ADJUSTABLE HEIGHT TUBULAR BED FRAME

BACKGROUND OF THE INVENTION

1. FIELD OF THE INVENTION

[0001] The present invention relates to a safe and attractive, affordable bedframe for supporting a mattress set and, more particularly, to a stable bedframe that assembles and is adjustable to multiple sizes and heights without the need for using tools with fasteners.

2. DESCRIPTION OF THE RELATED ART

[0002] Bed frames that are low in cost and non-decorative and typically constructed with stamped metal legs combined with angle iron rails. The stamped metal legs have hard edges and are not ideal for handling during assembly. Also, the nature of the leg means that the height of the bed is fixed. If it is determined at the time of installation that the consumer sleep surface is time too high, the remedy with this type of bed frame is to return to the store and obtain a low-profile frame or foundation.

[0003] Many of these types of frames are also difficult to assemble with multiple loose parts and extensions and that use keyhole interlocks or stamped metal connections that squeak and rattle during use. Assembly of these frames also requires that the purchaser have equipment knowledge and be capable of tool assembly. The use of tools to assemble bedding is undesirable because if the tools are not available then the assembly cannot be done. Also, tool assemblies can be difficult and complicated. Current approaches to tool-less bed frames are made of interlocking stamped sheet metal plates, which can be sharp and dangerous as well as heavy. The weight of bedding and bed occupants creates a downward force on the bedding, which must be transferred to the floor. The connection points between the side rail and the floor are thus an inherent weakness of the structure. Sheet metal, by its nature, has edges that concentrate the forces of the weight of the bedding and any occupants and the connections can be unreliable and loosen over time. Any movement is liable to cause a squeaking noise, which is recognized in the industry as a defect that is almost as critical as a collapse.

[0004] Finally, these frames can be of a fixed size that only fit one mattress type. Some frames may be adjustable, but the adjustment mechanism results in the center support rail and legs not being positioned in the middle of the bed for all size adjustments, thereby providing less than optimum support. Accordingly, there is a need in art for a bed frame that provides superior support for different size and thickness mattress sets and uses smooth contoured attractive resin legs that assemble and adjust without the need for tools or fasteners.

BRIEF SUMMARY OF THE INVENTION

[0005] The present invention provides a bed frame assembly for supporting a mattress or mattress set with two side rails, one center rail and at least one cross member that provides support for size and thickness mattress sets and uses smooth contoured attractive resin legs that assemble and adjust without the need for tools or fasteners. The frame supports the load of a mattress set using multiple support legs units. The rails and the cross member are secured together with a tool-less interlocking wedge and receiver system which uses the weight of the supported load to combine the separate component parts in to one leg unit. The leg unit forms the connection between the side and cross rail, and also the connection between the cross rail and the center rail. In a preferred embodiment, the side rail has the wedge portion of the connection and the cross rail has the receiver incorporated with the bed frame legs. The assembly utilizes three-dimensional wedge shapes at the ends of the side member and in the center of the cross member to both connect and stabilize the leg and frame. Both the wedge and the receiver are made of molded composite plastic. The wedge has continuous surface contact with the receiving leg which dissipates the stress on this connection.

[0006] The present invention also provides embodiments with the beneficial ability to adjust the height of the frame. In some cases, a thicker mattress set will require a shorter frame to lower the sleep surface. For this reason, each of the leg units has a removable lower extension. With the extension in place on all the leg units the frame is at a standard height. With all of the extensions removed, the bed will be at a low-profile height. The extensions are secured in place using a wedge and receiver system comparable to that which holds the rails in place. In this embodiment of the invention, the wedge portion is upstanding, and the receiver is downward facing. In this way, the extension has the wedge and the leg unit has the receiver, thereby allowing the leg unit to function as the low-profile leg. The fully assembled leg unit with the extension in place encapsulates two wedge and receiver systems that are opposite and opposing in their orientation. This approach is advantageous in that it secures all of the components into a single solid supporting structure using the weight of the bedding load.

