Abstract
A shippable mattress foundation that assembles quickly without any tools, ship in a small Fedex/UPS package, fits easier on a skid in a retail store, and allows an end customer to take it home in a car. It holds over 2500 lbs. of distributed weight, allows for easy attachment of a headboard of various dimensions, has an attractive optionable, washable and detachable outer stylish cover, and is designed to allow up to 12 of underneath storage. Also has stamped holes for receipt of the cross slats and a bespoken plastic clip for adjoining the cross slats.
Claims
1. A shippable mattress foundation, said shippable mattress comprising: a frame having a head element, a foot element, a center support, a right-side element having stamped holes and left-side element having stamped holes; cross slats couplable to the frame; stamped holes within the right-side element and left-side element for receipt of the cross slats; an interlocking side flange; and an attachment clip on the center support for adjoining the cross slats.
2. The attachment clip of claim 1 wherein said attachment clip is configured to have a first receptacle and a second receptacle, wherein said first and second receptacle are configured to be on opposing sides, wherein said first and second receptacle are configured to receive said cross slats vertically.
3. The receptacles of claim 2 wherein said receptacles utilize at least two side walls.
4. The receptacles of claim 2 wherein said receptacles utilize a floor.
5. The receptacles of claim 4 wherein said receptacles hold said cross slat into position.
6. The shippable mattress foundation of claim 1 wherein said frame is attached to vertical support legs providing at least 10 inches of clearance from ground level.
7. The shippable mattress foundation of claim 1 wherein said frame can support at least 2,500 lbs of a distributed load.
8. The shippable mattress foundation of claim 1 wherein said attachment clip is made of plastic.
9. The shippable mattress foundation of claim 1 wherein said attachment clip contains a bottom protrusion that fits within a top hole on said center support.
10. The side flange of claim 1 wherein said flange side is configured to interlock with a second element portion, wherein interlocking with said second element portion enables for a strong connection between bed frame elements.
Description
DESCRIPTION OF THE DRAWINGS
[0124] FIG. 1 illustrates a top left perspective view of an assembled mattress foundation and a box for shipping an unassembled mattress foundation according to the invention.
[0125] FIG. 2 illustrates a top left perspective view of the assembled mattress foundation shown in FIG. 1
[0126] FIG. 3 illustrates the front, bottom, left perspective view of the box shown in FIG. 1.
[0127] FIG. 4 illustrates a top rear perspective view of a left side vertical support, right side vertical support, central vertical support, and front horizontal support, each in an unfolded position.
[0128] FIG. 5 illustrates a top rear right perspective view of the left side vertical support and the front horizontal support shown in FIG. 4 shown attached to each other.
[0129] FIG. 6 illustrates a top elevational view of the central vertical support joined to two slats.
[0130] FIG. 7 illustrates a top elevational view of the central vertical support joined to slats and bundled horizontal slats.
[0131] FIG. 8 illustrates a top elevational view of the central vertical support joined to slats and bundled horizontal slats.
[0132] FIG. 9 illustrates a top, rear, right perspective view of the left side vertical support joined to the rear horizontal support with a cover shown in a draped position.
[0133] FIG. 10 illustrates the top, rear, right perspective view of a headboard plate being attached to the rear horizontal support shown in FIG. 9.
[0134] FIG. 11 illustrates the top rear perspective view of the headboard plate shown in FIG. 10.
[0135] FIG. 12 illustrates a top left perspective view of an assembled mattress foundation with first leg segments installed.
[0136] FIG. 13 illustrates the top left perspective view of the assembled mattress foundation shown in FIG. 12 with the first segments and second leg segments installed.
[0137] FIG. 14 illustrates the top left perspective view of the assembled mattress foundation shown in FIG. 12 with the first segments, the second leg segments, and third leg segments installed.
[0138] FIG. 15 illustrates a front perspective view of an unassembled mattress foundation.
[0139] FIG. 16 illustrates a left top perspective view of a king-size mattress foundation with a cover installed over the frame and a box for shipping the mattress foundation.
