BACKGROUND
The present disclosure is directed to a bed foundation that is adapted to support the mattress of a bed on top of the bed foundation. More particularly, the present disclosure relates to a bed foundation including a base having a first frame pivotally coupled to a second frame such that the first and second frames may be selectively pivoted between an unfolded position for use in supporting a mattress and a folded position for shipping or transport of the bed foundation.
Bed foundations are rigid and inflexible, and are large in size. For example, a bed foundation adapted to support a Queen-size mattress may have a width of approximately sixty inches (60″), a length of approximately eighty inches (80″), and a height of approximately nine inches (9″). Bed foundations are difficult to transport and ship from one location to another location due to their large size and inflexibility. A bed foundation for a Queen-size bed will not fit within most automobiles for shipment or transport between a store and an end user's home. It is also difficult to transport a large bed foundation within a house or other structure, such as when a bed foundation is moved up or down stairways, around stairway railings, and around corners and through doorways in a house or other structure.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description particularly refers to the accompanying figures in which:
FIG. 1 is a top perspective view of the base of the bed foundation having a first frame and a second frame shown in the open unfolded position ready for supporting the mattress of a bed.
FIG. 2 is a perspective view of the base of FIG. 1 shown in the closed folded position wherein the second frame of the base has been pivoted with respect to the first frame of the base to overlie the first frame.
FIG. 3 is a perspective view of the first frame and of the second frame of the base separated from one another and shown partially completed.
FIG. 4 is a bottom perspective view of the base of the bed foundation shown in the open unfolded position.
FIG. 5 is a side elevational view of the hinge that pivotally connects the first frame of the base to the second frame of the base for pivotal movement of the first frame and second frame with respect to one another about a pivot axis.
FIG. 6 is a side elevational view of a corner cover for the first and second frames of the base.
FIG. 7 is a top view of the corner cover taken along line 7-7 of FIG. 6.
FIG. 8 is partial cross sectional view of an interior corner of the first frame of the base showing the corner cover of FIG. 6 coupled to the first frame of the base.
FIG. 9 is a perspective view of the bed foundation shown in the closed folded position for transport or shipping of the folded bed foundation.
FIG. 10 shows the second frame of the base partially pivoted toward the open unfolded position with respect to the first frame of the base.
FIG. 11 shows the second frame of the base pivoted further toward the open unfolded position with respect to the first frame of the base.
FIG. 12 shows the bed foundation with the first and second frames of the base in the open unfolded position wherein the bed foundation is adapted to support the mattress of a bed.
FIG. 13 is a diagrammatic illustration of a single bed foundation in the open unfolded position adapted to support a single mattress of a bed.
FIG. 14 is a diagrammatic illustration of two bed foundations in the open unfolded position and located side-by-side for supporting a single mattress of a bed.
DETAILED DESCRIPTION
The present disclosure relates to a bed foundation for a bed adapted to support a mattress of the bed. The bed foundation 10 includes a base 12, as shown in FIG. 1, having a rigid first frame 14A and a rigid second frame 14B located in a side-by-side relationship. Frames 14A and 14B each comprise a respective platform that are adapted to support the mattress of the bed, such as a Queen or King size mattress. Frames 14A and 14B are constructed substantially identical to one another, but they are arranged in a mirror image with respect to one another. Second frame 14B, as shown in FIG. 1, although constructed in the same manner as frame 14A, is rotated end-for-end, or 180°, with respect to first frame 14A. A pivotal connector, such as a hinge 18, pivotally connects first frame 14A to second frame 14B such that frames 14A and 14B are selectively pivotal with respect to one another about an elongate generally linear pivot axis 20.
Each frame 14A and 14B includes a generally planar bottom 24 and a generally planar top 26 that is spaced apart from and generally parallel to bottom 24. Each frame 14A-B extends generally parallel to pivot axis 20 between a first end 28 and a second end 30. Each frame 14A-B extends generally transversely with respect to pivot axis 20 between an inner side 32 and an outer side 34. Inner side 32 of first frame 14A is located adjacent to inner side 32 of second frame 14B when base 12 and frames 14A and 14B are located in the open unfolded position as shown in FIG. 1. Inner side 32 of first frame 14A is pivotally coupled to inner side 32 of second frame 14B by hinge 18 for pivotal movement of frames 14A and 14B with respect to each other about pivot axis 20. Frames 14A and 14B may be selectively rotated or pivoted with respect to one another about pivot axis 20 between the open unfolded position as shown in FIG. 1 and a closed folded position as shown in FIG. 2 wherein base 12 is folded in half. When base 12 and frames 14A-14B are in the open unfolded position as shown in FIG. 1, bottom 24 of first frame 14A is generally coplanar with bottom 24 of second frame 14B, and top 26 of first frame 14A and top 26 of second frame 14B are generally coplanar, such that base 12 and frame 14A and 14B are adapted to support a mattress of a bed that overlies tops 26 of frames 14A and 14B. When frames 14A and 14B are pivoted with respect to one another about pivot axis 20 to the closed folded position as shown in FIG. 2, second frame 14B overlies first frame 14A, and top 26 of second frame 14B is located adjacent to and overlies top 26 of first frame 14A, for transport or shipping of foundation 10.