[0007] The present invention further provides embodiments that offer a tool-less plastic double opposing wedge and receiver connection for assembly of the frame structure without needing standard or specialized tools. The wedge inter fit is an elegant and robust connection. The user can easily see the wedge portion fits to the receiver. The fit locks the frame together quickly and securely as well as holding the extension in place with no additional movement. The downward pressure of the bedding makes the connections rock solid. Any looseness that might develop is taken away by the automatic and constant resetting of the wedges in the receivers. The tool-less assembly of the cross member to the side member translates the downward force is to an outward force via the angular wedge shape member. The outward force is then constrained by the continuous inner surface of the receiving member. Because the entirety of the wedge member is acting on the receiving member this outward force is universally felt and dissipated where on one point, line our surface is under greater stress. Because the receiver is a continuous surface entirely surrounding the wedge member its surface is put in tension and is very stable under the stress. This allows the wedge and the receiver to become integral to each other and resist not only downward pressure but also twisting forces.

[0008] The present invention further provides embodiments that have the ability to change the width of the frame to accommodate different size mattress sets. The cross rail of preferred embodiment is constructed of a square metal tube positioned in the center of the frame and having smaller diameter tubes inserted in either end. The smaller tubes can be deployed telescopically to different lengths out of the center tube creating the different widths of the frame. Holes drilled in the telescoping tube align at different predetermined widths allowing a spring-loaded button to passed between them. This acts as a lock holding the tube at a fix position and length corresponding to a bed size. The installer can depress the button to allow the tube to slide within each other and create a different length cross rail. Because the outer positioned tubing slides in and out of both ends of the center tubing the wedge connection on the cross rail will remain in the exact middle of the cross rail and thus the frame regardless of which size mattress the frame is adjusted to match. This approach allows the leg unit and the center rail to always remain in the center of the bed frame, which is the best location to retain bed support and stability.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) [0009] The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings, in which:

[0010] FIG. l is a perspective view of the complete adjustable tubular frame assembled.

[0011] FIG. 2 is a perspective view of the complete adjustable tubular frame exploded to show the assembly required by the installer. [0012] FIG. 3 is a perspective exploded view of a corner leg unit.

[0013] FIG. 4 is a side exploded a corner leg unit.

[0014] FIG. 5 is a cross sectional exploded view of a side leg.

[0015] FIG. 6A is a cross sectional view of a side leg.

[0016] FIG. 7 is an exploded view a center leg unit.

[0017] FIG. 8 is an end exploded view of center leg unit.

[0018] FIG. 9 is a cross sectional exploded view of a center leg unit.

[0019] FIG. 10 is a cross sectional view of a center leg unit.

[0020] FIG. 11 is an exploded view of a cross-rail subassembly,

[0021] FIG. 12 is an end view of a cross-rail subassembly with the extension tube fully inserted into the center tube and then fully extended from the center tube.

[0022] FIG. 13 is a perspective view of another embodiment of a complete adjustable tubular frame assembled.

[0023] FIG. 14 is a perspective view of the complete adjustable tubular frame exploded to show the assembly required by the installer.

[0024] FIG. 15 is an exploded view of FIG. 14 showing the detail of the comer leg unit.

[0025] FIG. 16 is a side exploded view of the complete adjustable tubular frame with a cross sectional view identified.

[0026] FIG. 17 is a cross sectional exploded view of the side leg as identified in FIG.

16.

[0027] FIG. 18 is a cross sectional view of the assembled side leg of FIG. 16.

[0028] FIG. 19 is an exploded view of a center cross rail.

[0029] FIG. 20 is an exploded view of a cross rail.

