plane associated with the upper support 88.
As illustrated in
As illustrated in
When the spring system 24 is unloaded, the slats 50 may maintain a flat position and sit in an even plane with the frame 52. When the slats 50 are in a flat, unloaded position, the catch 130 may extend beyond the securing edge 102 such that the catch 130 may not come into contact with the securing edge 102. When the spring system 24 is loaded or weighted, however, the slats 50 may bend or flex, positioning the center of the slat 52 below that of the frame 52. When loading occurs and the slats 50 are flexed, the flexion of the slats 50 causes the distance between the first end 58 and the second end 60 of the slats 50 to shorten, thereby causing the catch 130 to tension on the securing edge 102 of the frame 52. The flanges 114 engage with the retention grooves 134 allowing the flanges 114, and more generally the catch 130, to slide within the track defined by the flanges 114 and the walls or webs 98 of the securing compartments 100.
The slats 50 can be made of any stiff material that can be flexed to accommodate a weight load of up to 250 lbs, more preferably up to 300 lbs, more preferably up to 350 lbs, more preferably up to 400 lbs, more preferably up to 450 lbs, or more preferably up to 500 lbs. For instance, the slats 50 can be from a polymer, wood, metal, alloys, composites, fiberglass, carbon fiber, and combinations thereof, or the like.
The slats 50 can flex in a bow-shape when loaded and return to an initial flat or elongate shape when unloaded. In some embodiments, the slats 50 can include a graduating thickness, where the middle portion 62 of the slat 50 is the thickest portion of the slat 50. The upper surface 64 of the slat 50 where the cushion 16 can be placed can maintain a continuous, flat surface, while the lower surface 66, or underside or bottom side, of the slat 50 can exhibit a curved shape to allow for greater thickness in the middle portion 62. The greater thickness in the middle portion 62 of the slats 50 may increase structural integrity of the slats 50 and prevent or slow wear by users of the furniture system over time. Varying a thickness of the middle portion 62, and/or portions of the slats 50 near the first end 58 and second end 68, can vary the biasing force; areas of the slats 50 with greater thickness being more resistant to bending and so the biasing force is greater than a situation where areas of the slats 50 are thinner. Additionally, varying a composition of the material forming the frame 52, including the slat 50, can also vary the biasing force.
Generally, the slats 50 can have a length ranging from about 10.0″ (10 inches) to about 80.0″ (80 inches), from about 12.0″ to about 78″, and from about 14″ to about 75″. A thickness in the middle portion 62 can range from about 0.060″ to 2.0″, from about 0.080″ to 1.0″, or from about 0.10″ to 0.9″. A thickness at one or both of the first end 58 and second end 68, closer to the middle portion than the catch 130, can range from about 10% of the max thickness of the middle portion 62 of the slats 50, to about 70%, from about 20% to about 65%, or from about 30% to about 60%. The slats 50 can have varying thicknesses along the length of the slats 50. The varying thickness along the length can provide reinforced support in certain locations along the slat, while providing for a greater range of flexibility at other locations along the length of the slats 50 as discussed herein.
In some embodiments where the slats 50 are made of metal, the thickness of the slats 50 can be substantially less than the thicknesses recited above. For example, thickness of the middle portion 62 of a slat 50 made of metal can range from about 0.00003″ to about 0.25″, from about 0.0003″ to about 0.20″, or from about 0.003″ to about 0.15″.
Generally, the slats 50 have a general uniform width along their width, as illustrated in
As illustrated, the spring system 24a cooperates with a furniture cushion 16. The furniture cushion 16 can sit on top of the lid 22 of the spring system 24a including a frame 52a and a plurality of slats 50a. The slats 50a can have a catch 130a at either one or both ends of the slats 50a. The catch 130a includes retention protrusions 140a that extends outwardly from the sides 132a. The retention protrusions 140a are secured within the walls or webs 98a of the securing compartments 100a, and more particularly within slots 142a, when the catch 130a is positioned within the securing compartment 100a. While the retention protrusions 140a maintain engagement between the slats 50a and the frame 52a, because the slats 50a can be disengaged from the frame 52a, such as when the slats 50 lose structural integrity, such that flexion is reduced, the slats 50a can be individually replaced. This allows a user to repair and/or replace individual slats and reduces the need to replace the furniture as a whole. The retention protrusions 140a, either alone or in combination with the slots 142a, is another example of a retention member or a means for retaining the slat in contact with the frame.
When the spring system 24a is unloaded, as illustrated in
The slats 50a can be made of any stiff material that can be flexed to accommodate a weight load of up to 250 lbs, more preferably up to 300 lbs, more preferably up to 350 lbs, more preferably up to 400 lbs, more preferably up to 450 lbs, or more preferably up to 500 lbs. For instance, the slats 50a can be from a polymer, wood, metal, alloys, composites, fiberglass, carbon fiber, and combinations thereof, or the like.
The slats 50a can flex in a bow-shape when loaded and return to an initial flat or elongate shape when unloaded. In some embodiments, the slats can include a graduating thickness, where the middle portion 62a of the slat 50a is the thickest portion of the slat 50a. The upper surface 64a of the slat 50a where the cushion 16 (
Generally, the slats 50a can have a length ranging from about 10.0″ to about 80.0″, from about 12.0″ to about 78″, and from about 14″ to about 75″. A thickness in the middle portion 62a can range from about 0.060″ to 2.0″, from about 0.080″ to 1.0″, or from about 0.10″ to 0.9″. A thickness at one or both of the first end 58a and second end 68a, closer to the middle portion than the catch 130a, can range from about 10% of the max thickness of the middle portion 62a of the slats 50a, to about 70%, from about 20% to about 65%, or from about 30% to about 60%. The slats 50a can have varying thicknesses along the length of the slats 50a. The varying thickness along the length may provide reinforced support in certain locations along the slat, while providing for a greater range of flexibility at other locations along the length of the slats 50a as discussed herein.
In some embodiments where the slats 50a are made of metal, the thickness of the slats 50a can be substantially less than the thicknesses recited above. For example, thickness of the middle portion 62a of a slats 50a made of metal can range from about 0.00003″ to about 0.25″, from about 0.0003″ to about 0.20″, or from about 0.003″ to about 0.15″.
Generally, the slats 50a have a general uniform width along their width, as illustrated in
The first end 58b and the second end 60b of the slats 50b includes a catch 130b that is formed at right angles to a middle portion 62b, although other angles less or greater than 90 degrees are possible. The first end 58b and the second end 60b can extend towards the outside of the frame 52b beyond a securing edge 102b when the slats 50b are unloaded or unweighted. The frame 52b can include securing compartments 100b defined by walls or web 98b. The securing compartments 100b may be of equal size and/or equal spacing. In other embodiments, the securing compartments 100b can vary in size to accommodate different size slats and/or different slat patterns or configurations. While the retention pin 146b maintains engagement between the slats 50b and the frame 52b, because the slats 50b can be disengaged from the frame 52d, such as when the slats 50d loose structure integrity, such that flexion is reduced, the slats 50d can be individually replaced. This allows a user to repair and/or replace individual slats and reduces the need to replace the furniture as a whole.
Loading on the spring system 24b with a force or load L, as illustrated in
As with the other embodiments, the slats 50b can be made of any stiff material that can be flexed to accommodate a weight load of up to 250 lbs, more preferably up to 300 lbs, more preferably up to 350 lbs, more preferably up to 400 lbs, more preferably up to 450 lbs, or more preferably up to 500 lbs. For instance, the slats 50b can be from a polymer, wood, metal, alloys, composites, fiberglass, carbon fiber, and combinations thereof, or the like.
