Patent Application
20130098791
The present disclosure generally relates to support foundations for mattresses, and more particularly, to multi-piece mattress foundations.
Mattress supporting foundations for conventional box springs are often typically constructed of a combination of materials, including wood, metal, and fiber with a cloth outer cover and may include support sub-assemblies such as edge-reinforcing springs. The conventional box springs are large and heavy. They require considerable storage space and therefore are expensive in stocking in inventory, especially in different sizes; and they have a high cost for transporting them from the factory to the customer or mattress manufacturer. Improvements are always sought in the expense of manufacturing, handling, assembling, and transporting bed foundations, and in the quality of the end product. The size and number of materials, typically selected for low cost, present numerous difficulties for consumers, including handling and disposal. In fact, many U.S. states have instituted disposal fees for mattress foundations, which can be as high as $100.00.
The present disclosure is directed to multi-piece mattress foundations and support units for forming the mattress foundation. In one embodiment, a multi-piece mattress foundation for supporting a mattress comprises at least two support units in an abutting relationship that form a rectangular shape at each end of the mattress foundation and provide an elevated planar support surface having length and width dimensions effective to support a mattress disposed thereon, wherein the multi-piece mattress foundation is free of springs.
In another embodiment, the multi-piece mattress foundation for supporting a mattress comprises at least two support units in an abutting relationship that form a rectangular shape at each end of the mattress foundation and provide a planar support surface having length and width dimensions effective to support a mattress disposed thereon, wherein each support unit comprises opposing end units and a planar surface support extending therebetween, wherein each of the opposing end units comprises a quadrilateral shape.
A support unit for a mattress foundation comprises a first end unit comprising a quadrilateral cross sectional shape; a second end unit spaced apart from the first end unit that is a mirror image of the first end unit; and a planar surface support extending between the first and second end units and configured to provide an elevated support surface for supporting a mattress, wherein the first and second end units are spaced apart at a distance about equal to a length dimension of a mattress to be disposed on the mattress foundation when assembled.
The disclosure may be understood more readily by reference to the following detailed description of the various features of the disclosure and the examples included therein.
Referring now to the figures wherein the like elements are numbered alike:
Disclosed herein are multi-piece foundations for mattresses. The multi-piece foundations include at least two support units that can be abuttingly arranged to provide a planar support surface having a width and length similarly dimensioned to a mattress supported by the multi-piece foundation. Each of the support units includes end units and planar surface supports bridging the end units. The end units can generally have a cross-sectional quadrilateral shape that in combination with the planar surface supports elevate as well as support a mattress disposed thereon. Advantageously, each support unit can be configured to provide a minimal footprint prior to assembly, thereby minimizing storage space related to stocking in inventory, especially in different sizes. Moreover, because the support units themselves are defined by multiple pieces that are easily stacked, transportation costs from the factory to the customer or mattress manufacturer are reduced. Likewise, space can be minimized when shipped via delivery trucks, containers, and the like. Still further, many of the same components of the support units can be used to assemble more than one differently sized mattress foundations as will be discussed in greater detail below, which further reduces costs associated with manufacturing and reduces inventory as well as storage requirements. Finally, it should be apparent that the proposed mattress foundations are free of springs and can be free of an outer cloth cover as is generally employed in conventional box springs.
Referring now to
Referring now to
Each end unit 22, 24, 42, 44 has four planar surfaces that generally form a cross-sectional quadrilateral shape. In one embodiment, the end units have a trapezoidal cross sectional shape, wherein the geometry and dimensions of the trapezoidal cross sectional shape are substantially the same for each pair of end units albeit mirror images of one another. End unit 22 includes a vertical sidewall 30, an angled sidewall 32 relative to the vertical sidewall 30, and parallel support walls 34, 36 extending therebetween. End unit 24 is a mirror image of end unit 22 and includes a vertical sidewall 30′, an angled sidewall 32′ relative to the vertical sidewall 30′, and parallel support walls 34′ and 36′ (as shown more clearly in
During assembly of the twin-sized foundation 10, the support units 20, 40 are positioned such that the vertical sidewalls, e.g., 30 and 50, of each respective pair of end units 22, 24 and 42, 44 are oriented to define an exterior vertical wall of the foundation 10, and the angled sidewalls, e.g., 32 and 52, of each respective pair of end units 22, 24 and 42, 44 face an interior region of the foundation and abut one another. The planar surface support 26 of support unit 20 is configured to span between the end units 22 and 24 to define a portion of an upper surface for elevating and supporting the twin mattress relative to ground.