DETAILED DESCRIPTION OF THE INVENTION

[0030] Referring to the figures, wherein like numerals refer to like parts throughout, there is seen in FIG. 1 a perspective view of an embodiment of the bed frame 50 constructed in accordance with the present invention. As can be seen, bed frame 50 is assembled and ready for a foundation and mattress and is comprised of two side rails 52, 54 that are attached to two cross rails 56 that extend between the ends of side rails 52, 54. The two cross rails 56 are also attached to each other by a center rail 58 that extends between the midpoints of side rails 52, 54. The side rails 52, 54 are comprised of steel angle iron. The two cross rails 56 are, as will be explained, are comprised of telescoping tubular steel. The center rail 58 is comprised of two steel angle irons forming a T shaped cross section. As further seen in FIG. 1, there are side rail legs 60 positioned at each of the four junctures between side rails 52, 54 and cross rails 56 and cross rail legs 62 positioned at each junction of side rails 52, 54 and center rail 58. Side rail legs 60 and cross rail legs 62 support frame 50 in spaced relation to a horizontal surface, such as the floor of a bedroom. Side rail legs 60 and cross rail legs 62 are comprised of molded plastic.

[0031] Referring to FIG. 2, which shows an exploded view of an embodiment of frame 50, it may be seen that cross rail leg 62 is formed by a side rail receiver 68 that is coupled to an end of the corresponding cross rail 56 and is configured to receive a wedge 70 affixed the corresponding end of one of side rails 52, 54. Center rail 58 is fitted to each cross rail 56 by means of a cross rail wedge 74 secured to the midpoint of each cross rail 56 and configured to engage a center rail receiver 66 positioned at each end of center rail 58. Each side rail leg 60 and cross rail leg 62 further comprises a lower extension 64 that can be releasably coupled to side rail receiver 68 or center rail receiver 66, respectively.

[0032] Complete assembly of frame 50 is accomplished by transitioning from the configuration shown in FIG. 2 to the configuration shown in FIG. 1, so that each cross rail 56 is dropped into place on the ends of the center rail 58 with center rail receiver 66 inter-fitting with cross rail wedges 74 of cross rail leg 62. In a similar manner, the side rails 52, 54 are dropped into place by inserting wedges 70 into receivers 68 of side rail legs 60, which are on opposite ends of cross rail 56. Lower extensions 64 may then be optionally inter-fit to the bottom of side rail receivers 68 and cross rail receivers 66, as further described herein. The inclusion or omission of Lower extensions 64 thus allows frame 50 to be positioned at one of two different heights from the floor depending on the presence or absence of lower extensions 64. Thus, entire frame 50 can be easily assembled without the need for tools and can be configured to allow for two different mattress heights when a mattress is placed on frame 50.

[0033] Referring to FIG. 3, the inter-fitting of side rails 52, 54 by inserting wedges 70 into receivers 68 of side rail legs 60 may be seen in greater detail. Side rail 52 is attached to wedge 70 and receiver 68 is attached to cross rail 56. Receiver 68 has a pocket 72 formed therein that provides a press fit with wedge 70 based on matching angled side walls of wedge 70 and pocket 72. The underside of receiver 68 also has an upstanding pocket 82 (not seen) that is similarly shaped to provide a press fit with an upstanding extension wedge 76 protruding from the inside of lower extension 64.

[0034] Referring to FIG. 4, each side rail leg 60 of bed frame 50 is formed by wedge 70 of side rail 52 fitting into pocket 72 of receiver 68 of cross rail 56 and being secured therein by a press fit due to matching angled side walls. The underside of receiver 68 also has an upstanding pocket 82 (not seen) that is shaped in the same way to fit upstanding extension wedge 76 protruding from the inside of lower extension 64.

[0035] Referring to FIG. 5, side rail leg 60 is shown in an exploded or disassembled view. Receiver 68 of each side rail leg 60 is comprised of a receiver cap 100 and a receiver foot 78. Preferably, receiver cap 100 and a receiver foot 78 are fastened together when frame 50 is manufactured, such as by using screws 80, and are thus shown coupled together. Wedge 70 is configured to be inter-fit with receiver 68 by inserting wedge 70 into pocket 72.