The slats 50b can flex in a bow-shape when loaded and return to an initial flat or elongate shape when unloaded. In some embodiments, the slats can include a graduating thickness, where the middle portion 62b of the slat 50b is the thickest portion of the slat 50b. The upper surface 64b of the slat 50b where the cushion 16 (
Generally, the slats 50b can have a length ranging from about 10.0″ to about 80.0″, from about 12.0″ to about 78″, and from about 14″ to about 75″. A thickness in the middle portion 62b can range from about 0.060″ to 2.0″, from about 0.080″ to 1.0″, or from about 0.10″ to 0.9″. A thickness at one or both of the first end 58b and second end 68b, closer to the middle portion than the catch 130b, can range from about 10% of the max thickness of the middle portion 62b of the slats 50b, to about 70%, from about 20% to about 65%, or from about 30% to about 60%. The slats 50b can have varying thicknesses along the length of the slats 50b. The varying thickness along the length may provide reinforced support in certain locations along the slat, while providing for a greater range of flexibility at other locations along the length of the slats 50b as discussed herein.
In some embodiments where the slats 50b are made of metal, the thickness of the slats 50b may be substantially less than the thicknesses recited above. For example, thickness of the middle portion 62b of a slats 50b made of metal can range from about 0.00003″ to about 0.25″, from about 0.0003″ to about 0.20″, or from about 0.003″ to about 0.15″.
Generally, the slats 50b have a general uniform width along their width, as illustrated in
When the spring system 24c is unweighted, as illustrated in
As with the other embodiments, the slats 50c may be made of any stiff material that can be flexed to accommodate a weight load of up to 250 lbs, more preferably up to 300 lbs, more preferably up to 350 lbs, more preferably up to 400 lbs, more preferably up to 450 lbs, or more preferably up to 500 lbs. For instance, the slats 50c can be from a polymer, wood, metal, alloys, composites, fiberglass, carbon fiber, and combinations thereof, or the like.
The slats 50c may flex in a bow-shape when loaded and return to an initial flat or elongate shape when unloaded. In some embodiments, the slats may include a graduating thickness, where the middle portion 62c of the slat 50c is the thickest portion of the slat 50c. The upper surface 64c of the slat 50c where the cushion 16 (
Generally, the slats 50c can have a length ranging from about 10.0″ to about 80.0″, from about 12.0″ to about 78″, and from about 14″ to about 75″. A thickness in the middle portion 62c can range from about 0.060″ to 2.0″, from about 0.080″ to 1.0″, or from about 0.10″ to 0.9″. A thickness at one or both of the first end 58c and second end 68c, closer to the middle portion than the catch 130c, can range from about 10% of the max thickness of the middle portion 62c of the slats 50c, to about 70%, from about 20% to about 65%, or from about 30% to about 60%. The slats 50c can have varying thicknesses along the length of the slats 50c. The varying thickness along the length may provide reinforced support in certain locations along the slat, while providing for a greater range of flexibility at other locations along the length of the slats 50c as discussed herein.
In some embodiments where the slats 50c are made of metal, the thickness of the slats 50c may be substantially less than the thicknesses recited above. For example, thickness of the middle portion 62c of a slats 50c made of metal can range from about 0.00003″ to about 0.25″, from about 0.0003″ to about 0.20″, or from about 0.003″ to about 0.15″.
Generally, the slats 50 have a general uniform width along their width, as illustrated in
When the spring system 24d is unloaded or unweighted, as illustrated in
As with the other embodiments, the slats 50d may be made of any stiff material that can be flexed to accommodate a weight load of up to 250 lbs, more preferably up to 300 lbs, more preferably up to 350 lbs, more preferably up to 400 lbs, more preferably up to 450 lbs, or more preferably up to 500 lbs. For instance, the slats 50d can be from a polymer, wood, metal, alloys, composites, fiberglass, carbon fiber, and combinations thereof, or the like.
The slats 50d may flex in a bow-shape when loaded and return to an initial flat or elongate shape when unloaded. In some embodiments, the slats may include a graduating thickness, where the middle portion 62d of the slat 50d is the thickest portion of the slat 50d. The upper surface 64d of the slat 50d where the cushion 16 (
Generally, the slats 50d can have a length ranging from about 10.0″ to about 80.0″, from about 12.0″ to about 78″, and from about 14″ to about 75″. A thickness in the middle portion 62d can range from about 0.060″ to 2.0″, from about 0.080″ to 1.0″, or from about 0.10″ to 0.9″. A thickness at one or both of the first end 58d and second end 68d, closer to the middle portion than the catch 130d, can range from about 10% of the max thickness of the middle portion 62d of the slats 50d, to about 70%, from about 20% to about 65%, or from about 30% to about 60%. The slats 50d can have varying thicknesses along the length of the slats 50d. The varying thickness along the length may provide reinforced support in certain locations along the slat, while providing for a greater range of flexibility at other locations along the length of the slats 50d as discussed herein.
In some embodiments where the slats 50d are made of metal, the thickness of the slats 50d may be substantially less than the thicknesses recited above. For example, thickness of the middle portion 62d of a slats 50d made of metal can range from about 0.00003″ to about 0.25″, from about 0.0003″ to about 0.20″, or from about 0.003″ to about 0.15″.
Generally, the slats 50d have a general uniform width along their width, as illustrated in
In the embodiment of
The slats 50e are formed with the frame 52e via the first end 58e and the second end 60e of the slats 50e. The first end 58e and the second end 60e are form with an interior support 86e of the frame 52e. The slats 50e form a bow-shape, with a center or mid-point 158e, or apex of the slats 50e is level with a top surface of the frame 52e. The slats 50e may have a mid-point 158e level or even with the height of the frame 52e to allow the furniture cushion 16 to sit comfortably or flat on top of the spring system 24e when the system is unloaded. When a load is applied downward on the spring system 24e, as illustrated in
As with the other embodiments, the slats 50e may be made of any stiff material that can be flexed to accommodate a weight load of up to 250 lbs, more preferably up to 300 lbs, more preferably up to 350 lbs, more preferably up to 400 lbs, more preferably up to 450 lbs, or more preferably up to 500 lbs. For instance, the slats 50e can be from a polymer, wood, metal, alloys, composites, fiberglass, carbon fiber, and combinations thereof, or the like.
Generally, the slats 50e can have a length ranging from about 10.0″ to about 80.0″, from about 12.0″ to about 78″, and from about 14″ to about 75″. A thickness at one or both of the first end 58e and second end 68e, closer to the middle portion than the catch 130e, can range from about 0.060″ to 2.0″, from about 0.080″ to 1.0″, or from about 0.10″ to 0.9″. A thickness in the middle portion 62e can range from about 10% of the max thickness of the thickness at one or both of the first end 58e and the second end 68e of the slats 50, to about 70%, from about 20% to about 65%, or from about 30% to about 60%. The slats 50e can have varying thicknesses along the length of the slats 50e. The varying thickness along the length may provide reinforced support in certain locations along the slat, while providing for a greater range of flexibility at other locations along the length of the slats 50e as discussed herein.
In some embodiments where the slats 50 are made of metal, the thickness of the slats 50 may be substantially less than the thicknesses recited above. For example, thickness of the middle portion 62 and or thickness of one or both of the first end 58e and the second send 68e of slats 50 made of metal can range from about 0.00003″ to about 0.25″, from about 0.0003″ to about 0.20″, or from about 0.003″ to about 0.15″.
Generally, the slats 50e have a general uniform width along their width, as illustrated in
In some embodiments, the frame and spring system described herein can be formed onto, or fixedly attached to a furniture base. In some embodiments, the spring system may be formed onto or fixedly attached to a furniture base without the use of a frame. In another embodiment, the frame may be formed onto or fixedly attached on all sides to a furniture base, wherein the frame may provide attachment points to which slats may be selectively attached and arranged in any manner described above. In these embodiments, the spring system and/or frame may not be removable from the furniture base. Similarly, the frame and/or spring system may not be moved to allow for storage within the furniture base. Rather, this configuration may only provide support for a user's weight applied to the furniture.
