BED SYSTEM
20190099006 ยท 2019-04-04
Inventors
- Douglas B. Gerig (Archbold, OH, US)
- Ronald D. Roth (Wauseon, OH, US)
- Barry J. Tuckerman (Wauseon, OH, US)
- Neal J. Fifer (McClure, OH, US)
- Brian D. Fritch (Stryker, OH, US)
Cpc classification
A47C17/86
HUMAN NECESSITIES
International classification
Abstract
A bed assembly includes first, second, third, and fourth side rails, first and second slat supports, first and second rail supports, and a slat. The side rails each include an end and a side. The end of the second side rail is coupled to the end of the first side rail. The end of the fourth side rail is coupled to the end of the third side rail such that the sides of the first and second side rails are facing the sides of the third and fourth side rails. The first and second slat supports are configured to engage the first and third side rails, respectively. The first and second rail supports each include a continuous surface coupled to two of the first, second, third, and fourth side rails and configured to inhibit movement of the two of the first, second, third, and fourth side rails.
Claims
1. A bed assembly comprising: a first side rail having an end and a side extending from the end; a second side rail having an end and a side extending from the end of the second side rail, wherein the end of the second side rail is coupled to the end of the first side rail; a third side rail having an end and a side extending from the end of the third side rail; a fourth side rail having an end and a side extending from the end of the fourth side rail, wherein the end of the fourth side rail is coupled to the end of the third side rail, and wherein the sides of the first and second side rails are facing the sides of the third and fourth side rails; a first slat support configured to engage the first side rail; a second slat support configured to engage the third side rail; a slat coupled to the first slat support and the second slat support; a first rail support having a continuous surface coupled to the first side rail and the second side rail and configured to inhibit movement of the first side rail relative to the second side rail; and a second rail support having a continuous surface coupled to the third side rail and the fourth side rail and configured to inhibit movement of the first side rail relative to the second side rail.
2. The bed assembly of claim 1, wherein the first rail support includes a dowel having a first end and a second end, the first end of the dowel configured to engage the end of the first side rail, the second end of the dowel configured to engage the end of the second side rail.
3. The bed assembly of claim 1, wherein the first rail support includes a leg configured to engage the first side rail and the second side rail.
4. The bed assembly of claim 1, wherein the first rail support includes a bracket having a base configured to engage the side of the first side rail and the side of the second side rail.
5. The bed assembly of claim 4, wherein the bracket includes an upper flange extending from the base in a first direction and configured to engage a bottom of the first side rail and a bottom of the second side rail.
6. The bed assembly of claim 5, wherein the bracket includes a lower flange extending from the base in a second direction opposite the first direction.
7. The bed assembly of claim 1, wherein: the first slat support includes a slat-support portion and a rail-support portion, the rail-support portion including a body portion configured to engage the side of the first side rail, the slat-support portion including a leg portion and a slat-lock portion, the leg portion extending from the body portion in a first direction, the slat-lock portion extending from the leg portion in a second direction transverse to the first direction and configured to engage the slat.
8. The bed assembly of claim 7, wherein the rail-support portion includes an arm portion and a catch portion, the arm portion extending from the body portion in a third direction, and the catch portion extending from the arm portion in a fourth direction transverse to the third direction.
9. The bed assembly of claim 8, wherein the body portion, the arm portion, and the catch portion collectively define a channel configured to receive the first side rail.
10. The bed assembly of claim 8, wherein the third direction is parallel to the first direction.
11. The bed assembly of claim 7, wherein the slat-lock portion includes a lip extending from the leg portion in second direction transverse to the first direction, and wherein the slat includes a groove configured to receive the lip.
12. The bed assembly of claim 11, wherein the body portion, the leg portion, and the lip collectively define a channel configured to receive the slat.
13. The bed assembly of claim 11, wherein the lip defines a notch, a first height extending from the leg portion adjacent the notch, and a second height extending from the leg portion at the notch, the second height being less than the first height.