Receiver foot 78 on the underside of receiver 68 is dimensioned and shaped to engage upstanding extension wedge 76 that protrudes from the inside of the lower extension 64 to allow the selectively attachment and release of lower extension 64 to receiver 68. Receiver 68 thus provides for double wedge fit, with one oriented upward for engaging wedge 70 and one oriented downward for engaging lower extension 64.

[0036] Referring to FIG. 6, an assembled side rail leg 60 shows that wedge 70 is inter-fit to receiver 68 at the location of pocket 72 to creates a press fit based on matching angled side walls. On the underside of receiver 68 in receiver foot 78, the upstanding pocket 82 is seen along with its shape for fitting the upstanding extension wedge 76 protruding from the inside of lower extension 64.

[0037] Referring to FIG. 7, center rail leg 62 is shown in an exploded or disassembled view with wedge 74 of cross rail 56 coupling to receiver 66 of center rail 58 via a pocket 84 that is dimensioned and configured to provide a press fit with wedge 74 based on matching angled side walls. The underside of receiver 66 also has an upstanding pocket 86 (not seen) that is shaped in the same way to fit an upstanding extension wedge 76 protruding from lower extension 64.

[0038] Referring to FIG. 8, cross rail 56 is shown attached to wedge 74 with receiver 66 attached to center rail 58 via pocket 84 that provides a press fit with the wedge 74 based on matching angled side walls. The underside of receiver 66 has upstanding pocket 86 (not seen) shaped in the same way to fit upstanding extension wedge 76 protruding from the inside of lower extension 64.

[0039] Referring to FIG. 9, center rail leg 62 is shown in an exploded or disassembled view with receiver 66 formed by a receiver cap 88 and a receiver foot 90. Receiver cap 88 and receiver foot 90 are preferably coupled together when frame is manufactured, such as by using two screws 80. Wedge 74 may be inter-fit to the receiver 66 at the location of pocket 84. On the underside of receiver 66, receiver foot 90 provides upstanding pocket 84 for engaging with upstanding extension wedge 76 protruding from the inside of lower extension 64.

[0040] Referring to FIG. 10, center rail leg 62 is shown in an assembled view, where wedge 74 is inter-fit to receiver 66 at the location of pocket 84 to creates a press fit based on matching angled side walls. On the underside of receiver 66 of receiver foot 90, upstanding pocket 86 has similarly engaged and inter fit with upstanding extension wedge 76 protruding from the inside of lower extension 64.

[0041] Referring to FIG. 11, an embodiment of cross rail 56 may comprise an assembly of a center cross rail tube 92 that is tubular with a rectangular cross-section and is telescopically engaged with a pair of cross rails end tubes 94 that are also tubular with a rectangular cross-section and dimensioned to slide telescopically into and out of both opposing ends of center cross rail tube 92. Each outwardly positioned end of each cross rail end tube 94 is attached to a receiver 68 such as with screws 80. A center wedge 74 is secured to the center of center cross rail tube 92 such as with screws 80. The telescoping motion of each end cross rail end tube 94 may be selectively locked into a predetermined position with a spring button 98 associated with each cross rail end tube 94 that is biased outwardly to engage one of a series of holes 96 formed in center cross rail tube 92. The series of holes 96 are positioned such that the overall length of cross rail 56 can be selected by a user so that the final dimensions of frame 50 correspond to a particular matter size, e.g., twin, full, queen, king, and California king.