In some embodiments, the lid and spring system described herein can be integrated into a cushion.
The bottom side 230 of the cushion 216 can include a flap 236 or selectively openable portion of the liner 234. The edges or corners of the spring system 224 may be secured within pockets 238 on an interior side of the liner 234 on the bottom side 230 of a cushion 216. Stated another way, the pockets 238 are formed between the fill member 232 and the liner 234 and can receive the spring system 224.
Once the spring system 224 is positioned into the pocket 238 of the cushion 216, the flap 236 may cover and secure the spring system 224 inside the cushion 216, as shown in
The spring system of the present disclosure may be utilized in various types of modular furniture, including part of a bed system or modular bed system. The modular system advantageously simplifies manufacturability, durability through flipping, relocating & replacing worn modules, and simplifies packing/shipping. The modular bed system allows modular components to be used to resize a bed overtime. For instance, the modular components forming a twin bed can be utilized to form Full, Queen, King, and California King beds by adding other modular components.
With reference to
The modular components 310 may be detachably coupled through the use of securing mechanisms 342 (
The modular mattress 316 can include materials such as foam, polyurethane, memory foam, pocket coils, DURAFOAM, high-density foam, and other materials used in mattress construction. In some embodiments, the modular mattress 316 may be a dual-comfort module, where a first side of the modular mattress 316 provides soft or light support, and a second side provides medium or firm support. The consumer may turn the modular mattress 316 so that the preferred side of the dual-comfort module is facing up to form the sleeping surface. The advantage of this feature is that the consumer may adjust the support level of the mattress as often as they might prefer.
In some embodiments, the spring system 324 may be incorporated into the interior of a modular mattress 316 or mattress module 310. For example, mattress materials such as foam can be molded on to and cover the spring system 324 on all surfaces so that the spring system 324 is fixed inside of a mattress module 310.
Individual component modules 310 and/or the bed system 300 as a whole, can include removable toppers 340 (
As mentioned above, the modular components 310 forming a twin bed can be utilized to form Full, Queen, King, and California King beds by adding other modular components. Some embodiments utilize modular components 310 complying with an equation:
y=2x
where, x is the component width (W) and y is the component length (L).
In the bed system 300a of
The modular components 310A and 310B, with associated support structure, mattress modules, and spring systems, may be manufactured in a number of sizes to allow a user to incrementally add components to create a particular bed size. For example, and as illustrated in
25″ × 12.5″
The modular combinations described above are non-limiting examples of modular component combinations which may be utilized to create the bed systems. As such, a modular component can have a length from about 4.0″ to about 85.0″, from about 4.5″ to about 78.0″, from about 5.0″ to about 75.0″, from about 5.5″ to about 72.5″, or from about 6.0″ to about 70.0″. The modular component can have a width from about 3.0″ to about 85.0″, from about 3.5″ to about 78.5″, from about 4.0″ to about 75.0″, from about 4.5″ to about 72.5″, or from about 5.0″ to about 70.0″.
The number and size of the modular components 310 used may be dependent on the comfort and support preferences of a user. For example, a user requiring more variation in support (i.e. firm support, soft support, etc.) may prefer a configuration utilizing modular components 310 in order to increase/decrease the degree of support for different areas of the user's body. In such a case, the modular component 310 near the user's hips might have firmer support than the modular components 310 near the user's head or feet. Alternatively, the modular component 310 near the user's hips might have softer support than the modular components 310 near the user's head or feet. Each modular component 310 used in a particular bed system 300 can have the same or different support properties. Where two or more persons share the same bed system 300, each user may customize their portion of the bed system 300 to their support preference. This feature may also be beneficial in places like hotels, guest rooms, and other short-term use situations where the user of the mattress module might change frequently and may prefer a different degree of comfort and support relative to other uses.
In addition to changing the particular modular component 310, and any of the mattress module 316 and the spring system 324, a density of modular components 310 can also vary to change the support properties. For instance, for selective support a higher number of modular components 310 can be used to form the bed area. Conversely, a user who prefers uniform support may prefer a bed system 300 having fewer modular components 300 which may simplify and/or decrease the degree of variation.
In some embodiments, the modular components described above may, in certain combinations, require that a casing be applied to achieve the correct mattress size. The casing may be sized and shaped to compensate for missing length and/or width and/or depth needed to form a standard size mattress. For example, in one embodiment shown in
In one embodiment, in order to form a mattress, mattress modules 310a are configured inside of the casing 600. The upper section 601 of the casing 600 is then joined to the lower section 602 of the casing 600 via the connector 603 in order to close the casing. In the embodiment shown in
In some embodiments, the flap 605 can also function as a mattress topper and can be formed of down, memory foam, etc. to provide an additional degree of customization and support to the mattress modules 310a. When the flap 605 or the upper section 601 of the casing 600 functions as a topper, it can also provide continuity between mattress modules 310a and prevent splitting or sinking between modules.
In one embodiment, if needed to fill the entire space of the casing 600, an extender 604 is fixed within the interior of the lower portion 602 of the casing 600. In some embodiments, the extender portion 604 can be selectively removeable and/or repositionable within the casing 600. In casing 600, the extender 604 is positioned at an end of the casing 600 in order to extend the length of the mattress formed by the mattress modules 310a. In some embodiments, the extender 604 may be used to expand the width of the mattress. The extender 604 can be made of materials generally used in mattress construction such as foam, foam alternatives, polyester blends, quilting, padding, gel, and other similarly resilient materials. The extender 604 must be stiff enough to support a user and not collapse under weight, while providing a comfortable surface. The mattress modules 310a can be placed side by side within the casing 600, and are preferably flush with each other and the extender 604, if an extender is employed, so as to avoid gaps in the completed mattress.
In another embodiment, however, an extender is not employed, such as when the mattress modules are flush with each other and fill the casing without requiring an extender. This may occur, for example, when module(s) forming a twin XL sized mattress, or other sizes, are placed within an appropriately-spaced, compatible casing that may not require extenders to achieve a desired size.
The casing for a twin-size mattress can add a width at least from about 0.5″, from about 1.0″, or from about 1.5″. For example, a twin-size casing may add a width from about 0.5″ to about 2.0″, or from about 1.0″ to about 1.75″. A casing for a twin XL size mattress may add only length, while some twin XL casings may add both length and width to several modules forming a mattress. As such, a casing for a twin XL size mattress may add at least about 3.0″ in length, at least about 4.0″ in length, or at least about 5.0″ in length. For example, a twin XL casing may add a length of about 3.0″ to about 6.0″, about 3.5″ to about 5.5″, or about 4.0″ to about 5.0″. A casing for a twin XL may also add the width for a twin-size mattress as recited above.
A casing for a full-size mattress can add a width from at least 0.5″, from about 1.0″, or from about 1.5″. For example, a full-size casing may add a width from about 0.5″ to about 3.0″, or from about 1.0″ to about 2.5″. A casing for a full XL size mattress may add only length, while some full XL casings may add both length and width to several modules forming a mattress. As such, a casing for a full XL size mattress may add at least about 3.0″ in length, at least about 4.0″ in length, or at least about 5.0″ in length. For example, a full XL casing may add a length of about 3.0″ to about 6.0″, about 3.5″ to about 5.5″, or about 4.0″ to about 5.0″. A casing for a full XL may also add the width for a full-size mattress as recited above.