Each frame 14A-B includes an elongate inner support member 40, an elongate outer support member 42, and may include one or more elongate center support members 44 located between inner support member 40 and outer support member 42. Support members 40, 42 and 44 are generally parallel to, and spaced apart from, one another and extend generally parallel to pivot axis 20. Each support member 40, 42 and 44 extends generally linearly between a first end 46 and a second end 48. An inner support member 40 extends along inner side 32 of each frame 14A and 14B, and an outer support member 42 extends along outer side 34 of each frame 14A and 14B. Each support member 40, 42 and 44 includes an elongate generally plate-like bottom slat 50 and an elongate generally plate-like top slat 52 that is spaced apart from and generally parallel to bottom slat 50. Top slat 52 includes a generally planar top surface having generally linear inner and outer edges. Bottom slat 50 includes a generally planar bottom surface having generally linear inner and outer edges. Top slat 52 of each support member 40, 42 and 44 includes opposing ends and extends between first end 46 and second end 48 of each support member 40, 42 and 44. Bottom slat 50 of each support member 40, 42 and 44 includes opposing ends that are spaced inwardly from first end 46 and second end 48 of each support member 40, 42 and 44. Each support member 40, 42 and 44 includes a corner post 54A that extends generally perpendicularly between bottom slat 50 and top slat 52 at first end 46, and a corner post 54B that extends generally perpendicularly between bottom slat 50 and top slat 52 at second end 48. Each support member 40, 42, and 44 may include one or more center posts 56 located between corner posts 54A and 54B that extend generally vertically between bottom slat 50 and top slat 52. Each corner post 54A-B and center post 56 may be formed as a generally rectangular block having generally rectangular and planar end surfaces and generally rectangular and planar side surfaces. Each support member 40, 42 and 44 may comprise a truss. Inner support member 40, outer support member 42 and center support members 44 are generally constructed in the same manner as one another. However, inner support member 40 includes square outer corners at first end 46 and second end 48, and outer support member 42 includes rounded or curved outer corners at first end 46 and second end 48.
Each frame 14A and 14B includes a bottom end slat 60 connected to first ends 46 of support members 40, 42 and 44. A first end of bottom end slat 60 is connected to first end 46 of inner support member 40 and a second end of bottom end slat 60 is connected to first end 46 of outer support member 42. Each frame 14A-14B also includes an elongate bottom end slat 62 that is connected to second ends 48 of support members 40, 42 and 44. A first end of bottom end slat 62 is connected to second end 48 of inner support member 40 and a second end of bottom end slat 62 is connected to second end 48 of outer support member 42. Bottom end slat 60 and bottom end slat 62 are spaced apart from one another and generally parallel to one another, and are generally perpendicular to pivot axis 20. The ends of bottom slats 50 of support members 40, 42 and 44 abut and are located adjacent to bottom end slats 60 and 62. Bottom end slats 60 and 62 each include a generally planar bottom surface having generally linear inside and outside side edges. The bottom surfaces of bottom end slats 60 and 62 are generally coplanar with the bottom surfaces of bottom slats 50 of support members 40, 42 and 44.
Each frame 14A and 14B also includes an elongate top end slat 66 connected to first ends 46 of support members 40, 42 and 44. Each top end slat 66 includes a first end connected to first end 46 of inner support member 40 and a second end connected to first end 46 of outer support member 42. Each frame 14A and 14B also includes a top end slat 68 connected to second ends 48 of support members 40, 42 and 44. Each top end slat 68 includes a first end connected to second end 48 of inner support member 40 and a second end connected to second end 48 of outer support member 42. Top end slats 66 and 68 overlie and are connected to top slats 52 of support members 40, 42 and 44. Top end slats 66 and 68 are spaced apart from one another and generally parallel to one another, and extend generally perpendicular to pivot axis 20. Top end slats 66 and 68 each include a generally planar top surface having generally linear inside and outside side edges.