[0042] Referring to FIG. 12, cross rail 56 is comprised of center rail tube 92 and two cross rail end tubes 94 that can telescope into and out of center rail tube 92, thereby changing the distance between the receivers 68 positioned on either side of center cross rail tube relative to each other and to center wedge 74 attached to center rail tube 92. As seen in the top portion of FIG. 12, cross rail end tubes 94 can be fully inserted into center rail tube 92 and locked into position using the center most of the series of holes 96 and spring button 98 to provide the narrowest possible width frame 50. As seen in the lower portion of FIG. 12, cross rail end tubes 94 can be fully extended from center rail tube 92 and locked into position using the outward most of the series of holes 96 and spring button 98 to provide the widest possible width frame 50. In order to transform the cross rail 56 from the configuration of the top of FIG.12 to that of the bottom of FIG. 12, or any of the other configurations possible, a user presses spring buttons 98 of both cross rail end tubes 94 into the holes 96 of center rail tube 92 and telescopically slides cross rail end tubes 94 into or out of to the next desired position. Because holes 96 on the center rail tube 92 are symmetrical about the center of frame 50 and each end cross rail end tube 94 slides in the opposite direction, the position of cross rail wedges 74 can always be centered about center rail tube 92 at any of the predetermined positions for frame 50. This correlates to cross rail legs 60 and center rail 58 being centered in the frame 50 at any fixed size so that center rail leg 62 is always positioned in the middle of frame 50 and any mattress positioned thereon.

[0043] Referring to FIG. 13, there is seen a perspective view of an embodiment of a bed frame 150 constructed in accordance with the present invention. As can be seen, bed frame 150 is assembled and ready for a foundation and mattress and is comprised of two side rails 152, 154 that are attached to three cross rails 156 that extend between the ends of side rails 152, 154, with one cross rail 156 positioned at the ends of each side rail 152, 154 and one cross rail 156 between the midpoints of each side rail 152, 154. Side rails 152, 154 are formed from steel angle irons and cross rails 156 are formed from two steel angle irons forming a T shaped cross section. As further seen in FIG. 13, there are side rail legs 160 positioned at each of the six junctures between side rails 152, 154 and a center cross rail leg 162 positioned at the midpoint of the middle cross rail 156. Side rail legs 160 and center cross rail leg 162 support frame 150 in spaced relation to a horizontal surface, such as the floor of a bedroom. Side rail legs 160 and center cross rail leg 162 are comprised of molded plastic.

[0044] Referring to FIG. 14, which shows an exploded view of an embodiment of frame 150, each side rail leg 160 is formed by a side rail receiver 168 that is coupled to cross rail 156 and is configured to receive a wedge 170 affixed one of side rails 152, 154. Center cross rail leg 162 of centrally positioned cross rail 156 includes a center receiver wedge 174 coupled to its midpoint that inter fits a center rail receiver 166. Each side rail leg 160 further comprises a lower extension 164 that can be releasably coupled to side rail receiver 68 or center rail receiver 66, respectively. As seen in FIG. 14, center receiver wedge 174 of center cross rail leg 162 center rail receiver 166 is dimensioned so that it corresponds to side rail receiver 168 and center lower extension 166 is dimensioned so that the overall size of center cross rail leg 162 corresponded to side rail leg 160 when lower extension 164 is included. [0045] Complete assembly of frame 150 is accomplished by transitioning from the configuration shown in FIG. 14 to the configuration shown in FIG. 13, so that each side rail 152, 154 is dropped into place over each cross rail 156 with each wedge 170 inter fitting into each side rail receiver 168. Lower extensions 164 may then be optionally inter-fit to the bottom of side rail receivers 168 and center rail receiver 166 to center rail wedge 174, as further described herein. The inclusion or omission of lower extensions 164 and center rail receiver 166 thus allows frame 150 to be positioned at one of two different heights from the floor depending on the presence or absence of lower extensions 164 as part of side rail legs 160 and center rail receiver 166 on center rail wedge 174. Thus, entire frame 150 can be easily assembled without the need for tools and can be configured to allow for two different mattress heights when a mattress is placed on frame 150.

[0046] Referring to FIG. 15, the inter-fitting of side rails 152, 154 by inserting wedges 170 into receivers 168 of side rail leg 160 may be seen in greater detail. Side rail 152 (as is the case for side rail 154) is attached to wedge 170 and receiver 168 is attached to cross rail 156. Receiver 168 has a pocket 172 formed therein that provides a press fit with wedge 170 based on matching angled side walls of wedge 170 and pocket 172. The underside of receiver 168 also has an upstanding pocket 182 (not seen) that is similarly shaped to provide a press fit with an upstanding extension wedge 176 protruding from the inside of lower extension 164.

