Abstract
A bedding product such as an adjustable bed comprises a stationary frame which is inclined regardless of the position of the adjustable bed. The stationary frame is supported by multiple leg assemblies of different heights. Due to wedges sandwiched between the leg assemblies and mounting brackets of the stationary frame, the leg assemblies remain flat on the ground providing a stable support for the bedding product. Each leg assembly is secured to one of the mounting brackets.
Claims
1. An adjustable bed base comprising: a stationary frame having mounting brackets; multiple leg assemblies, each of the leg assemblies being secured to one of the mounting brackets and being supported by a support surface; and multiple wedges, each of the wedges being sandwiched between one of the leg assemblies and one of the mounting brackets to incline the stationary frame relative to the support surface and keep a bottom surface of the leg assembly flat on the support surface regardless of the length of the leg assembly.
2. The adjustable bed base of claim 1, wherein each of the leg assemblies has an adjustable length.
3. The adjustable bed base of claim 1, wherein each of the wedges has an opening therethrough which allows a portion of one of the leg assemblies to pass through the opening in the wedge and engage one of the mounting brackets.
4. The adjustable bed base of claim 1, further comprising a deck comprising multiple deck members hinged to each other, at least one of the deck members being secured to the stationary frame.
5. The adjustable bed base of claim 3, wherein each of the wedges comprises a floor and lips extending upwardly from the floor on opposite sides of the floor to keep the wedge stationary.
6. The adjustable bed base of claim 5, wherein the opening extends through the floor of the wedge.
7. The adjustable bed base of claim 4, wherein the stationary frame has a head end and a foot end, one of the head and foot ends being higher than the other of the head and foot ends, regardless of the positions of the deck members.
8. An adjustable bed base comprising: a stationary frame including multiple mounting brackets; multiple legs, each of the legs being secured to the one of the mounting brackets; multiple wedges, each of the wedges being sandwiched between one of the legs and one of the mounting brackets, the wedges keeping an upper surface of the stationary frame in an inclined position relative to a horizontal support surface.
9. The adjustable bed base of claim 8, wherein each of the legs has an adjustable height.
10. The adjustable bed base of claim 8, wherein each of the wedges has a floor, lips extending upwardly from the floor on opposite sides of the floor and an opening extending through the floor which allows a portion of one of the legs to pass through the opening in the wedge and engage one of the mounting brackets.
11. The adjustable bed base of claim 8, further comprising a deck comprising multiple deck members hinged together, at least one of the deck members being secured to the stationary frame.
12. The adjustable bed base of claim 8, wherein the stationary frame has a head end and a foot end, one of the head and foot ends being at least two degrees higher than the other of the head and foot ends.
13. The adjustable bed base of claim 8, wherein the adjustable bed base has six legs.
14. An adjustable bed movable between multiple positions, the adjustable bed comprising: an adjustable bed base comprising a stationary frame having opposed side members, a head end member extending between the side members and a foot end member extending between the side members; multiple mounting brackets, each of the mounting brackets being secured to the stationary frame; multiple leg assemblies, each of the leg assemblies being secured to one of the mounting brackets; multiple wedges, each of the wedges being sandwiched between one of the leg assemblies and one of the mounting brackets to incline the stationary frame relative to a planar support surface regardless of the position of the adjustable bed.
15. The adjustable bed of claim 14, wherein each of the wedges has a floor, lips extending upwardly from the floor on opposite sides of the floor and an opening extending through the floor which allows a portion of one of the leg assemblies to pass through the opening in the wedge and engage one of the mounting brackets.
16. The adjustable bed of claim 14, wherein each of the wedges is identical.
17. The adjustable bed of claim 14, further comprising: a deck comprising multiple deck members hinged together, at least one of the deck members being secured to the stationary frame; and at least one linear actuator for moving the deck members such the deck may assume a planar position and at least one other desired deck position.
18. The adjustable bed of claim 17, wherein the wedges are stationary relative to the frame regardless of the position of the deck.
19. The adjustable bed base of claim 14, wherein some of the leg assemblies are different lengths than other of the leg assemblies.