[0140] FIG. 17 illustrates the left rear top perspective view of the mattress foundation shown in FIG. 16 with the cover retracted from a front left corner of the frame.
[0141] FIG. 18 illustrates the left rear top perspective view of the mattress foundation shown in FIG. 16 with the first and second leg segments installed.
[0142] FIG. 19 illustrates a left top perspective view of a twin-size mattress foundation with a cover partially installed over the frame and a box for shipping the mattress foundation.
[0143] FIG. 20 illustrates the partial, left rear top perspective view of the twin-size mattress foundation shown in FIG. 19, with the first and second leg segments installed.
[0144] FIG. 21 illustrates a side elevational view of four legs.
[0145] FIG. 22 illustrates a table listing dimensions of mattress foundation sizes and respective packaging sizes.
[0146] FIG. 23 illustrates a partial rear elevational view of the mattress frame shown in FIG. 9 with the mounting plate in a horizontal position.
[0147] FIG. 24 illustrates the partial rear elevational view of the mattress frame shown in FIG. 9 with the mounting plate in a vertical position.
[0148] FIG. 25 illustrates a perspective view of a threaded T-nut.
[0149] FIG. 26 illustrates a partial top right perspective view of the left vertical support shown in FIG. 4 with a hinge in a locked position.
[0150] FIG. 27 illustrates a side elevational view of rails.
[0151] FIG. 28 illustrates a partial side elevation view of the rails shown in FIG. 27.
[0152] FIG. 29 illustrates a perspective view of a slat separated from a rail.
[0153] FIG. 30 illustrates a side elevational view of a leg with two leg segments.
[0154] FIG. 31 illustrates an exploded perspective view of the leg shown in FIG. 30.
[0155] FIG. 32 illustrates a front top right perspective view of a mattress frame.
[0156] FIG. 33 illustrates the partial rear bottom right perspective view of the mattress frame shown in FIG. 32.
[0157] FIG. 34 illustrates a bottom perspective view of a cover.
[0158] FIG. 35 illustrates a top elevational view of a second embodiment of a mounting plate.
[0159] FIG. 36 illustrates a right elevational view of the mounting plate shown FIG. 35.
[0160] FIG. 37 illustrates a rear elevational view of the mounting plate shown in FIG. 35.
[0161] FIG. 38 illustrates a left elevational view of the mounting plate shown in FIG. 35.
[0162] FIG. 39 illustrates the top front left perspective view of the mounting plate shown in FIG. 35.
[0163] FIG. 40 illustrates the front elevational view of the mounting plate shown in FIG. 35.
[0164] FIG. 41 illustrates the bottom elevational view of the mounting plate shown in FIG. 35.
[0165] FIG. 42 illustrates a close-up view of the mattress foundation showing the S-clips.
[0166] FIG. 43 illustrates a top perspective view of the mattress foundation.
[0167] FIG. 44 illustrates a close-up view of the mattress foundation showing the support as well as how the side elements connect to the side flange throughout the frame.
DETAILED DESCRIPTION
[0168] FIG. 1-21 illustrate a preferred embodiment of a mattress foundation and the steps of a method for assembling the mattress foundation.
[0169] In one or more embodiments of the invention the first step includes a left side vertical support 10 to be unfolded and placed on a floor or an equivalent surface. A right side vertical support 11 is unfolded and placed parallel to the left side vertical support 10. A central vertical support 18 is unfolded and placed between the left side vertical support 10 and the right side vertical support 11. The word vertical is meant to mean longitudinal: i.e., running from front to back. The left side vertical support 10 has a left side front support 100. The right side vertical support 11 has a right side front support 110. A front horizontal support 12 is shown unfolded. Horizontal is mean to mean latitudinal; i.e., running from left to right. The front horizontal support 12 has a left support piece 120 and a right support piece 121.