A casing for a queen size mattress can add a length from at least about 3.0″, about 4.0″, or about 5.0″. For example, a queen size casing may add a length from about 3.0″ to about 7.0″, from about 4.0″ to about 6.5″, or from about 4.5″ to about 6.0″. A casing for a king size mattress can add a length and/or width to several mattress modules combined to form a king size bed. A king size mattress casing can add a length from at least about 3.0″, about 4.0″, or about 5.0″. For example, a king size casing may add a length from about 3.0″ to about 7.0″, from about 4.0″ to about 6.5″, or from about 4.5″ to about 6.0″. A king size casing can add a width from at least about 1.0″, about 2.0″, or about 3.0″. For example, a king size casing may add a width from about 1.0″ to about 4.0″, from about 2.0″ to about 3.5″, or from about 3.0″ to about 4.0″.
A casing for a California king size mattress can add a length to several mattress modules combined to form a California king size bed. A California king size mattress casing can add a length from at least about 7.0″, about 8.0″, or about 9.0″. For example, a California king size casing may add a length from about 7.0″ to about 12.0″, from about 8.0″ to about 11.00″, or from about 9.0″ to about 10.0″.
The casing may be formed of materials used in mattress construction such as foam, polyurethane, memory foam, pocket coils, Durafoam, high-density foam, or the like. Some casings may be a rigid casing in order to support the weight of a user without collapsing.
Turning now to
As depicted the spring system 424 includes a frame 452 and slats 450. The frame 452 is illustrated supported by a plurality of support structure 412, such as a base described herein. The slats 450 can attached to the frame 452 through the connections described earlier, such as catches and securing edges, retentions pins and elongate openings, projections and slots, plates, elongate openings and fasteners, being integrally formed as a monolithic one-piece structure, combinations therefore, or the like.
To accommodate for changing a size of the bed system 400, such as when a consumer may initially configure a twin-size bed for a child and as the child grows the bed system 400 is extended to the width of a full-size bed, the frame 452 can be replaced with a larger size and the slats 450 telescope to extend to the larger size. As illustrated in
In another configuration, as illustrated in
In another configuration, as illustrated in
As illustrated, the base 512 includes walls 536 with frame segments 552 having an exterior support 584, and interior support 586, and an intermediate support 592 similar to the other exterior supports, interior supports, and intermediate supports. In contrast to the previously described exterior supports, interior supports, and intermediate supports, the exterior support 584, the interior support 586, and the intermediate support 592 extend partially around the base 512. This accommodates for extension base member 520 that also includes the exterior support 584, the interior support 586, and the intermediate support 592.
The extension base member 520 mounts to the walls 536 to position the frame segment 552 in alignment with the other frame segments 552. The extension base member 520 can attach to the walls through attachment features 522, such as magnets, hook and loop fasteners, clips, other mechanical connectors, or the like. This allows a user to apply a variety of interchangeable, decorative panels or veneers (i.e. wood, faux wood, metal, patterns, etc.) to the exterior of the base 512.
The bed frame upon which the mattresses of the present invention rest can be a variety of different forms.
The base modules 802, as shown in
Additional base modules 802 can be added to or substituted from the original set of base modules 802 of
The base modules 802 can be selectively secured together by couplers 808 inserted into slits 806 on associated base modules 802. The telescoping corners 804 can have slits 806 located at the telescoping corner ends 804, which can maintain the connection between a corner end 804 and a base module 802 by use of a coupler 808 inserted into corresponding slits 806 on the base module 802 and corner end 804. This coupling mechanism can allow for the telescoping corners 804 to be extended without having to detach them from adjacent base modules 802. Further examples of such telescoping mechanisms are shown in
In some embodiments, the telescoping corners 804 can include mechanisms which allow a user to extend a telescoping corner 804 and then lock it in place to maintain a specific size bed frame 800. The locking mechanism can engage automatically upon the telescoping corner 804 being extended to a particular length, or the locking mechanism can be engaged manually by the user. The locking mechanism can include button clips, ball lock pins, clamps, telescoping clamps, twist lock clamps, or the like.
The bed frame 800 (and/or the bed frames disclosed in and discussed with respect to
The slats 810 can have similar retention member components at ends 814 of slats 810 to the retention members discussed with respect to
Bed frame 800 can be made from any of the materials discussed above, such as polymer, wood, fiberglass, metal, alloys, composites, carbon fiber, and combinations thereof, or the like. The base modules 802 comprising the adjustable bed frame 800 can comprise any of the aforementioned materials and can all be uniform in length. For example, the length of a base module can range from about 15.0″ to about 35.0″, or from about 20.0″ to about 30.0″, or from about 22.5″ to about 28.5″.
In one embodiment using the adjustable frame 800, a mattress system 850 as shown in
The mattress 852 of system 850 may be comprised of a foam material, for example, while the integrated slats of system 850 may be comprised of the same foam material formed in a different density or hardness. Optionally, different materials may be integrally-molded to form the integrated mattress/spring assembly of
One or more slats 856 form a spring system 854 that supports the mattress 852 on a bed frame, such as adjustable bed frame 800. Thus, in one embodiment the slats 856, either within cover 858 or with cover 858 removed, are selectively mounted onto respective securing edges 812 of adjustable frame 800. Thus, slats 856 and mattress 852 can be integrally-formed as a mattress/spring assembly in the form of a single molded member. The resulting single molded member can be selectively mounted onto the adjustable frame 800 as a mattress/spring assembly. Cover 858 is selectively mounted on the mattress/spring assembly to form mattress system 850.
Turning now to
These uniformities in geometries and size of the modules of the present invention, as shown in
Thus, the modular, adjustable bed frame systems of the present invention artfully allow for both standardization of certain components (e.g., uniform-length support modules and corner modules having substantially the same footprint dimensions) as well as customization when customization is desired (e.g., filler modules, telescoping members, and/or elongate end modules).
The modular bed frame configurations 900a-900g, as shown in
Corner modules (e.g., corner blocks 914), connect to two different support modules (e.g., keystone blocks 922) that are positioned at a transverse angle to each other, as shown in
Depending on a particular bed size configuration, a combination of keystone blocks and corner blocks may result in a number of spaces or gaps between sections of a particular modular bed frame. One aspect of this invention is the ability enabled by the present invention to fill gaps of varying sizes that may occur, for example, as the user changes the bed frame from a smaller bed frame to a larger bed frame.
A feature of at least some embodiments of the present invention is to provide systems and methods for filling those gaps 901, in order to provide a continuous, gap-less, bed frame structure when the bed frame size is changed from one size to another. The present invention is thus directed to methods and systems for filling gaps 901 of different sizes in different sized bed frame configurations. The present invention enables the use of corner modules 914 and support modules 922 of standard sizes and configurations and associated modules that can be readily adjusted to fill in gaps that occur when a bed size changes from one size to another.
In
Depending upon a particular size bed frame desired by a user, modular bed frame configurations 900 including keystone modules 922 and corner modules 914 may result in gaps 901 in the modular bed frame 900, which may be too small to fill with a keystone module 922 having a given standard length (e.g., 15 inches, 18 inches, 20 inches, 21 inches, 26 inches, or the like). As shown in
As shown in
As shown in
With continued reference to
As shown in
As further shown in
With reference now to
The keystone blocks 922 are uniform in length. For example, a keystone block 922 can have a length from about 15.0″ to about 30.0″, from about 18.0″ to about 28.0″, from about 20.0″ to about 27.0″, or from about 21.0″ to about 26.0″. The height of the keystone block 922 from the base to the top surface 940 can be, for example, from about 7.0″ to about 18.0″, from about 9.0″ to about 16.0″, from about 11.0″ to about 15.0″, or from about 12.0″ to about 14.0″. The width of a keystone block 922 measured at its widest point between the interior side 942 and the exterior side 944 can, for example, have a width of about 5.0″ to about 10.0″, about 6.0″ to about 9.0″, or about 7.0″ to about 8.0″.