20. The adjustable bed of claim 14, wherein each of the leg assemblies has an adjustable length.
21. The adjustable bed of claim 14, wherein the mounting brackets are secured to side members of the stationary frame.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a top perspective view of an adjustable bed constructed in accordance with the present invention.
[0025] FIG. 2 is a bottom perspective view of the adjustable bed of FIG. 1 showing an adjustable bed base supported by six adjustable leg assemblies.
[0026] FIG. 3 is a side view of the adjustable bed of FIG. 1, showing the inclined stationary frame of the adjustable bed base of the adjustable bed of FIG. 1 with the deck in a down or flat position.
[0027] FIG. 3A is a side view of the adjustable bed of FIG. 1, showing the inclined stationary frame of the adjustable bed base of the adjustable bed of FIG. 1 with the deck in a fully inclined position.
[0028] FIG. 4A is an enlarged bottom perspective view of a portion of the adjustable bed of FIG. 1, showing one of the leg assemblies being secured to the stationary frame of the adjustable bed base.
[0029] FIG. 4B is an enlarged bottom perspective view of the portion of the adjustable bed of FIG. 1 shown in FIG. 4A, showing one of the leg assemblies being further secured to the stationary frame of the adjustable bed base.
[0030] FIG. 5 is a cross-sectional view of the leg assembly of FIGS. 4A and 4B secured to the stationary frame of the adjustable bed base.
[0031] FIG. 6 is an enlarged view of a portion of FIG. 5 showing a connection between the leg assembly and the stationary frame of the adjustable bed base.
[0032] FIG. 7 is a perspective view of a wedge according to one embodiment of the invention;
[0033] FIG. 7A is a cross-sectional view taken along the line 7A-7A of FIG. 7.
[0034] FIG. 7B is a cross-sectional view like FIG. 7A of an alternative wedge.
[0035] FIG. 8 is a partially disassembled view of one of the leg assemblies.
[0036] FIG. 9 is a side view of a bedding foundation constructed in accordance with the present invention.
[0037] FIG. 9A is a bottom perspective view of the bedding foundation of FIG. 9.
[0038] FIG. 10 is a perspective view of a shippable container with the adjustable bed 10 therein ready to be assembled.
DETAILED DESCRIPTION OF THE INVENTION
[0039] Referring to FIG. 1, there is illustrated an adjustable bed 10, including an adjustable bed base 12 for supporting a mattress 14. The mattress 14 is shown in dashed lines. The adjustable bed 10 has a head end 5 and a foot end 7. As best shown in FIG. 2, the adjustable bed base 12 comprises a generally rectangular, stationary frame 16 supported by six leg assemblies 18. In any of the embodiments, any number of leg assemblies 18 such as four or eight may be supported by the stationary frame 16 of the adjustable bed base 12.
[0040] As best shown in FIG. 2, the generally rectangular frame 16 of the adjustable bed base 12 comprises two side members 22, a head member 24 extending between the side members 22, a foot member 26 extending between the side members 22 and an intermediate member 28 extending between the side members 22. Each of the side members 22 is hinged with hinge 17 to enable the adjustable bed base 12 to fold for shipping purposes as shown in FIG. 10.
[0041] As best shown in FIGS. 1 and 2, the adjustable bed base 12 further comprises a deck 30 comprising a head deck board 32, a first lumbar deck board 34, a second lumbar deck board 36, a thigh deck board 38 and a foot deck board 40. As best shown in FIG. 2, the head deck board 32 is joined to the first lumbar deck board 34 with three hinges 42 secured to lower surfaces of the first lumbar deck board 34 and head deck board 32. The first lumbar deck board 34 is stationary and secured to the side members 22 of the generally rectangular frame 16 of the adjustable bed base 12. Similarly, the second lumbar deck board 36 is stationary and secured to the side members 22 of the generally rectangular frame 16 of the adjustable bed base 12. The first lumbar deck board 34 is separated from the second lumbar deck board 36 with a gap 35 to allow the adjustable bed base 12 to fold or collapse into two parts for shipping purposes as shown in FIG. 10. One deck board may be used in place of the first and second lumbar deck boards in some embodiments.