Each frame 14A and 14B includes an elongate inner filler strip 70 that is connected to and that extends along the top surface of top slat 52 of inner support member 40. Inner filler strip 70 extends between a first end that is in abutting engagement with top end slat 66 and a second end that is in abutting engagement with top end slat 68. Each frame 14A-14B also includes an elongate outer filler strip 72 that is connected to and that extends along top slat 52 of outer support member 42. Outer filler strip 72 includes a first end in abutting engagement with top end slat 66 and a second end in abutting engagement with top end slat 68. Filler strips 70 and 72 are spaced apart from one another and are generally parallel to one another and to pivot axis 20. Each filler strip 70 and 72 includes a generally planar top surface that is generally coplanar with the top surfaces of top end slats 66 and 68. Each filler strip 70 and 72 includes an inner side wall that is spaced inwardly from an inner edge of top slat 52 of inner support member 40 and outer support member 42 thereby forming respective elongate channels that extend along top slats 52 and filler strips 70 and 72.
Each frame 14A and 14B includes one or more elongate cross slats 76 that are located between top end slat 66 and top end slat 68. Cross slats 76 are spaced apart from, and generally parallel to, one another and top end slats 66 and 68, and extend generally transversely with respect to support members 40, 42 and 44. Each cross slat 76 is connected to top slats 52 of inner support member 40, outer support member 42 and center support members 44, with a first end of each cross slat 76 being connected to inner support member 40 and a second end of each cross slat 76 being connected to outer support member 42. Each cross slat 76 includes a generally planar top surface that is generally coplanar with the top surfaces of top end slats 66 and 68 and filler strips 70 and 72. Each cross slat 76 extends between and is located closely adjacent to inner filler strip 70 and outer filler strip 72. Each cross slat 76 includes a first end located in the channel formed by inner filler strip 70 and a second end located in the channel formed by outer filler strip 72. Top end slats 66 and 68, filler strips 70 and 72, and cross slats 76 are adapted to support the mattress of the bed. FIG. 3 shows frames 14A and 14B partially assembled. FIG. 3 shows first frame 14A prior to installation of outer filler strip 72 and cross slats 76. FIG. 3 shows second frame 14B with inner filler strip 70 and outer filler strip 72 installed, and with one cross slat 76 installed. Each frame 14A and 14B of base 12 is substantially rigid and inflexible. Frames 14A and 14B may be made from wood materials or other rigid materials.
As shown in FIG. 1, hinge 18 pivotally connects inner side 32 and inner support member 40 of first frame 14A to inner side 32 and inner support member 40 of second frame 14B for pivotal movement of frames 14A and 14B with respect to one another about pivot axis 20. As shown in FIG. 5, hinge 18 includes a leaf 80A and a leaf 80B. Each leaf 80A-B includes an elongate generally rectangular and plate-like mounting base 82 having one or more mounting apertures. Each mounting base 82 of leafs 80A-B includes one or more spaced apart knuckles 84. Each knuckle 84 includes a generally cylindrical bore 86. Knuckles 84 of leafs 80A and 80B are alternately arranged with respect to one another such that each knuckle 84 of leaf 80A is located between two knuckles 84 of leaf 80B, and such that the bores 86 of the knuckles 84 of leafs 80A-B are located coaxially with one another and coaxially with pivot axis 20. An elongate generally cylindrical pin 88 extends through bores 86 of knuckles 84 and pivotally interlocks leafs 80A and 80B to one another, while allowing selective pivotal movement of leafs 80A and 80B with respect to one another about pivot axis 20.
Leaf 80A of hinge 18 is coupled to inner filler strip 70 and top slat 52 of inner support member 40 of first frame 14A by fasteners, such as threaded screws. Leaf 80B of hinge 18 is coupled to inner filler strip 70 and top slat 52 of inner support member 40 of second frame 14B by fasteners, such as threaded screws. Hinge 18 thereby pivotally connects inner side 32 and inner support member 40 of first frame 14A to inner side 32 and inner support member 40 of second frame 14B, such that frames 14A and 14B are pivotally moveable with respect to one another about pivot axis 20. Hinge 18 may comprise a piano hinge. Hinge 18 may alternatively be formed in other manners, such as a living hinge comprising a sheet of flexible material that flexibly and pivotally connects first frame 14A to second frame 14B. Hinge 18 may comprise a single hinge that extends substantially the entire length of inner support members 40 of frames 14A and 14B. Alternatively, a plurality of spaced apart hinges 18 may be located along the length of inner support members 40 of frames 14A and B.