As further shown in
A shown in
Corner blocks 914 can have at least one or more slits 924 positioned along adjacent edges of the corner block 914 to accept a coupler 915, allowing for the selective attachment of a corner block 914 to a keystone block 922.
Corner blocks can also have an undercut section 950 (
As discussed with respect to
For example, with reference to
where,
The “Total Dimension Measured” can be the total length of a side of a modular bed frame or the total width of a modular bed frame, as depicted in
The Number of Gaps can vary based on the chosen method for filling the gaps in the frame. For example, when utilizing a telescoping corner block, it can be advantageous to decrease the size of a single gap by distributing the Gap between a number of smaller gaps along a side of the bed frame. Conversely, when utilizing a filler block 918 in a configuration where a single filer block is used, NG can equal 1, corresponding to there only being one gap. However, in configurations having more than one filler block 918 forming a side of a bed frame, NG can equal greater than 1.
For example, with reference to
where 39″ is the width of a twin-sized bed frame to be measured, 21″ is the length of a keystone block (e.g., a block 922), 1 is the number of keystone blocks 922 used to form the width of the twin sized bed frame 900a, 6″ is the length of each of the corner blocks (e.g., corner blocks 914), and 2 is the Number of Gaps desired to be filled. The 3″ gap can be filled through a variety of methods, such as telescoping corners, filler blocks, etc.
The Gap and Number of Gaps is calculated for one side of a bed frame, therefore, the resulting Gap calculation can be applied to an opposing side of the bed frame having the same length. The Gap and Number of gaps can be calculated for each of the widths and lengths of the bed frame, as reflected in
The following table provides various possible examples of Gap distance calculated assuming a single Gap using the equation of
In order to fill the resulting gap, which may be divided into multiple gaps, the corner blocks 914 may be configured with at least one or more telescoping members 916 which can extend from a corner block and be selectively connected to an adjacent keystone block 922.
For example, as shown in
In another embodiment, one or more uniform-length support modules may have a telescoping mechanism that couples to another uniform-length support module or corner module. In one embodiment, a corner block 914 and a keystone block 922 can be moved in opposite directions from one another to expose the telescoping member 916 housed within them, causing a length of a modular bed frame to be extended or elongated to create a secondary configuration of a bed frame which is larger relative to an initial size of a bed frame before a length of the bed frame is extended.
As shown in the
The exterior-facing sides of the modular components, such as the keystone blocks 922, corner blocks 914, filler blocks 918, and elongate end blocks 920 can include features (not shown) for attaching veneers or aesthetic coverings to the modular bed frame 900. Fasteners such as hook and loop fasteners, clips, buttons, snaps, magnets, or the like can be used to attach veneers or aesthetic coverings to the exterior sides of the modular bed frame 900.
Although the uniform-length support modules 922 and corner modules 914 of the present invention can be in the form of keystone blocks and corner blocks, such as discussed above, a variety of other forms of support modules and corner modules may be employed in order to accomplish the goals of providing various types of modular bed frame systems.
For example,
Returning to
The platform blocks 960 and the platform corners 962 can include a top surface 974, wherein at least one side of the top surface 974 includes a notched edge 966 extending the length of the platform block 960 or platform corner 962. The notched edge 966 can include a plurality of slat connection points 926 to allow for the attachment of slats 913 between opposing sides of the bed frame 980. The platform blocks 960 and platform corners 962 can include at least one or more slits 924 situated on opposing ends of the platform pieces to allow the pieces to be selectively attached to one another via attachment devices such as couplers 915.
The platform corners 962 can have a receiving space 968 for receiving a telescoping member 964. The platform blocks 960 can have a similarly-shaped receiving space 970 to allow for a telescoping member 964 to be housed within and/or between a platform corner 962 and a platform block 960. The telescoping member 964 can have a plurality of slits 934 providing for linking of a platform corner 962 to a platform block 960 when the bed frame 980 is extended to a larger size. For example,
The bed frame 980 can be expanded, as illustrated in
In yet another aspect of the present invention,
In the long configuration the length of the corner module 1004a, 1004b is substantially aligned with a longitudinal axis of the rail 1002. In the short configuration the length of the corner module 1004a, 1004b is substantially perpendicular to the longitudinal axis of the rail.
In the long configuration, the length of the corner module 1004a, 1004b is substantially aligned with a longitudinal axis of the rail 1002 in order to extend the length of the rail 1002 to its longest possible length. In a short configuration, the length of a corner module 1004a, 1004b is substantially perpendicular to the longitudinal axis of the rail 1002 so that the width of the corner module 1004a, 1004b (i.e., the shorter portion) is the amount of length added to the total length of the rail 1002.
Thus, as reflected in
In some embodiments, the rail 1002 can be provided segmented into two or more sections and the sections can be assembled together to form a rail 1002. The rail 1002 may also be formed of blocks or segments similar to the keystone blocks 922 described above. It may be advantageous to have a rail which can be segmented for easier shipping, as well as easier re-configuration and re-positioning of the bed frame by the user.
As shown in
For example, as shown in
The rotatable corner modules 1004a, 1004b can have a length of about 5.0″ to about 20.0″, from about 8.0″ to about 15.0″, or from about 10.0″ to about 12.0″, for example. The rotatable corner modules can have a width of about 2.0″ to about 10.0″, about 4.0″ to about 8.0″, or about 5.0″ to about 7.0″ for example. It may be advantageous for the corner modules 1004 to have a rectangular shape, or an “L” configuration, or another configuration wherein the length and the width of the corner modules 1004a, 1004b are not of equal distance, which allows for the rotatable size adjustment feature of the corner modules 1004a, 1004b.
The rotatable corner modules 1004a, 1004b have slits 1006 on the top surface 1008 of the rotatable corner modules 1004a, 1004b which align with slits 1006 on the top surface 1010 of the rail 1002 in order to selectively connect the rotatable corner modules 1004a, 1004b to the rail 1002. The rotatable corner modules 1004a, 1004b can be selectively attached to the rail 1002 by way of attachment mechanisms described above, such as couplers 915 inserted into adjacent slits 1006 on the rotatable corner module 1004a, 1004b and on the respective rail 1002.
The rail 1002 can include a plurality of slat connection points 1012 for the attachment of slats 1014, for example, the telescoping slats 810 or other slats as previously described herein. The rail 1002 can be made of materials including wood, wood composite, polymer, fiberglass, metal, alloys, composites, carbon fiber, and combinations thereof, or the like. The rail 1002 can have a length of about 55.0″ to about 70.0″, or from about 60.0″ to about 65.0″, for example. By way of example, the rail 1002 may be made up of smaller segments, e.g., having a segment length of no more than 36 inches, for example (e.g., up to 30 inches, up to 26 inches, up to 21 inches, up to 20 inches, etc.) Such segmentation can facilitate easier shipping, packaging, and storage.
In order to achieve further modularity and flexibility and to accommodate different sized beds and bed frames, the width of a bed frame 1000a (e.g., having at least one rail 1002 and rotatable corner blocks 1004a, 1004b) can be framed with an adjustable headboard and/or adjustable footboard, each of which are examples of adjustable “end boards”.
To form a modular bed frame system of the present invention, any of the bed frames described herein may be used in conjunction with a modular end board, e.g., a modular headboard or modular foot board, as described herein. The modular end boards of the present invention, e.g., as shown in
For example, an adjustable end board, e.g., headboard 1050, shown in
In another embodiment of an adjustable end board, e.g., headboard 1052 of
In some embodiments, the posts 1056 and/or posts 1054, may include notches, pins, pegs, dials or the like configured to assist a user in expanding the headboard 1052 to the correct bed size and locking the headboard size once the headboard 1052 is the correct width for the desired bed size.