[0170] FIGS. 4-5 illustrate the next step for assembling the mattress foundation. The front horizontal support 12 is connected to the right side vertical support 11. The left side front support 100 is placed against the left support piece 120. The right side front support 110 is placed against the right support piece 121. In addition, a threaded socket 1200 is formed in the left support piece 120 as well as the right support piece. A hole 1003 is formed in the left side front support 100. A bolt, which is not shown, is to be inserted through the hole 1003 and screwed into the threaded socket 1200. Similarly, the central vertical support 18 and the right side vertical support 11 are joined to the front horizontal support 12. In no particular sequence the rear horizontal support 13 is joined to the left vertical support 10, the right vertical support 11, and the central vertical support 18.
[0171] FIG. 6 illustrates a central vertical support 18 which has a resinous left seat 183 and resinous right seat 184. A left slat 16 is held in the left seat 183. A right slat 17 is held in the right seat 184. The left seat 183 and the right seat 184 are at a different height along the central vertical support 18.
[0172] In another embodiment, a preferred spacing between adjacent left slats 16 and adjacent right slats 17 is eighteen centimeters (18 cm).
[0173] FIG. 7-8 illustrates a left bundled slat 14 and a right bundled slat 15. The left bundled slat 14 includes four horizontal slats 140, 141, 142, 143, a left slat 16, a right slat 17 and a central vertical support 18. A left vertical slat 144 supports the four horizontal slats 140, 141, 142, 143. The right bundled slat 15 includes four horizontal slats 150,151, 152, 153. A right vertical slat 154 supports the four horizontal slats 150, 151, 152, 153.
[0174] In another embodiment a preferred spacing between adjacent horizontal slats 140, 141, 142, 143 in a left bundled slat 14 and the four horizontal slats 150, 151, 152, 153 in the right bundled slat 15 is eight and nine-tenths centimeters (8.9 cm).
[0175] FIG. 9 illustrate a rear horizontal support 13. The rear horizontal support 13 includes a right support piece 131, top support piece 133, and a bottom support piece 134. Bolts 50, 52, and 53 fasten the rear horizontal support 13 to the right-side vertical support 11. Threaded sockets 60, 61, 62 are disposed in the top support piece 133. Threaded socket 63 is formed in the right support piece 131. Threaded socket 64 is disposed in the bottom support piece 134.
[0176] FIGS. 10-11 illustrate a mounting plate 4 attached to the rear horizontal support 13. As explained in conjunction with FIGS. 35-41, the mounting plate 4 is placed with an outer third-edge slot 440 overlying threaded socket 64 and with outer first-edge slot 400 overlying threaded sockets 61 and 62. Bolts 54, 55, and 56 are inserted through outer first-edge slots 400 and outer third-edge 440 and screwed into overlying threaded sockets 62, 61, and 64.
[0177] FIGS. 12-14 illustrate a mattress foundation with different heights. Each figure illustrates different height sizes due to the different leg 3 lengths. In FIG. 12, each leg 3 includes a first leg segment 30. The first leg segment 30 includes a foot 300, a body 301, and a bolt (which is not visible in FIG. 12). The body 301 can be cylindrically, or rectangular shaped.
[0178] FIG. 15 illustrates an unassembled mattress foundation where all of the parts that make up the mattress foundation are unattached and are in a folded position. Included in the figure are the left side vertical support 10, the right-side vertical support 11, and the central vertical support 18 are shown in a folded position unattached to another part. The front horizontal support 12 and the rear horizontal support 13 are shown in a folded position. A plurality of legs 3 are shown. Left slats 16 and right slats 17 are shown. The Figure is intended to illustrate that all of the mentioned parts fit compactly within a box 7.
[0179] FIG. 16 illustrates an assembled frame 1 with a cover 2. A box 7 is shown. Also shown in FIG. 16 is a box 7 which houses all components that make up the bed mattress as listed in FIG. 15.