As shown in FIGS. 9-12, foundation 10 includes a one-piece integral cover 100 that extends over and around top 26, first end 28, second end 30 and outer side 34 of frames 14A and 14B. Cover 100 includes a sheet-like top panel 102 that extends over and across tops 26 of frames 14A and 14B, and over and across top end slats 66 and 68, filler strips 70 and 72, and cross slats 76 of frames 14A and 14B. Cover 100 includes a sheet-like end panel 104A that extends downwardly from top panel 102 and that extends along and covers outer side 34 and outer support member 42 of first frame 14A. Cover 100 includes a sheet-like end panel 104B that extends downwardly from top panel 102 and that extends along and covers outer side 34 and outer support member 42 of second frame 14B. Cover 100 includes a sheet-like side panel 106A that extends downwardly from top panel 102 and that extends along and covers bottom end slat 60 and top end slat 66 at first end 28 of first frame 14A. Cover 100 includes a sheet-like side panel 106B that extends downwardly from top panel 102 and that extends along and covers bottom end slat 60 and top end slat 66 at first end 28 of second frame 14B. Cover 100 includes a sheet-like side panel 108A that extends downwardly from top panel 102 and that extends along and covers bottom end slat 62 and top end slat 68 at second end 30 of first frame 14A. Cover 100 includes a sheet-like side panel 108B that extends downwardly from top panel 102 and that extends along and covers bottom end slat 62 and top end slat 68 at second end 30 of second frame 14B. Ends of end panel 104A are respectively connected to outer ends of side panels 106A and 108A. Ends of end panel 104B are respectively connected to outer ends of side panels 106B and 108B. Each side panel 106A-B and 108A-B includes a generally linear and vertical inner edge 110 that extends downwardly from adjacent top panel 102 and along corner posts 54A and 54B of inner support members 40 of frames 14A and 14B.
Side panel 106A is separated from side panel 106B, and side panel 108A is separated from side panel 108B, to allow for the pivotal movement of first frame 14A and second frame 14B with respect to one another about pivot axis 20. If desired, side panels 106A and 106B may initially be formed as a single continuous panel, and side panels 108A and 108B may be formed as a single continuous panel, when cover 100 is placed over frames 14A and 14B of base 12, and slits are subsequently cut in the side panels to thereby separate side panel 106A from side panel 106B and to separate side panel 108A from side panel 108B. The cutting or slitting of side panels 106A-B and 108A-B may leave the inner edges 110 thereof with a rough or unfinished looking appearance. Cover 100 may be coupled to frames 14A and 14B of base 12 by fasteners such as staples and adhesives. Cover 100 may be made from a flexible fabric material and may include padding.
Foundation 10 may include a corner cover 116 at each inner edge 110 of side panels 106A-B and 108A-B that provides a finished appearance to the inside ends of the side panels. As shown in FIGS. 6 and 7, corner cover 116 includes a sheet 118 of flexible material, such as a non-woven fabric. Sheet 118 extends between a generally linear first side edge 120 and a generally linear second side edge 122, and between a generally linear bottom edge 124 and a generally linear top edge 126. Sheet 118 includes a generally planar first surface 128 on a first side of sheet 118 and a generally planar second surface 130 on a second side of sheet 118. An elongate plate-like strip 134 is coupled to first surface 128 of sheet 118 by a fastener, such as an adhesive. Strip 134 may be formed from a plastic material. Strip 134 extends between bottom edge 124 and top edge 126 of sheet 118 generally parallel to and spaced inwardly from second side edge 122 of sheet 118. Strip 134 may be located inwardly from second side edge 122 of sheet 118 by approximately three-quarter of an inch. Strip 134 may be approximately one-half inch wide and approximately nine and one-half inches long. Sheet 118 may be approximately nine and one-half inches square.
As best shown in FIG. 8, second surface 130 of sheet 118 of corner cover 116 is placed adjacent side panel 106A of frame 14A such that second side edge 122 of sheet 118 is located adjacent and generally parallel to inner edge 110 of side panel 106A. Corner cover 116 may then be connected to inner support member 40 by inserting fasteners, such as staples, through strip 134, sheet 118, side panel 106A, and into corner post 54A. Sheet 118 and strip 134 of corner cover 116 thereby connect side panel 106A to corner post 54A of inner support member 40. Sheet 118 of corner cover 116 may then be wrapped around strip 134 such that first side edge 120 of sheet 118 is located adjacent the outside surface of corner post 54A and such that first surface 128 of sheet 118 extends along and in engagement with the outside side surface of corner post 54A. Sheet 118 of corner cover 116 may be connected to the side surface of corner post 54A with fasteners, such as staples. Sheet 118 of corner cover 116 thereby provides a finished appearance to the inner end of side panel 106A. Corner covers 116 may similarly be used in connection with the inner edges 110 of side panels 106B, 108A and 108B.