The frame assemblies of
Each of headboards 1050, 1052 and/or footboard 1050b can include a plurality of decorative attachment points 1060 to allow decorative veneers or panels 1064 to be applied to one or more sides of the frame assembly thereof, e.g., through magnets, hook and pile (e.g., VELCRO, etc.). In some embodiments, decorative attachment points 1060 may be positioned on opposing front and back sides of a frame assembly to allow for the attachment of veneers 1064 to both sides thereof. The decorative attachment points 1060 can include magnets, hook and loop fasteners, clips, buttons, snaps, pins, or the like.
Optionally, the panels may attach to the frame assembly of the headboard or footboard so as to overlap with one another, e.g., where one panel is positioned in the center of such an arrangement and includes edges that are covered by adjacent outer panels that cover the edges of such central panel. The outer panels may slide back and forth, for example with respect to the central panel. Such an overlapping configuration can aid in ensuring that the full width of a given headboard or footboard is aesthetically covered, while accommodating changes in width possible with the adjustable headboard or footboard.
The base ends of the upright members of headboards 1050, 1052, 1050a and footboard 1050b can include attachment or locking features to selectively connect a headboard to an adjustable bed frame, such as any of the adjustable bed frames described herein. For example, the attachment features shown in
The rotatable corner modules 1004a, 1004b can include a number of different types of attachment features for the selective connection of a headboard 1050a, 1052, or footboard 1050b to the modular bed frame 1000a to form a modular bed frame system. In one embodiment, as shown in
Any embodiments herein including telescoping members may be configured so that the telescoping member is at least partially received into an opening of an adjacent module, or abuts the adjacent module, or is cantilevered, or the like. Any of the adjustable corner modules of any embodiments disclosed herein may be swappable, or interchangeable, allowing a user to move a corner from a given location, for use in another corner location (e.g., top right to any other of top left, bottom left, or bottom right, etc.).
Any gaps to be filled when adjusting from one bed size to another may be filled by use of telescoping module(s), or use of a filler modules, as described herein.
Any of the corner modules or uniform-length support modules may include a recess included therein, e.g., adjacent the floor, e.g., to minimize stubbing of toes, etc. by a user.
As discussed above,
In the embodiment of
Furthermore,
In one embodiment, the uniform-length support modules, e.g., keystone blocks, filler blocks, and/or platform blocks, disclosed herein can similarly telescope to fill a gap by employing a telescoping member 977 or a similar telescoping member. Thus, the corner modules and/or uniform-length support modules herein may be telescoping modules.
The four corner members 1084 are each angled at substantially transverse angles so as to movably connect at one end of each of the corner members 1084 or to movably connect at both ends of each of the corner members to respective rails 1082. Frame 1080 may be supported by feet or castors above a floor surface, for example.
Following are some further example embodiments of the invention. These are presented only by way of example and are not intended to limit the scope of the invention in any way.
A furniture spring system, comprising a lid configured to provide a seating surface, the lid comprising a frame comprising two opposing frame members and a retention member associated with at least one of the two opposing frame members; a slat extending between the two opposing frame members, the slat comprising an elongate body having a first end and a second end and a catch disposed at the first end or second end; wherein the catch engages the retention member to retain the slat to the frame and the catch is configured to slide back-and-forth relative to the retention member as a portion of the elongate body between the first end and the second end elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
The furniture spring system as recited in Embodiment 1, wherein the frame comprises one or more securing compartments formed into a top surface of each of the two opposing frame members.
The furniture spring system of any of Embodiments 1-2, wherein the catch comprises a hooked end and the catch extends downwardly into one of the one or more securing compartments to retain the slat to the frame.
The furniture spring system of any of Embodiments 1-3, wherein the retention member is configured to prevent the catch from disengaging the retention member, the retention member is disposed above the securing compartment and the catch, the retention member being configured to prevent the catch from lifting up and out of the securing compartment as the portion of the slat elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
The furniture spring system of any of Embodiments 1-4, wherein the retention member comprises a bore extending upward from one of the two opposing frame members.
The furniture spring system of any of Embodiments 1-5, wherein the catch comprises an elongate opening extending through the elongate body into a terminal end of the first or second end of the slat and the bore extends upward through the elongate opening to retain the slat to the frame.
The furniture spring system of any of Embodiments 1-6, wherein the retention member is configured to prevent the catch from disengaging from the frame, the retention member comprising a fastener inserted into the bore, the retention member configured to prevent the catch from lifting up and off of the bore as the middle portion of the slat elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
The furniture spring system of any of Embodiments 1-7, wherein the retention member is configured to limit a back-and-forth sliding distance of the catch relative to the retention member such that flexion of the slat is limited by the retention member.
The furniture spring system of any of Embodiments 1-8, wherein the spring system is configured to be mounted on a base frame of a furniture base.
A furniture spring system, comprising a frame comprising two opposing frame members, and a retention member disposed on at last one of the two opposing frame members, and elongate slat extending between the two opposing frame members, the slat comprising an elongate body having an upper surface, a lower surface, a first end, a second end, and a flexible middle portion extending between the first end and the second end, and a catch disposed at the first end or the second end, the catch engaging the retention member to retain the slat to the lid frame.
The furniture spring system of Embodiment 10, wherein the catch is configured to slide back-and-forth relative to the retention member as the middle portion elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
The furniture spring system of any of Embodiments 10-11, wherein the lower surface of the slat is an arcuate surface such that the middle portion is thicker than the first and second ends of the slat.
The furniture spring system of any of Embodiments 10-12, wherein the spring system is configured to be mounted on a base frame of a furniture base.
A furniture assembly, comprising a transverse member and a base member, the base member comprising a storage base and a lid configured to be mounted on a top of the storage base, such that the lid covers a storage cavity formed within the storage base, the lid comprising a frame with opposing frame members having one or more retention members, and one or more slats, each slat having an elongate member and one or more catches that engage the one or more retention members of the frame.
The furniture assembly of Embodiment 14, wherein the engagement of the retention members with the catches limits a vertical distance of flexion of the slats such that the slats do not extend further into the storage cavity than the vertical distance of flexion, thus protecting objects disposed in the storage cavity during use.
The furniture assembly of any of Embodiments 14-15, wherein each slat of the lid comprises an arcuate profile along a longitudinal axis thereof.
The furniture assembly of any of Embodiments 14-16, wherein each of the one or more catches of each sat is disposed on an end of the slat.
The furniture assembly of any of Embodiments 14-17, further comprising a retention plate disposed above each end of each slat, the retention plate being configured to prevent the one or more catches from disengaging the retention members of the lid when the slats flex downward during use.
The furniture assembly of any of Embodiments 14-18, wherein the one or more catches are configured to move back-and-forth relative to the retention members as the slats flex downward and upward during use.
A furniture spring system comprising, a lid configured to be mounted onto a base frame of a furniture base, the lid configured to provide a seating surface, the lid comprising, a frame comprising two opposing frame members, and a plurality of retention members associated with each of the two opposing frame members, a plurality of slats extending between the two opposing frame members, each of the slats comprising an elongate body having a first end and a second end and first and second catches disposed at the first end and second end, respectively, of the elongate body, wherein each catch engages a retention member to retain the corresponding slat to the frame, and wherein each catch of a slat is configured to slide back-and-forth relative to the corresponding retention member as a portion of the elongate body between the first end and the second end elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
A modular mattress system, comprising a plurality of mattress modules configured to form a first modular mattress of a first selected geometry and being reconfigurable to form a second modular mattress of a second selected geometry, each of the mattress modules having a width (x) and a length (y), wherein the length (y) is substantially equal to two times the width (x); a bed casing (e.g., a rigid bed casing) configured to secure the plurality of mattress modules to form a completed mattress; and a mattress topper sized and shaped to substantially cover the completed mattress and provide additional cushioning to a user.