14. The bed assembly of claim 13, wherein the groove extends through a first side and a second side of the slat, and wherein the lip is configured to abut the first side of the slat.
15. The bed assembly of claim 14, wherein the notch is disposed between the first and second sides of the slat.
16. A method of assembling a bed, the method comprising: coupling an end of a first side rail to an end of a second side rail; coupling an end of a third side rail to an end of a fourth side rail; coupling a first slat support to the first side rail; coupling a second slat support to the third side rail; coupling a continuous surface of a first rail support to the first side rail and the second side rail to inhibit movement of the first side rail relative to the second side rail; coupling a continuous surface of a second rail support to the third side rail and the fourth side rail to inhibit movement of the third side rail relative to the fourth side rail; and coupling a slat to the first slat support and the second slat support.
17. The method of claim 16, wherein the first slat support includes a lip and the slat includes a groove, and wherein coupling the slat to the first slat support includes positioning the lip within the groove.
18. The method of claim 17, wherein the first slat support defines a channel, and wherein coupling the slat to the first slat support includes positioning the slat in the channel.
19. The method of claim 18, wherein coupling the slat to the first slat support includes abutting the lip with a side of the slat.
20. The method of claim 16, wherein coupling a continuous surface of a first rail support to the first side rail and the second side rail includes at least one of (i) positioning a first end of a dowel in the end of the first side rail and positioning a second end of the dowel in the end of the second side rail, (ii) coupling a leg to the first side rail and the second side rail, or (iii) coupling a bracket to the side of the first side rail and to the side of the second side rail.
Description
DRAWINGS
[0017] The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.
[0018]
[0019]
[0020]
[0021]
[0022]
[0023]
[0024] Corresponding reference numerals indicate corresponding parts throughout the drawings.
DETAILED DESCRIPTION
[0025] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.
[0026] The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles a, an, and the may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms comprises, comprising, including, and having, are inclusive and therefore specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.
[0027] When an element or layer is referred to as being on, engaged to, connected to, attached to, or coupled to another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being directly on, directly engaged to, directly connected to, directly attached to, or directly coupled to another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., between versus directly between, adjacent versus directly adjacent, etc.). As used herein, the term and/or includes any and all combinations of one or more of the associated listed items.
[0028] The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as first, second, and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.
[0029] With reference to
[0030] The bed system 10 may include a plurality of side rails 12, a headboard 14, a footboard 16, a plurality of rail supports 18, a plurality of slat supports 20, and a plurality of slats 22. As illustrated in
[0031] The first side rail 12-1 may be substantially similar to the second, third, and fourth side rails 12-2, 12-3, 12-4, apart from any exceptions described below or shown in the Figures. Accordingly, references herein to the side rail 12 will be understood to apply equally to the first, second, third, and fourth side rails 12-1, 12-2, 12-3, 12-4, except as otherwise provided herein.
[0032] With reference to
[0033] As illustrated in
[0034] As will be explained in more detail below, in an assembled configuration (e.g.,
[0035] With reference to
[0036] Apart from any exceptions described below or shown in the Figures, (i) the first rail support 18-1 may be substantially similar to the second rail support 18-2, (ii) the third rail support 18-3 may be substantially similar to the fourth rail support 18-4, (iii) the fifth rail support 18-5 may be substantially similar to the sixth rail support 18-6, and (iv) the seventh rail support 18-7 may substantially similar to the eighth rail support 18-8. Accordingly, references herein to the first, third, fifth, and seventh rail supports 18-1, 18-3, 18-5, 18-7 will be understood to apply equally to the second, fourth, sixth, and eighth rail supports 18-2, 18-4, 18-6, 18-8, respectively, except as otherwise provided herein.