[0042] As best shown in FIG. 2, the second lumbar deck board 36 is joined to the thigh deck board 38 with three additional hinges 44 secured to lower surfaces of the second lumbar deck board 36 and thigh deck board 38. Lastly, the thigh deck board 38 is joined to the foot deck board 40 with three additional hinges 46 secured to lower surfaces of the thigh deck board 38 and foot deck board 40.
[0043] The deck 30 is movable between a flat position shown in FIG. 2 and a fully adjusted position shown in FIG. 3A. When the deck 30 is in its flat position, the deck boards 32, 34, 36, 38 and 40 are generally co-planar and rest on top of an upper surface 33 of the side members 22 of the generally rectangular frame 16 of the adjustable bed base 12. As best shown in FIG. 3, when the deck 30 is in its flat position, the aligned deck boards 32, 34, 36, 38 and 40 are generally co-planar in a plane P which is inclined at an angle θ to a horizontal plane. The angle θ may be any number but is typically between two and four degrees due to the construction of the wedges 72, 72' described below.
[0044] As shown in FIG. 3A, in the deck’s fully adjusted position, the head deck board 32 is inclined, the front edge 48 of the head deck board 32 being above the rear edge 50 of the head deck board 32 due to operation of a motorized linear actuator 60. Regardless of the deck’s position, the first lumbar deck board 34 and second lumbar deck board 36 are stationary and secured to the side members 22 of the generally rectangular frame 16 of the adjustable bed base 12. In the deck’s fully adjusted position shown in FIG. 3A, the thigh deck board 38 is inclined, the front edge 52 of the thigh deck board 38 being below the rear edge 54 of the thigh deck board 38 due to operation of a motorized linear actuator 62. In the deck’s fully adjusted position, the foot deck board 40 is inclined, the front edge 56 of the foot deck board 40 being above the rear edge 58 of the foot deck board 40 as seen in FIG. 3A.
[0045] Although not shown, only one of the two linear actuators 60, 62 may be activated such that only a portion of the deck 30 is inclined. As best shown in FIG. 1, a foam border 80 surrounds the deck 30 for protection. As shown in FIG. 1, the foam border 80 has gaps 82 therein to enable the adjustable bed base 12 to be folded in half for shipping purposes. See FIG. 10. As is conventional in adjustable beds, a generally U-shaped mattress stop 84 is secured to the foot deck board 40 to prevent the mattress 14 from moving relative to the adjustable bed base 12.
[0046] As best shown in FIGS. 2, 4A and 4B, the generally rectangular frame 16 of the adjustable bed base 12 further comprises six mounting brackets 64 welded to the side members 22 of the generally rectangular frame 16. As best shown in FIG. 2, three of the mounting brackets 64 are welded to each side member 22 of the generally rectangular frame 16.
[0047] FIGS. 4A and 4B illustrate one of the front corners at the head end 5 of the generally rectangular frame 16. As best shown in FIGS. 4A and 4B, each of the mounting brackets 64 is a generally U-shaped unitary member. Each of the mounting brackets 64 comprises a generally planar floor 66 and two side walls 68 extending upwardly from the generally planar floor 66. As best shown in FIG. 4A, the generally planar floor 66 of the mounting bracket 64 has a lower surface 67 which is coplanar with the lower surface 19 of the side member 22 of the generally rectangular frame 16. The side walls 68 of the mounting bracket 64 are perpendicular to the generally planar floor 66 of the mounting bracket 64.
[0048] As best illustrated in FIG. 6, a threaded boss 70 is welded or otherwise secured to the generally planar floor 66 of the mounting bracket 64. The threaded boss 70 extends upwardly from the generally planar floor 66 of the mounting bracket 64. Each of the side walls 68 is generally triangular. Because each of the mounting brackets 64 is welded to one of the side members 22 of the generally rectangular frame 16, the mounting brackets 64 may be considered part of the generally rectangular frame 16 of the adjustable bed base 12.
[0049] However, the mounting brackets 64 may be removably secured to the side members 22 of the generally rectangular frame 16 of the adjustable bed base 12 in which case the mounting brackets 64 would not be considered integral parts of the generally rectangular frame 16 of the adjustable bed base 12.