[0180] FIG. 17-18 illustrate a king-sized mattress foundation. A cover 2 is placed over the left vertical support 10 and the front horizontal support 12. The cover 2 includes a top 20, a rear 23, and a left 24. The rear 23 has a right rear opening 230 and a left rear opening 231 formed therein. The right rear opening 230 and the left rear opening 231 provide access to the mounting plates 4.
[0181] FIG. 19 illustrates a twin-sized mattress foundation. In the figure a left top perspective view of a twin-size mattress foundation is illustrated with a cover partially installed over the frame and a box for shipping the mattress foundation.
[0182] FIG. 20 illustrates the partial, left rear top perspective view of the twin-size mattress foundation shown in FIG. 19, with the first and second leg segments installed. The Figure also illustrates a cover 20 that includes a rear 23 and left 24. The rear 23 has a left rear opening 231 formed therein that provides access to the mounting plate 4. A leg 3 is shown with first leg segment 30 and second leg segment 31.
[0183] FIG. 21 illustrates legs 3 that include first segment 30 and second segment 31. The first segment 30 includes a foot 300 and a body 301. The second segment 31 includes a body 311 and a threaded bolt 312.
[0184] FIG. 22 illustrates a table listing dimensions of mattress foundation sizes and respective packaging sizes. In this table different mattress widths, lengths, heights, and weights are included. In addition, box widths, lengths, and heights are also included. Each of the different dimensions discussed above are included for different respective packaging sizes such as Twin, Twin XL, Full, Queen, King, California King and Split King. The inclusion of different packaging sizes allows for the transport of compact bed mattress Foundations to a variety of users with different weights and heights. The flexibility of compact packings of different mattress foundation sizes allows users access to a bed mattress foundation of their choice no matter their weight and/or height.
[0185] FIG. 23 illustrates a mounting plate 4 secured to a rear horizontal support 13. Bolt 54 and bolt 55 are inserted through slots in the mounting plate 4. The mounting plate 4 is oriented but not limited to a landscape position with the larger dimension being horizontal and the shorter dimension being vertical.
[0186] FIG. 24 illustrates a mounting plate 4 secured to a rear horizontal support 13. Bolts 61 and 64 are inserted through slots in the mounting plate 4. The mounting plate is in a portrait position, with the larger dimension being vertical, and the smaller dimension being horizontal. The cutout avoids interference with the threaded socket 62.
[0187] FIG. 25 illustrates an inner-threaded bolt 8. The inner-threaded bolt 8 has a head 80 and a body 81. A threaded bore 82 is formed axially through the head 80 and the body 81.
[0188] FIG. 26 illustrates a hinge 9. The hinge 9 includes a first leaf 90 and a second leaf 91. A plurality of hinges 92 and 93 alternate along the length of the hinge 9. A hinge pin 94 is inserted through the hinges 92 and 93. The first leaf 90 is welded to frame support 95. The second leaf 91 is welded to the frame support 96. When the hinge 9 is open, a cotter bolt 97 is driven through the frame support 95 and frame support 96. A lock nut 98 secures the cotter bolt 97.
[0189] FIGS. 27-28 illustrates a left slats 16 and right slats 17. The left stats 16 and the right stats 17 are extruded, hollow rectangular tubes. The slats have a plurality of rectangular notches 160 and 170 formed therein.
[0190] FIG. 29 illustrates a top support piece 185 of a central vertical support 18. A left resinous seat 183 and a resinous right seat 184 are held in a form locking connection within rectangular notches in the vertical support 18. The left resinous seat 183 and the right resinous seat 184 are made from a resin. A left slat 16 has an endpiece 162 that rests in the left resinous seat 183. The left slat 16 has a notch 161 that defines the endpiece 162. The notch 161 receives a cutout edge 163. The sides of the notch 161 are exact.
[0191] FIGS. 30-31 illustrate a leg 3, which includes a first leg segment 30 and a second leg segment 31. The first leg segment 30 has a foot 300, a body 301, and a bolt extending vertically from the cylindrical body 301.