[0037] With reference to
[0038] With reference to
[0039] As will be explained in more detail below, in the assembled configuration, the dowel 50 of the third rail support 18-3 may be coupled to the first and second side rails 12-1, 12-2, and the dowel 50 of the fourth rail support 18-4 may be coupled to the third and fourth side rails 12-3, 12-4. For example, the dowel 50 of the third rail support 18-3 may be disposed within the second aperture 40-2 of the first side rail 12-1 and the fourth aperture 40-4 of the second side rail 12-2, such that the continuous outer surface 52 of the dowel 50 of the third rail support 18-3 engages the first and second side rails 12-1, 12-2. Similarly, the dowel 50 of the fourth rail support 18-4 may be disposed within the second aperture 40-2 of the third side rail 12-3 and the fourth aperture 40-4 of the fourth side rail 12-4, such that the continuous outer surface 52 of the dowel 50 of the fourth rail support 18-4 engages the third and fourth side rails 12-3, 12-4. The cam 48 may be disposed within one of the first, second, third or fourth side rails 12-1, 12-2, 12-3, 12-4. During assembly, the user may rotate the cam 48 to lock the cam 48 to the dowel 50 and thereby secure a location of the first side rail 12-1 relative to the second side rail 12-2, or secure a location of the third side rail 12-3 relative to the fourth side rail 12-4. In some implementations, four cams 48 are used. For example, one cam 48 may be used in each of the first, second, third, and fourth side rails 12-1, 12-2, 12-3, 12-4.
[0040] With reference to
[0041] The upper flange 58 may extend from and along the upper end 66 of the base 56 in a first direction and may include a continuous upper flange surface 76. The lower flange 60 may extend from and along the lower end 68 of the base 56 in a second direction and may include a continuous lower flange surface 78. The second direction may be opposite the first direction. In some implementations, the continuous upper and lower flange surfaces 76, 78 extend from the continuous inner and outer surfaces 70, 72, respectively, of the base 56, such that the continuous upper flange surface 76 is substantially parallel to the continuous lower flange surface 78.
[0042] As will be explained in more detail below, in the assembled configuration, the fifth rail support 18-5 may be coupled to the first and second side rails 12-1, 12-2, and the sixth rail support 18-6 may be coupled to the third and fourth side rails 12-3, 12-4. For example, the fifth rail support 18-5 may be coupled to the first and second side rails 12-1, 12-2 such that the continuous inner surface 70 or the continuous lower flange surface 78 engage the inner side 32 or the bottom 28, respectively, of the first and second side rails 12-1, 12-2, and the sixth rail support 18-6 may be coupled to the third and fourth side rails 12-3, 12-4 such that the continuous outer surface 72 or the continuous upper flange surface 76 engage the inner side 32 or the bottom 28, respectively, of the third and fourth side rails 12-3, 12-4. In this regard, it will be appreciated that the fifth and sixth rail supports 18-5, 18-6 may be reversible, or otherwise interchangeable, relative to assembly to and with (i) the first and second side rails 12-1, 12-2 and (ii) the third and fourth side rails 12-3, 12-4.
[0043] With reference to
[0044] In the assembled configuration, the first, second, third, fourth, fifth, sixth, seventh, or eighth rail supports 18-1, 18-2, 18-3, 18-4, 18-5, 18-6, 18-7, 18-8 may inhibit movement of the first and third side rails 12-1, 12-3 relative to the second and fourth side rails 12-2, 12-4. In particular, the rail supports 18 help to prevent the proximal ends 34 of the first and third side rails 12-1, 12-3 from moving relative to the distal ends 36 of the second and fourth side rails 12-2, 12-4.
[0045] With reference to
[0046] The first slat support 20-1 may be substantially similar to the second, third, fourth, fifth, and sixth slat supports 20-2, 20-3, 20-4, 20-5, 20-6, apart from any exceptions described below or shown in the Figures. Accordingly, references herein to the slat support 20 will be understood to apply equally to the first, second, third, fourth, fifth, and sixth slat supports 20-1, 20-2, 20-3, 20-4, 20-5, 20-6, except as otherwise provided herein.