The width of the planar surface support 26 is about equal to the length of the parallel support wall 36 of the end unit 22. Similarly, the planar surface support 46 of support unit 40 is configured to span between the end units 42 and 44 to define a portion of the upper surface for elevating and supporting the twin mattress relative to ground. The width of the planar surface support 46 is about equal to the length of the parallel support wall 54 of the end unit 42. In this regard, the corresponding upper portion of each end unit (e.g., support wall 36 of end unit 22 and support wall 54 of end units 42 may include a flange (see, for example,
In some embodiments, the planar surface supports 26 and 46 further include a slip resistant coating and/or pad 60 disposed on an upper surface and is positioned to be in contact with the mattress when disposed thereon. Alternatively, the planar surface support can have a textured surface. In still other embodiments, the planar support surface can include one or more openings to provide improved airflow to the overlying mattress. The size and shape of the openings are not intended to be limited.
The quadrilateral shape of the various end units 22, 24, 42, and 44 can have arcuate-shaped corners as shown. When arcuate-shaped corners are present in this and the various embodiments discussed below, an optional spacer member 62 may be disposed between abutting support units 20, 40 to minimize a gap that may be formed therebetween and provide greater stability as well as additional support. The spacer member 62 can generally have an S-shape so as to fill the gaps at the ground level and/or within the planar surface of the abutting support units 20, 40. In other embodiments, the spacer member is disposed along a length of top surface of the mattress and has a shape generally conforming the space formed by the abutting support units.
The various pieces defining a support unit, e.g., end units 22, 24, and planar surface support 26, can be fixedly coupled to one another by fastener, adhesive, frictional engagement of the pieces themselves, combinations thereof, or the like to form the respective support unit. In this as well as the various embodiments that follow, each support unit 20 or 40 can be of a single unitary construction.
The support units as well as the optional spacer member 62 can be formed of any material such as wood, metal, plastic, glass, combinations thereof, and the like. In one embodiment, the components defining the support units and spacer member are formed of an extruded or assembled plastic; molded plastic; recyclable plastic; plastic reinforced with metal core, metal fiber, glass fiber, carbon fiber, resin or a combination of these. Those of ordinary skill in the art would know that various types of plastics can be used in the mattress foundation including but not limited to polyurethane, polyethylene, polystyrene, polypropylene, and the like.
In one embodiment, the various components that define the mattress foundations are formed, in whole or in part, of a biocomposite resin. For example, the biocomposite resin can be formed of a soy-based resin such as those described in US Pat. Pub. Nos. 2011/0272856, 2011/0271616, and 2009/0042003, incorporated herein by reference in their entireties.
As will be described in greater detail below, the same complementary pairs of end units, e.g., 22, 24 and 42, 44 as well as the same planar surface supports 26 and 46 can be used in combination with at least one additional support unit to support larger width mattresses. In the event the length of the foundation is larger than that of the twin sized mattress, e.g., a twin XL mattress foundation having a length of about 79 inches as opposed to the typical standard twin foundation length of about 74 inches, a longer planar surface support can be readily employed with the same end units employed for the smaller length foundations. In this manner, larger sized foundations can be readily assembled using at least some of the inventory common to the different sized mattress foundations, which minimizes waste and provides a significant commercial advantage to the manufacturer. Moreover, because there are three different components that generally define a support unit, e.g., a pair of end units and a planar surface support, the planar surface supports can be readily stacked with one another prior to assembly to minimize space requirements during storage or transportation. Likewise, the end units can be readily stacked for storage and/or transportation prior to assembly. However, it should be apparent that the two abutting support units as described above may simply be fabricated with larger width and length dimensions to accommodate the different sized mattress foundations for supporting mattresses larger than the twin mattress described above.