The furniture spring system of Embodiment 21, wherein the second modular mattress also comprises one or more additional mattress modules having a length (y′) that is substantially equal to a length of the second selected geometry.
The furniture spring system of any of Embodiments 21-22, wherein the second modular mattress comprises a greater quantity of mattress modules than that of the first modular mattress.
The furniture spring system of any of Embodiments 21-23, wherein the bed casing (e.g., a rigid bed casing) is adjustable to selectively fit the first selected geometry and the second selected geometry.
The furniture spring system of any of Embodiments 21-24, wherein the bed casing also comprises veneer side panels selectively secured to the bed casing by magnets.
The furniture spring system of any of Embodiments 21-25, wherein the modular mattress system includes a casing applied to the plurality of mattress modules, wherein the casing is sized and shaped to compensate for missing length and/or width needed to form a standard size mattress.
A modular mattress system comprising, a plurality of mattress modules configured to form a first modular mattress of a first selected geometry and being reconfigurable to form a second modular mattress of a second selected geometry, each of the mattress modules having a width (x) and a length (y), wherein the length (y) is equal to two times the width (x), a bed casing configured to secure the plurality of mattress modules to form a completed mattress; and a mattress topper sized and shaped to cover the completed mattress and provide additional cushioning to a user.
A modular bed frame, comprising: a plurality of bed frame modules configured to form a first modular bed frame having a first selected geometry and being reconfigurable to form a second modular bed frame having a second selected geometry, the bed frame modules comprising: a plurality of uniform-length support modules, and a plurality of corner modules, wherein the corner modules and the uniform-length support are reconfigurable such the second modular bed frame is selectively formed, and wherein both the first and second selected geometries feature a continuous bed frame structure.
The modular bed frame of Embodiment 28, wherein at least one of the bed frame modules is a telescoping module that is reconfigurable such that the second geometry of the second modular bed frame is selectively formed.
The modular bed frame of any of Embodiments 28-29, wherein the telescoping module is a corner module having a telescoping member that telescopes to fill a gap.
The modular bed frame of any of Embodiments 28-30, wherein the telescoping corner module telescopes from a plurality of ends of the corner module.
The modular bed frame of any of Embodiments 28-31, wherein one or more additional modules are selectively added to the plurality of uniform-length support modules and the plurality of corner modules to form the second modular bed frame having the second selected geometry, the one or more additional modules being selected from: (1) one or more filler modules that have a different configuration from each of the uniform-length support modules of the plurality of uniform-length support modules and from each of the corner modules of the plurality of corner modules; (2) one or more additional uniform-length support modules having the same size and configuration as the uniform-length support modules of the plurality of uniform-length support modules; and (3) one or more elongate end modules that have a different configuration from the uniform-length support modules and the corner modules and that span the entire length between corner modules without any gaps.
The modular bed frame of any of Embodiments 28-32, wherein each of the corner modules of the plurality of corner modules are interchangeable between at least two corners of the bed frame, and wherein each of the uniform-length support modules of the plurality of uniform-length support modules have substantially the same geometry and size.
The modular bed frame of any of Embodiments 28-33, wherein each of the corner modules of the plurality of corner modules have the same footprint dimensions, and wherein each of the uniform-length support modules of the plurality of uniform-length support modules have the same footprint dimensions.
The modular bed frame of any of Embodiments 28-34, wherein, when the second modular bed frame of the second geometry is formed from the plurality of corner modules and the plurality of uniform-length support modules, one or more gaps appear in the second geometry, and wherein the one or more gaps are selectively filled by one or more filler modules, or one or more elongated end modules that span the entire length between corner modules without any gaps.
The modular bed frame of any of Embodiments 28-35, wherein a gap distance of the one or more gaps is calculated as: (i) a total dimension measured, minus (ii) a uniform-length support module length multiplied by the number of uniform-length support modules, minus (iii) two times the length of a corner module, (iv) the foregoing divided by number of gaps.
The modular bed frame of any of Embodiments 28-36, wherein, when a second modular bed frame of a second geometry is formed, one or more gaps appear in a total dimension of the second geometry measured, wherein a gap distance of the one or more gaps is calculated according to the following formula:
where,
In one such embodiment, each of the support modules of the plurality of uniform-length support modules comprise elongate blocks that are of equal size and configuration.
The modular bed frame of any of Embodiments 28-36, wherein each of the corner modules of the plurality of corner modules have substantially the same geometry and size, and wherein each of the uniform-length support modules of the plurality of uniform-length support modules have substantially the same geometry and size.
The modular bed frame of any of Embodiments 28-37, wherein a plurality of slats extend between opposing uniform-length support modules of the modular bed frame, each of the slats comprising, an elongate body having a first end and a second end, and first and second catches disposed at the first end and second end, respectively, of the elongate body, wherein each catch engages a retention member to retain the corresponding slat to the modular bed frame, and wherein each catch of a slat is configured to slide back-and-forth relative to the corresponding retention member as a portion of the elongate body between the first end and the second end elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
The modular bed frame of any of Embodiments 28-38, wherein the bed frame comprises one or more securing compartments formed into a top surface of each of the two opposing bed frame rails, wherein each catch of the first and second catches comprises a hooked end, and each catch extends downwardly into one of the one or more securing compartments to retain the slat to the frame, and wherein the retention member is configured to prevent the catch from disengaging the retention member, wherein the retention member is disposed above the securing compartment and the catch, the retention member being configured to prevent the catch from lifting up and out of the securing compartment as the portion of the slat elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
A Modular bed frame of any of embodiments 28-39, wherein the retention member comprises a bore extending upward from one of the two opposing bed frame rails, wherein: the catch comprises an elongate opening extending through the elongate body into a terminal end of the first or second end of the slat; and the bore extends upward through the elongate opening to retain the slat to the frame, and wherein the retention member is configured to prevent the catch from disengaging from the frame, the retention member comprising a fastener inserted into the bore, the retention member configured to prevent the catch from lifting up and off of the bore as the middle portion of the slat elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
The modular bed frame of any of Embodiments 28-40, wherein at least one telescoping end of a corner module of the plurality of corner modules is telescopically extendable to fill a gap and is connectable to at least one of the uniform-length support modules of the plurality of uniform-length support modules.
The modular bed frame of any of Embodiments 28-41, wherein both the first and second selected geometries feature a continuous, gapless bed frame structure.
A modular bed frame assembly having components for forming modular bed frames having different configurations, the modular bed frame assembly comprising: a plurality of bed frame modules configured to form a first modular bed frame having a first selected geometry and being reconfigurable to form a second modular bed frame having a second selected geometry, the bed frame modules comprising: a plurality of uniform-length support modules, and a plurality of corner modules, wherein the corner modules and uniform-length support modules are reconfigurable such that the second modular bed frame is selectively formed, and wherein both the first and second selected geometries feature a continuous, gap-less, bed frame structure; wherein at least one of the bed frame modules is a telescoping module that is reconfigurable such that the second modular bed frame is selectively formed; and further comprising: one or more filler modules that have a different configuration from each of the uniform-length support modules of the plurality of uniform-length support modules and from each of the corner modules of the plurality of corner modules.
A modular bed frame assembly of embodiment 43, wherein the modular frame assembly comprises four corner modules, at least six uniform-length support modules, and at least two filler modules.