[0047] With reference to
[0048] The rail-support portion 80 may include a body portion 88, an arm portion 90, and a catch portion 92. The arm portion 90 may extend between the body portion 88 and the catch portion 92. In particular, the arm portion 90 may extend in a first lateral direction from the body portion 88 to the catch portion 92. In some implementations, the arm portion 90 extends in a direction substantially perpendicular to the body portion 88, and the catch portion 92 extends in a direction substantially parallel to the body portion 88. As illustrated, the body portion 88, the arm portion 90, and the catch portion 92 may define a substantially J-shaped construct, such that the body portion 88, the arm portion 90, and the catch portion 92 collectively define a channel 94. The size and shape of the body portion 88, the arm portion 90, and the catch portion 92 may be such that the size and shape of the channel 94 is substantially the same as, or equal to, the size and shape defined by the top 26, the outer side 30, and the inner side 32 of the side rails 12. Accordingly, as illustrated in
[0049] The slat-support portion 82 may include a leg portion 98 and a slat-lock portion 100. As will be explained in more detail below, in the assembled configuration, the slat-lock portion 100 may engage, and secure the position of, the slats 22. In this regard, the leg portion 98 may extend between the slat-lock portion 100 of the rail-support portion 80 and the body portion 88 of the rail-support portion 80. The slat-lock portion 100 may include a lip 102 extending from the leg portion 98. In some implementations, the leg portion 98 may extend in a second lateral direction from the body portion 88 to the lip 102. In particular, the leg portion 98 slat-support portion 82 may extend in a direction substantially perpendicular to the body portion 88, and the lip 102 slat-support portion 82 may extend in a direction substantially parallel to the body portion 88. In this regard, the leg portion 98 may extend in a direction substantially opposite, and parallel to, the arm portion 90 of the rail-support portion 80, and the lip 102 may extend in a direction substantially opposite, and parallel to, the catch portion 92 of the rail-support portion 80. As illustrated, the body portion 88, the leg portion 98, and the lip 102 may define a substantially J-shaped construct, such that the body portion 88, the leg portion 98, and the lip 102 collectively define a channel 104.
[0050] With reference to
[0051] With reference to
[0052] As previously described, in the assembled configuration, the slats 22 may be coupled to the slat-lock portion 100 of the slat support 20. In particular, the lip 102 of the first, second, or third slat support 20-1, 20-2, 20-3 may be disposed within the first groove 120 of the slats 22, and the lip 102 of the fourth, fifth, or sixth slat support 20-4, 20-5, 20-6 may be disposed within the second groove 122 of the slats 22. In this regard, the lip 102 of the first slat support 20-1 may be disposed within the first groove 120 such that (i) the notch 106 is aligned with the first groove 120 and (ii) the lip 102 abuts the first or second sides 112, 114 of the slat 22 at the second height H2. For example, the side 107 of the lip 102 of the first slat support 20-1 or the side 109 of the lip 102 of the first slat support 20-1 may abut, or otherwise face, the first or second sides 112, 114, respectively, of the slat 22. Similarly, the lip 102 of the fourth slat support 20-4 may be disposed within the second groove 122 such that (i) the notch 106 is aligned with the second groove 122 and (ii) the lip 102 abuts the first or second sides 112, 114 of the slat 22 at the second height H2. For example, the side 107 of the lip 102 of the fourth slat support 20-4 or the side 109 of the lip 102 of the fourth slat support 20-4 may abut, or otherwise face, the first or second sides 112, 114, respectively, of the slat 22. In this way, the slat-lock portion 100 is able to secure the location of each slat 22 relative to the other slats 22 in a spaced-apart (e.g., equally spaced) configuration and to evenly support a mattress or box spring.
[0053] In some implementations, the bed kit 10, including the plurality of side rails 12, the headboard 14, the footboard 16, the plurality of rail supports 18, the plurality of slat supports 20, and the plurality of slats 22, may be disposed within a package (e.g., a box, carton, container, etc.) having a length between three feet and five feet, a width between one half foot and two feet, and a depth between one half foot and one foot. In this regard, the bed kit 10 may be disposed within a package that can be lifted and otherwise handled by a single person.