[0050] As best shown in FIG. 2, a leg assembly 18 is secured to each of the mounting brackets 64 of the generally rectangular frame 16 with a wedge 72 therebetween. The location of the mounting brackets 64 is not intended to be limited by the drawings; the mounting brackets 64 may be secured to other portions of the generally rectangular frame 16. As best shown in FIG. 2, the adjustable bed 10 has six mounting brackets 64, six wedges 72 and six leg assemblies 18.
[0051] As shown in FIGS. 7 and 7A, one embodiment of wedge 72 is a unitary member comprising a main portion 128 and two wings 130 extending upwardly from the main portion 128. An oval shaped opening 126 extends through the main portion 128 of the wedge 72, as best shown in FIG. 7. The wedge 72 has a generally U-shaped front surface 132 and a generally U-shaped rear surface 134. Each of the wings 130 of wedge 72 has an inner surface 135 and outer surface 136. The wedge 72 has a length L defined as the linear distance between the front and rear surfaces 132, 134, respectively. The wedge 72 has a uniform width W defined as the linear distance between outer surfaces 136 of the wings 130, as shown in FIG. 7. The main portion 128 of the wedge 72 has an upper surface 138 which slopes downwardly from back to front. The wedge 72 has a planar bottom surface 140. As shown in FIG. 7A, a plane defined by the upper surface 138 of the main portion 128 of wedge 72 forms an angle θ to the horizontal plane defined by the bottom surface 140 of wedge 72. The angle θ may be any number but is typically between two and four degrees. In one preferred embodiment, the angle θ is four degrees, as shown in FIG. 7A. As best shown in FIG. 7A, the main portion 128 of the wedge 72 decreases in thickness moving in the forward direction from the rear surface 134 to the front surface 132 of the wedge 72. Thus, the main portion 128 of the wedge 72 has a tapered thickness, decreasing from back to front.
[0052] In another preferred embodiment, the angle θ is two degrees as shown in wedge 72' of FIG. 7B. For simplicity like numbers represent like parts but with a prime after the number representing the part. Wedge 72' is a unitary member comprising a main portion 128' and two wings 130' extending upwardly from the main portion 128'. An oval shaped opening 126' extends through the main portion 128' of the wedge 72'. The wedge 72' has a generally U-shaped front surface 132' and a generally U-shaped rear surface 134'. Each of the wings 130' of wedge 72' has an inner surface 135' and outer surface 136'. The wedge 72' has a length L defined as the linear distance between the front and rear surfaces 132', 134', respectively. The wedge 72' has a uniform width W defined as the linear distance between outer surfaces 136' of the wings 130'. The main portion 128' of the wedge 72' has an upper surface 138' which slopes downwardly from back to front. The wedge 72' has a planar bottom surface 140'. As shown in FIG. 7B, a plane defined by the upper surface 138' of the main portion 128' of wedge 72' forms an angle θ to the horizontal plane defined by the bottom surface 140' of wedge 72'.
[0053] As best shown in FIG. 8, each leg assembly 18 has an adjustable length. Each leg assembly 18 includes a receiver 74 and a lower member 76. As shown in FIG. 8, the receiver 74 has an upper edge 78, which abuts or otherwise contacts the lower surface 140 of wedge 72 upon assembly and a lower edge 79. As best shown in FIG. 6, receiver 74 comprises a wall 84 having an interior surface 86 defining a hollow interior 88 therein and an exterior surface 90. As shown in FIGS. 5 and 6, receiver 74 has an inner diameter D1 and an outer diameter D2. Thus, the receiver 74 has a generally cylindrical shape. As best shown in FIG. 8, receiver 74 has two rows 91, 93 of aligned holes 92, each hole 92 extending through the wall 84 of the receiver 74. Although six aligned holes 92 are illustrated in row 91 and five aligned holes 92 are illustrated in row 93, the receiver 74 may have any desired number of holes or openings of any desired shape in either row.
[0054] As best shown in FIG. 6, at an upper portion of the receiver 74, a washer 95 is secured inside the hollow interior 88 of the receiver 74 via welding, for example. As best shown in FIG. 6, washer 95 has a central opening 96 therein through which passes a shaft 98 of a fastener 100. The fastener 100 has a head 102 below the opening 96 of washer 95. See FIGS. 6 and 8. The shaft 98 of fastener 100 has external threads 104, the function of which is described below.