A modular bed frame assembly of any of Embodiments 43-44, wherein the modular frame assembly comprises four corner modules, at least six uniform-length support modules, and further comprises one or more elongate end modules that have a different configuration from the uniform-length support modules and the corner modules and that span the entire length between corner modules without any gaps.
A modular bed frame assembly of any of Embodiments 43-45, wherein the modular frame assembly further comprises at least two filler modules.
A modular bed frame assembly of any of Embodiments 43-46, wherein at least two of the corner modules have telescoping members, and wherein each of the corner modules of the plurality of corner modules have substantially the same footprint dimensions, and wherein each of the uniform-length support modules of the plurality of uniform-length support modules have substantially the same footprint dimensions.
A modular bed frame, comprising: a plurality of bed frame modules configured to form a first modular bed frame having a first selected geometry and being reconfigurable to form a second modular bed frame having a second selected geometry, the bed frame modules comprising: one or more rails, and a plurality of corner modules, wherein each of the corner modules of the plurality of corner modules has a length and a width, wherein the length is greater than the width, and wherein each of the corner modules are configured to be selectively repositionable.
The modular bed frame of Embodiment 48, wherein each of the corner modules are configured to be selectively repositionable from a long configuration to a short configuration, wherein, in the long configuration, the length of the corner module is substantially aligned with a longitudinal axis of the rail, and wherein, in the short configuration, the length of the corner module is substantially perpendicular to the longitudinal axis of the rail.
The modular bed frame of any of embodiments 48-49, wherein the corner modules can be moved to any corner positions of the modular bed frame.
The modular bed frame of any of embodiments 48-50, wherein the one or more rails include a plurality of slat attachment points configured to receive a plurality of slats.
The modular bed frame of any of embodiments 48-51, wherein the modular bed frame further comprises an end board that is selectively adjustable from one dimension to another dimension.
The modular bed frame of any of embodiments 48-52, wherein the end board can be positioned on the modular bed frame to serve as a headboard or footboard.
The modular bed frame of any of embodiments 48-53 wherein a plurality of slats extend between opposing rails of the modular bed frame, each of the slats comprising: an elongate body having a first end and a second end; and first and second catches disposed at the first end and second end, respectively, of the elongate body; wherein each catch engages a retention member to retain the corresponding slat to the rail; and wherein each catch of a slat is configured to slide back-and-forth relative to the corresponding retention member as a portion of the elongate body between the first end and the second end elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
The modular bed frame of any of embodiments 48-54, wherein: the bed frame comprises one or more securing compartments formed into a top surface of each of the two opposing bed frame rails, wherein each catch of the first and second catches comprises a hooked end, and each catch extends downwardly into one of the one or more securing compartments to retain the slat to the frame, and wherein the retention member is configured to prevent the catch from disengaging the retention member, wherein the retention member is disposed above the securing compartment and the catch, the retention member being configured to prevent the catch from lifting up and out of the securing compartment as the portion of the slat elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
A modular bed frame of any of embodiments 48-55, wherein the retention member comprises a bore extending upward from one of the two opposing bed frame rails, wherein: the catch comprises an elongate opening extending through the elongate body into a terminal end of the first or second end of the slat; and the bore extends upward through the elongate opening to retain the slat to the frame, and wherein the retention member is configured to prevent the catch from disengaging from the frame, the retention member comprising a fastener inserted into the bore, the retention member configured to prevent the catch from lifting up and off of the bore as the middle portion of the slat elastically flexes downward and upward in response to forces intermittently pushing downward on the slat during use.
An adjustable end board configured to be mounted onto a bed frame, the adjustable end board comprising: (1) an adjustable frame assembly, the adjustable frame assembly comprising: (A) first and second upright members, and (B) a moveable connecting system for connecting the first and second upright members to each other such that the distance between the first and second upright members can be selectively adjusted, and (2) one or more panels that are selectively mounted on the frame assembly.
The adjustable end board of embodiment 57, wherein the end board is an adjustable headboard or an adjustable footboard and the one or more panels are decorative panels.
The adjustable end board of any of embodiments 57-58, wherein the adjustable frame assembly of the adjustable end board is configured to be coupled to a modular bed frame, the adjustable frame assembly being configured such that the width of the modular bed frame can be reconfigurable from a first geometry to form a second modular bed frame of a second selected geometry, the end board and the bed frame each configured such that they can be adjusted to have the same width in the first geometry and the same width in the second geometry.
A bed frame system, comprising: (1) a modular end board for use in a bed frame system, the modular end board comprising: (A) an adjustable frame assembly, the adjustable frame assembly comprising: (i) first and second upright members; and (ii) a moveable connecting system for connecting the first and second upright members to each other such that the distance between the first and second upright members can be selectively adjusted; and (B) one or more decorative panels that are selectively mounted onto the frame assembly; and (2) a modular bed frame configured to be coupled to the modular end board, the modular bed frame configured such that the modular bed frame can be reconfigurable from a first geometry to form a second modular bed frame having a second selected geometry, the end board and the bed frame each being configured such that they can be adjusted to each have a corresponding dimension in the first geometry and a corresponding dimension in the second geometry.
A system as recited in embodiment 60, wherein the end board is an adjustable headboard or an adjustable footboard.
A telescoping bed frame, comprising: (i) a plurality of support modules; and (ii) a plurality of corner modules that are movably connected to the support modules, the corner modules each being comprised of a corner member having two ends that are positioned at a substantially transverse angle with respect to each other, each of the ends of a respective corner member being movably coupled to a respective support module, such that each corner module selectively moves with respect to each of the support modules to which it is coupled, such that the telescoping bed frame is configured to form a first modular bed frame having a first selected geometry and is telescopically reconfigurable to form a second modular bed frame having a second selected geometry.
A telescoping bed frame as recited in embodiment 62, wherein the support modules are bed frame rails.
The articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements in the preceding descriptions. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within 5%, within 1%, within 0.1%, or within 0.01% of a stated value.
A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function” clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims.
The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to “up” and “down” or “above” or “below” are merely descriptive of the relative position or movement of the related elements.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
This application is a continuation-in-part of U.S. patent application Ser. No. 16/707,568, filed on Dec. 9, 2019, entitled MOLDED MANUFACTURING FOR MODULAR FURNITURE, which claims the benefit of and priority to U.S. Provisional Patent Application No. 62/806,516, filed on Feb. 15, 2019, entitled INTEGRATED MANUFACTURING FOR MODULAR FURNITURE, each of which are incorporated herein in their entireties by reference. This application is also a continuation-in-part of U.S. patent application Ser. No. 16/707,571, filed on Dec. 9, 2019, entitled FURNITURE STORAGE BASE, which claims the benefit of and priority to U.S. Provisional Patent Application No. 62/806,516, filed on Feb. 15, 2019, entitled INTEGRATED MANUFACTURING FOR MODULAR FURNITURE, each of which are incorporated herein in their entireties by reference. This application is also a continuation-in-part of U.S. patent application Ser. No. 16/707,574, filed on Dec. 9, 2019, entitled FURNITURE SPRING SYSTEM, which claims the benefit of and priority to U.S. Provisional Patent Application No. 62/806,516, filed on Feb. 15, 2019, entitled INTEGRATED MANUFACTURING FOR MODULAR FURNITURE, each of which are incorporated herein in their entireties by reference. Each of the foregoing patent applications is incorporated herein in its entirety by reference.
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| Number | Date | Country | |
|---|---|---|---|
| 20200260880 A1 | Aug 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62806516 | Feb 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16707574 | Dec 2019 | US |
| Child | 16788026 | US | |
| Parent | 16707568 | Dec 2019 | US |
| Child | 16707574 | US | |
| Parent | 16707571 | Dec 2019 | US |
| Child | 16707568 | US |