[0054] With reference to
[0055] The slat support 20a may include the body portion 88 of the rail-support portion 80 and the leg portion 98 and the slat-lock portion 100 of the slat-support portion 82. In this regard, the slat support 20a may be formed without the arm portion 90 and the catch portion 92 of the rail-support portion 80. Accordingly, the slat support 20a (e.g., the body portion 88) may be coupled to the side rails 12 (e.g., the inner side 32) using a mechanical fastener 126 (e.g., a screw, a bolt, a nail, a pin, etc.), an adhesive, or another suitable fastening technique.
[0056] A method of assembling the bed system 10 may include removing (i) the plurality of side rails 12, (ii) the headboard 14, (iii) the footboard 16, (iv) the plurality of rail supports 18, (v) the plurality of slat supports 20, 20a and (vi) the plurality of slats 22 from the package.
[0057] The method of assembling the bed system 10 may include coupling the distal end 36 of the first and third side rails 12-1, 12-3 to the headboard 14 and coupling the proximal end 34 of the first and third side rails 12-1, 12-3 to the distal end 36 of the second and fourth side rails 12-2, 12-4, respectively. The method may also including coupling the proximal end 34 of the second and fourth side rails 12-2, 12-4 to the footboard 16.
[0058] The method of assembling the bed system 10 may also include coupling one or more of the rail supports 18 to (i) the first and second side rails 12-1, 12-2 and (ii) the third and fourth side rails 12-3, 12-4. For example, the method may include coupling the rail supports 18-1, 18-2, 18-3, 18-4, 18-5, 18-6, 18-7, 18-8 to (i) the first and second side rails 12-1, 12-2 or (ii) the third and fourth side rails 12-3, 12-4.
[0059] The method of assembling the bed system 10 may further include coupling one or more of the slat supports 20, 20a to one or more of the side rails 12. For example, the method may include coupling the slat supports 20-1, 20-2, 20-3, 20-4, or 20a to one or more of the side rails 12-1, 12-2, 12-3, or 12-4. In particular, the method may include positioning one or more of the side rails 12 within the channel 94 of the rail-support portion 80 of the slat support 20, or otherwise fastening the slat support 20a to one or more of the side rails 12 using a mechanical fastener or other fastening technique, as previously described.
[0060] The method of assembling the bed system 10 may also include coupling a slat 22 to a plurality of the slat supports 20, 20a. For example, the method may include positioning the lip 102 of a slat support 20, 20a within a first groove 120 of the slat 22 such that (i) the notch 106 is aligned with the first groove 120 and (ii) the lip 102 abuts the first and second sides 112, 114 of the slat 22. For example, the slat 22 may be positioned within the notch 106 of a first of the slat supports 20, 20a such that the sides 107, 109 of the lip 102 abut, or otherwise face, the first or second sides 112, 114, respectively, of the slat 22. Similarly, the method may include positioning the lip 102 of another slat support 20, 20a within the second groove 122 such that (i) the notch 106 is aligned with the second groove 122 and (ii) the lip 102 abuts the first and second sides 112, 114 of the slat 22. For example, the slat 22 may be positioned within the notch 106 of a second of the slat supports 20, 20a such that the sides 107, 109 of the lip 102 abut, or otherwise face, the first or second sides 112, 114, respectively, of the slat 22. The first and second of the slat supports 20, 20a may be positioned on opposite sides of the bed system 10 (e.g., on bed side rails 12-1, 12-3) such that a slat 22 extends between and connects side rails 12-1 and 12-2. Multiple slats 22 may be positioned between slat supports 20-1, 20-2, 20-3 on bed rails 12-1, 12-2 and slat supports 20-4, 20-5, 20-6 on bed rails 12-3, 12-4, in the same manner.
[0061] The configuration of, and related methods of assembling, the bed system 10 described herein, including, for example, the method of securing the proximal end 34 of a side rail 12 to a distal end 36 of another side rail 12, and the method of securing the rail supports 18, slat supports 20, 20a, and slats 22 to the side rails 12, can allow a user to easily and efficiently assemble a bed system having superior strength and durability.
[0062] The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.