[0192] FIGS. 32-33 illustrate an assembled frame 1. See also FIG. 4. A rear left flange 135 is connected to the bottom support piece 134. A middle-left flange 105 is connected to the bottom support piece 104. A front left flange 106 is connected to the bottom support piece 134. A front right flange 125 is connected to the bottom support piece 134. A front middle flange 127 is connected to the bottom support piece 134. The middle right flange 115 is connected to the bottom support piece 134. The rear right flange 116 is connected to the bottom support piece 134. Each flange 105, 106, 115, 116, 125, 127, and 135 is horizontal (i.e., parallel to the ground) and extends inward. A threaded hole is drilled in 1050, 1060, 1150, 1250, and 1350 is formed in each respective flange 105, 106, 115, 116, 125, and 135.
[0193] FIG. 34 illustrates a preferred embodiment of a cover 2. The cover has a front 21, a right 22, and a bottom 25. The bottom has a reinforced opening 250. The reinforced opening 250 is centered 2.5 cm from the front 21 and right 22 so the opening overlies the threaded hole 1250 in the front right flange 125. After the frame 1 is assembled but before the legs 3 are attached, the cover 2 is placed over the frame 1. The threaded bolt 312 of the leg 3 is fed through the reinforced opening 250 and screwed into the threaded hole 1250.
[0194] FIGS. 35-41 illustrate a second preferred embodiment of a mounting plate 4. The mounting plate 4 is preferably made of steel and has a generally (except for the recessed segments 42 and 46) rectangular shape. FIG. 40 shows a perimeter of the mounting plate 4, which includes a first edge segment 40, which connects to a second edge 41, which connects to a third edge tab segment 47, which connects to a lateral third-edge-recess wall 422, which connects to a recessed third edge segment 42, which connects to a medial third-edge-recess wall 421, which connects to a third edge segment 44, which connects to a fourth edge segment 45, which connects to a first edge tab segment 48, which connects to a lateral first-edge-recess wall 462, which connects to a first edge recessed segment 46, which connects to a medial first-edge-recess wall, which connects to the first edge segment 40. The mounting plate 4 has the following discorectangular (also referred to as stadium-shaped) slots formed therein: outer first-edge slot 400, inner first-edge slot 401, first-edge-side outer second-edge slot 410, first-edge-side inner second-edge slot 411, third-edge-side outer second-edge slot 412, third-edge-side inner second-edge slot 413, recessed-third-edge slot 420, outer third-edge slot 440, inner third-edge slot 441, third-edge-side outer fourth-edge slot 450, third-edge-side inner fourth-edge slot 451, first-edge-side outer fourth-edge slot 452, first-edge-side inner fourth-edge slot 453, and recessed-first-edge slot 460.
[0195] FIGS. 42-44 illustrate a mattress All-In-One metal foundation that assembles quickly without any tools, ships in a small Fedex/UPS package, fits easier on a skid in a retail store, and allows an end customer to take it home in a car. It holds at least 2500 lbs. of weight, allows for easy attachment of a headboard of various dimensions, has an attractive optionable, washable and detachable outer stylish cover, and is designed to allow of up to 12 of underneath storage. Also has stamped holes 4216 for receipt of the cross slats and a bespoken plastic clip for adjoining the cross slats.
[0196] More specifically, FIG. 42 illustrates an attachment clip 4200 on the center support 4208 for adjoining the cross slats 4202 as such is configured in accordance with one or more embodiments of the invention. The attachment clip 4200 is configured to fit into punched holes or other anchoring elements within a center support 4208. The attachment clip 4200 contains a bottom protrusion 4220 that fits within a top hole 4218. In addition, the attachment clip 4200 contains a first receptacle 4204 and a second receptacle 4206 within which cross slats (4202) fit. It should be noted that the first receptacle 4204 and the second receptacle 4206 are configured to be on opposing sides. The first and second receptacles (4204 and 4206) are oriented to vertically receive the cross slats 4202 in one or more embodiments of the invention. The receptacles may, however, be configured to receive cross slats 4202 horizontally if desired. Each receptacle utilizes two side walls 4210, a back wall 4212 and floor 4214 to hold the cross slat 4202 in position. The cross slat 4202 is placed into the receptacle via an open top albeit in an alternative embodiment of the invention the top may be close such that the cross slat 4202 is inserted into the receptacle. The receptacle openings are placed on opposing sides to enable cross slats 4202 to be placed in them on a first side and second side or right and left when the bed frame is horizontal.