Foundation 10 may include a bottom cover 140A coupled to frame 14A and a bottom cover 140B coupled to frame 14B. Each bottom cover 140A-140B includes a sheet-like bottom panel 142 that are respectively coupled to and extend across bottoms 24 of each frame 14A and 14B. Each bottom cover 140A and 140B may also include a sheet-like inside panel 144 that is connected to bottom panel 142, and that is connected to and extends along respective inner sides 32 and inner support members 40 of frames 14A and 14B. Bottom covers 140A-140B may be made from a fabric material.
As shown in FIG. 9, frame 14B of foundation 10 is folded over on top of frame 14A, such that foundation 10 is in the closed folded position to provide ease of transport or shipping of folded foundation 10. When foundation 10 is in the closed folded position, as shown in FIG. 9, foundation 10 may have overall dimensions of approximately sixty inches wide in a direction parallel to pivot axis 20, approximately forty inches long in a direction transverse to pivot axis 20, and approximately nineteen inches deep between respective bottoms 24 of frames 14A-14B. This compact size of the folded foundation 10 enables the folded foundation 10 to be placed in vehicles, such as automobiles, such that an end user can transport the folded foundation 10 from a store to the user's home, and such that the folded foundation 10 can also be easily shipped from one location to another location by delivery services. The compact size of the folded foundation 10 also enables users to easily transport the folded foundation 10 within a structure, such as a house or apartment, up and down staircases, around corners, and through doorways, to the final desired location of foundation 10.
FIGS. 9-12 illustrate the pivotal movement of frame 14B with respect to frame 14A of foundation 10 about pivot axis 20 to move or pivot frame 14B with respect to frame 14A from the closed folded position as shown in FIG. 9, wherein base 12 and top panel 102 of cover 100 are both folded in half and overlie themselves, to the open unfolded position as shown in FIG. 12, wherein tops 26 of frames 14A-14B are generally coplanar with one another and top panel 102 of cover 100 is generally planar. Foundation 10 as shown in FIG. 12 in the open unfolded condition is adapted to support the mattress of a bed on top panel 102 of cover 100 and tops 26 of frames 14A-14B of base 12. Foundation 10 may be moved or pivoted from the open unfolded position, as shown in FIG. 12, to the closed folded position, as shown in FIG. 9, by pivoting frame 14A and frame 14B with respect to each other about pivot axis 20 for transport or shipping of folded foundation 10.
FIG. 13 diagrammatically illustrates a single foundation 10 adapted to support a single mattress of a bed such as a Queen-size mattress. In this example, each frame 14A and 14B of base 12 of foundation 10 may have a width parallel to pivot axis 20 of approximately 59½ inches, a length transverse to pivot axis 20 of approximately 39½ inches, and a height of approximately 9½ inches, such that when base 12 is in the open unfolded position base 12 has a width of approximately 59½ inches, a length of approximately 79 inches, and a height of approximately 9½ inches.
FIG. 14 is a diagrammatic illustration of a bed support having two foundations 10 located side-by-side with pivot axis 20 of each foundation 10 being coaxially aligned with one another. The use of two side-by-side foundations 10, as shown in FIG. 14, enables the foundations 10 to have an even shorter width than the single foundation 10 as shown in FIG. 13, while supporting the same size mattress. The two foundations 10 of FIG. 14 may be used to support a single Queen-size or King-size mattress. As an example, each frame 14A and 14B of base 12 of foundation 10, as shown in FIG. 14, may have a width parallel to pivot axis 20 of approximately 29¾ inches, a length transverse to pivot axis 20 of approximately 39½ inches, and a height of 9½ inches, such that when base 12 is in the open unfolded position base 12 has a width of approximately 591/2 inches, a length of approximately 79 inches, and a height of approximately 9½ inches for use in supporting a Queen-size mattress. Alternatively, each frame 14A and 14B of base 12 of foundation 10, as shown in FIG. 14, may have a width parallel to pivot axis 20 of approximately 37½ inches, a length transverse to pivot axis 20 of approximately 39½ inches, and a height of approximately 9½ inches, such that when base 12 is in the open unfolded position base 12 has a width of approximately 75 inches, a length of approximately 79 inches, and a height of approximately 9½ inches for use in supporting a King-size mattress. The use of two side-by-side foundations 10 to support a single mattress enables the size of each such foundation 10 to be even smaller and compact in size when in the closed folded condition than even is the single foundation 10 as shown in FIG. 13, to provide additional ease of transport and shipping of each foundation 10.
Patent Application
20210337976