[0055] As best shown in FIG. 8, each leg assembly 18 further comprises a lower member 76 having an upper edge 106 and a lower edge 108. As best shown in FIGS. 5 and 8, lower member 76 comprises a wall 110 having an interior surface 112 defining a hollow interior 114 therein and an exterior surface 116. As shown in FIGS. 5 and 8, lower member 76 has an inner diameter D3 and an outer diameter D4. Thus, the lower member 76 has a generally cylindrical shape. As shown in FIG. 5, the outer diameter D4 of the lower member 76 is slightly less than the inner diameter D1 of receiver 74 so the lower member 76 may fit inside the hollow interior 88 of the receiver 74.
[0056] As best shown in FIG. 8, each leg assembly 18 further comprises a push pin assembly 118 secured inside the hollow interior 114 of the lower member 76. The push pin assembly 118 includes a generally C-shaped spring 120 having a push pin 122 welded or secured to one end of the generally C-shaped spring 120. As best shown in FIGS. 5 and 8, the generally C-shaped spring 120 resides inside the hollow interior 114 of lower member 76, the push pin 122 of push pin assembly 118 extending through one of the two openings 124 in the lower member 76. When the leg assembly 18 is fixed at a desired height, the push pin 122 of push pin assembly 118 also extends through one of the holes 92 of receiver 94. The leg assembly 18 stays at its desired height when the adjustable bed is in use. Because the push pin 122 of push pin assembly 118 extends through both one of the openings 124 in the lower member 76 and through one of the holes 92 of receiver 94, the lower member 76 is fixed relative to the receiver 94. The lower member 76 only moves when an operator pushes in the push pin 122 and then moves the receiver 94 so the push pin 122 extends through a different hole 92 of receiver 94.
[0057] Each leg assembly 18 may further comprise a riser 142 which has a cavity 144 for receiving a lower portion of the lower member 76 of leg assembly 18. Although in the embodiment of adjustable bed 10 shown, two of six leg assemblies 18 of adjustable bed base 12 are illustrated having a riser 142, four or six of the leg assemblies 18 may have a riser 142. Alternatively, none of the leg assemblies 18 may have a riser 142.
[0058] As best shown in FIGS. 3 and 3A, regardless of the position of the deck 30 the head end 13 of the generally rectangular frame 16 is above the foot end 15 of the generally rectangular frame 16 due to the wedges 72 or 72'. Alternatively, the wedges 72 or 72' may be oriented to keep the generally rectangular frame 16 in a declined position such that the foot end 15 of the generally rectangular frame 16 is above the head end 13 of the generally rectangular frame 16 due to the wedges 72 or 72'.
[0059] Although the drawings illustrate only leg assemblies having adjustable lengths, it is within the scope of the present invention that unitary legs, not adjustable in length, may be used in accordance with the present invention.
[0060] As best shown in FIGS. 3 and 3A, a pair 21 of leg assemblies 18 proximate the head end 13 of the generally rectangular frame 16 are adjusted in length to be a length L1. Another pair 23 of leg assemblies 18 proximate the foot end 15 of the generally rectangular frame 16 are adjusted in length to be a length L2 less than the length L1. A middle pair 25 of leg assemblies 18 between the head and foot ends 13, 15 of the generally rectangular frame 16 are adjusted in length to be a length L3 which is greater than length L2 and less than length L1.
[0061] As shown in FIGS. 4A and 4B, in order to secure one of the leg assemblies 18 to one of the mounting brackets 64 of the generally rectangular frame 16 of the adjustable bed base 12, the fastener 100 of the receiver 74 of the leg assembly 18 extends through the oval shaped opening 126 in the main portion 128 of wedge 72 and into the threaded boss 70 of the mounting bracket 64. The external threads 104 of fastener 100 engage the internal threads of the threaded boss 70 of the mounting bracket 64 so that upon rotation of the leg assembly 18, the leg assembly 18 is secured to the mounting bracket 64 with the wedge 72 sandwiched therebetween.