[0197] Each attachment clip 4200 may utilize flanges on each side to minimize side to side movement once the cross slat 4202 is placed into position. Downward flanges may also be incorporated into the attachment clip 4200 to better secure the clip onto the center support 4208. The attachment clip 4200 which couples with the center support 4208 is formed of durable plastic in one embodiment of the invention maybe formed using any material suitable for supporting the cross slats 4202. The advantage of having the configuration described herein is that because the attachment clips 4200 are removeable and the cross slats 4202 and other components of the bed frame 1 can be broken down into a shippable length, freight costs, storage needs, and other important business aspects are furthered in a desirable manner.
[0198] FIG. 43 illustrates a bed frame with a cross slats 4202, head element 4300, foot element 4302, a left-side element 4304, a cross support element 4305, a right-side element 4306, and stamped holes 4216 as it is configured in accordance with one or more embodiments of the invention. The head element 4300, cross slats 4202 and foot element 4302 are bisected and have ends placed over vertical support legs 4308 located at each corner of the assembled bed frame. A a center spine support 4310 also links into additional vertical support legs 4308 to provide extra support for the middle portion of the frame. These vertical support legs 4308 are placed under the head element 4300, foot element 4302, left-side element 4304, cross support element 4305, and right-side element 4306 as needed for support. In one or more embodiments of the invention such vertical support legs 4308 are on each corner of the frame and also placed along the center support spine 4310 which is oriented in the center of the frame. These center support 4208 members serve to elevate the bed frame to a desired height and support the body weight of a user. The head element 4300, cross support element 4305 and foot element 4302 couple with or rest upon the vertical support legs 4308 and sit flush with the height of the attachment clips 4200 and cross slats 4202 so that a flat surface is created. The attachment clips 4200 attach to the cross slats 4202 in a vertical manner thereby providing a structural strength to the overall frame 1 The head element 4300, foot element 4302, left-side element 4304, cross support element 4305, and right-side element 4306 may be shipped in a first element portion 4312 and a second element portion 4314 so that there are separate pieces which adjoin at the center support spine 4310 and the cross support element 4305. The pieces may be separable or hinged together but in either instance can be broken down to minimize the package size required to ship the frame. The vertical support legs 4308 may be constructed with a side flange 4311 upon which the second element portion 4314 sits. The side flange 4311 is configured to interlock with the second element portion 4314 thereby providing a strong connection between right-side element 4306, the left-side 4304 element, the head element 4300 and the foot element 4302. This interlocking connection between the side flange and the second element portion is illustrated in FIG. 4 This strong connection in turn mitigates undesired movement of the frame 1 when a person is shifting their weight on the bed. Alternatively, the vertical support legs 4308 may be configured in other ways to receive the elements of the bedframe required for support. In one embodiment the support legs 4308 can be welded onto the frame corners of the frame 1. This means that in this embodiment there will be nine support legs 4308 that are welded to the frame 1. A hole or receptacle may be placed in the vertical support structure 4308 within which an end of the bed frame element may fit. A yoke or other such way to secure the bed frame elements may also be utilized. A core aspect of the invention is that the pieces are easily disassembles and assembled for shipment. When assembled the bed frame utilizes support legs that provide at least 10 inches of clearance from the ground level. The assembled frame 1 is able so support at least 2,500 pounds of distributed load when weight is placed upon it.
[0199] Thus, shippable mattress foundation has been described. The reader should note however that the claims set forth below and the full scope of their equivalents are what define the scope of the invention.