Turning now to
Referring now to
Support unit 80 includes a pair of end units 82 generally having an isosceles trapezoidal shape (one of which is shown) and a planar surface support 86 that extends between the two end units 82. Each end unit 82 includes angled sidewalls 90, 92, and parallel support walls 94, 96 extending therebetween. The length of parallel support wall 96 is greater than parallel support wall 94. Angled sidewall 90 is at an angle of about equal to 180 degrees minus the angle defined by parallel support wall 34 and angled sidewall 32 of end unit 22. Angled sidewall 92 is at an angle of about equal to 180 degrees minus the angle defined by parallel support wall 34′ and angled sidewall 32′ of end unit 24. In this manner, the two support units 20 and intermediate support unit 80 can be provided in an abutting relationship with minimal gaps in the planar surface defined by planar surface supports 26 and 86.
It should be apparent that in order to provide the abutting relationship and provide a width effective to accommodate the width of the full sized mattress, the orientation of the two support units 20 are end units 22 and 24 are provided at each end of the mattress foundation 12. As such, the mattress foundation 12 utilizes two planar surface supports 26 and one planar surface support 86. The width of planar surface support 86 and the width of the two planar surface supports 26 provide the mattress foundation 12 with an increase in width effective to compensate for the transition from the twin sized mattress to the full sized mattress. That is, the width of planar surface supports 26, 26, and 86 is equal to the width of the full sized mattress.
Referring now to
Support unit 120 includes two of end units 122 generally having an isosceles trapezoidal shape and a planar surface support 124 that extends between the two end units 122. Each end unit 122 includes angled sidewalls 130, 132, and parallel support walls 134, 136 extending therebetween. Angled sidewall 130 is at an angle about equal to 180 degrees minus the angle defined by parallel support wall 34 and angled sidewall 32 of end unit 22. Angled sidewall 132 is at an angle about equal to 180 degrees minus the angle defined by parallel support wall 34′ and angled sidewall 32′ of end unit 24. In this manner, the two support units 100 and intermediate support unit 120 can be provided in an abutting relationship with minimal gaps in the planar surface defined by planar surface supports 27 and 124.
Referring now to
Because the king sized mattress foundation has a length about equal to that of the queen sized mattress foundation 14 and has a width that is about twice that of the twin sized mattress foundation 10, the king sized mattress foundation can be configured with many of the same components used to form the twin and queen sized mattress foundations 10 and 14, respectively. The king sized mattress foundation includes two support units 100 and two intermediate support units 140. Support units 100 are defined by pairs of end units 22, 24 and planar support surface 27 as previously described and shown in
Alternatively, mattress foundation 16 can be formed using three pieces as described in relation to mattress foundation 14, wherein one or more of the two support units and intermediate support unit provide an increased dimension to accommodate the overlying king sized mattress.
Optionally, the end units in any of the embodiments disclosed herein may further include casters to permit rolling of the assembled mattress foundation as may be desired for some applications. Likewise, the end units may further include flanges for attachment of a headboard. Also, it should be apparent that the various components may include ribbing as well as structure supports integral to and/or attached to a selected one of the end units and planar surface supports described above.
As demonstrated above, because the various sized beds typically have common lengths for multiple mattress sizes, the foundation inventory still remains relatively small since at least some of the end units and planar surface supports can be retained for use in all of the different sizes of the mattress foundations. Moreover, packaging size requirements are minimized since the mattress foundation is a composite of numerous components that are relatively small in size or can be stackedly arranged to minimize space requirements.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
This non-provisional application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/549,404 filed Oct. 20, 2011, which is fully incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61549404 | Oct 2011 | US |