[0062] As best shown in FIG. 4B, the wedge 72 is sized so that one of the wings 130 abuts an outer surface 23 of one of the side members 22 of the generally rectangular frame 16. The other wing 130 of the wedge 72 abuts an inner edge of one of the mounting brackets 64. This alignment helps keep the wedge 72 in place and enables a user to quickly and easily pass the fastener 100 of the leg assembly 18 through the oval shaped opening 126 of the wedge 72 and into the threaded boss 70 of the mounting bracket 64.
[0063] All the wedges of adjustable bed 10 are identical to impart the desired angle of inclination or declination to the adjustable bed base 12. In the illustrated embodiment of adjustable bed 10, six wedges 72 are shown. However, six wedges 72' could be used to impart a different angle of inclination or declination to the adjustable bed base 12.
[0064] As best shown in FIGS. 5 and 6, upon assembly, the bottom surface 140 of wedge 72 stays horizontal or parallel the floor or supporting surface 3. The bottom surface 140 of wedge 72 abuts and contacts the upper edge 78 of receiver 74 of leg assembly 18. As best shown in FIG. 4B, the upper surface 138 of the main portion 128 of wedge 72 contacts and remains flush with a lower surface 19 of a side member 22 of generally rectangular frame 16. Additionally, the upper surface 138 of the main portion 128 of wedge 72 contacts and remains flush with the lower surface 67 of floor 66 of mounting bracket 64. As best shown in FIGS. 5 and 6, due to the construction of the wedge 72, upon assembly, the leg assembly 18 remains in a generally vertical orientation, providing stability to the leg assembly 18. In addition, the mounting bracket 24 and side member 22 of the generally rectangular frame 16 remain inclined. The generally rectangular frame 16 remains inclined at an angle θ determined by the construction of the wedges and remains stationary regardless of the positions of the deck members. As seen in FIG. 6, the lower surfaces 19 of side members 22 of the generally rectangular frame 16 remains inclined at an angle θ relative to a horizontal plane P.
[0065] FIGS. 9 and 9A illustrate a bedding foundation 200 constructed in accordance with the present invention. The bedding foundation 200 has the same parts as the adjustable bed 10 but a different bed base 212. The bed base 212 is the similar to adjustable bed base 12 but has a unitary deck member 230 in place of an articulated deck 30 and frame side members 222 which are not hinged. For simplicity like numbers represent like parts.
[0066] Although none of the leg assemblies 18 of bedding foundation 200 are illustrated having a riser 142, it is within the scope of the present invention that two, four or all six leg assemblies of bedding foundation 200 may have risers 142. It is also with the scope of the present invention that bedding foundation 200 may be foldable with hinged frame side members and a foldable deck.
[0067] The adjustable bed base 12 may be shipped in a container 300. FIG. 10 illustrates container 300 showing the adjustable bed base 12 folded in half or in a collapsed position with the leg assemblies 18 and wedges 72 separated from the adjustable bed base 12. Although FIG. 10 shows the adjustable bed base 12 folded a certain direction, those skilled in the art will appreciate that the adjustable bed base may be folded the other direction. The container 300 includes six leg assemblies 18 including six risers 142 and six wedges 72. Although not shown, the risers may be packaged in plastic and so may be the wedges and the leg assemblies for protection during shipping.
[0068] Alternatively, the container 300 may contain only two or four risers 142 or any number of risers 142. The container 300 may be shipped via United Parcel Service or any other shipping company and assembled at the destination without tools. In some applications, four or eight or any number of leg assemblies 18 and risers 142 and wedges 72 may be shipped in the container depending upon the design of the adjustable bed or bedding foundation. The size and configuration of container 300 are not intended to be limited by the drawings. Any size container may be used of any shape.
[0069] The various embodiments of the invention shown and described are merely for illustrative purposes only, as the drawings and the description are not intended to restrict or limit in any way the scope of the claims. Those skilled in the art will appreciate various changes, modifications, and improvements which can be made to the invention without departing from the spirit or scope thereof. The invention in its broader aspects is therefore not limited to the specific details and representative apparatus and methods shown and described. Departures may therefore be made from such details without departing from the spirit or scope of the general inventive concept. The invention resides in each individual feature described herein, alone, and in all combinations of any and all of those features. Accordingly, the scope of the invention shall be limited only by the following claims and their equivalents.