[0047] Referring to FIG. 16, each side rail leg 160 of bed frame 150 is formed by wedge 170 of side rail 152 fitting into pocket 172 of receiver 168 of cross rail 156 and being secured therein by a press fit due to matching angled side walls. The underside of receiver 168 also has an upstanding pocket 182 (not seen) that is shaped in the same way to fit upstanding extension wedge 176 protruding from the inside of lower extension 164.

[0048] Referring to FIG. 17, side rail leg 160 is shown in an exploded or disassembled view. Receiver 168 of each side rail leg 160 is comprised of a receiver cap 176 and a receiver foot 178. Preferably, receiver cap 176 and a receiver foot 178 are fastened together when frame 150 is manufactured, such as by using screws 180, and are thus shown coupled together. Wedge 170 is configured to be inter-fit with receiver 168 by inserting wedge 170 into pocket 172. Receiver foot 178 on the underside of receiver 168 is dimensioned and shaped to engage upstanding extension wedge 176 that protrudes from the inside of the lower extension 164 to allow the selectively attachment and release of lower extension 164 to receiver 168. Receiver 168 thus provides for double wedge fit, with pocket 172 oriented upward for engaging wedge 170 and pocket 182 oriented downward for engaging lower extension 164.

[0049] Referring to FIGS. 18, an assembled side rail leg 160 shows that wedge 170 is inter-fit to receiver 168 at the location of pocket 172 to creates a press fit based on matching angled side walls. On the underside of receiver 168 in receiver foot 178, the upstanding pocket 182 is seen along with its shape for fitting the upstanding extension wedge 176 protruding from the inside of lower extension 164. [0050] Referring to FIG. 19, center cross rail leg 162 is shown in an exploded or disassembled view with center rail wedge 174 of middle cross rail 156 capable of coupling to center rail receiver 166 via a pocket 184 that is dimensioned and configured to provide a press fit with center receiver wedge 174 based on matching angled side walls. Center rail wedge 174 is dimensioned so that it corresponds to the total height of wedges 170 and side rail receiver 168, rather than just side rail wedges 170, to provide support for the lower mattress position of frame 150, and center rail receiver 166 is dimensioned so that the overall size of center cross rail leg 162 corresponds to side rail leg 160 when center rail receiver 166 is uses to that all legs support frame 150 when configured for a higher mattress position. [0051] Referring to FIG. 20, each outwardly positioned end of each cross rail 156 is securely attached to a receiver cap 200 and a receiver foot 178 such as with screws 180 at the time of manufacturing and prior to delivery to a user. As a result, a user does not need any tools and can assemble frame 150 simply by inter fitting both side rails 154 to all three cross rails 156 prior to placing a mattress of frame 150.

[0052] As explained above, a first aspect of the invention is bed frame having: a pair of cross rails, each of which has a first receiver positioned at a first end and a second receiver positioned at a second end, wherein each of the first receiver and the second receiver includes a first pocket facing in a first direction and a second pocket facing in a second direction; a pair of side rails, each of which has a first wedge positioned at a first end and a second wedge position at a third end, wherein the pair of side rails are coupled to the cross rails such that the first wedge of each of the pair of side rails is inter fit with the first pocket of the first receiver of each of the pair of cross rails and the second wedge of each of the pair of side rails is inter fit with the second receiver of each of the pair of cross rails; and a series of extensions, each of which includes an upper geometry for selectively engaging the second pocket of each of the first receiver and the second receiver of each of the pair of cross rails. In a second aspect, the invention is further comprises a center rail having a third receiver position at a first end and a fourth receiver positioned at a second end, wherein the center rail is coupled to an intermediate portion of each of the pair of cross rails by a third wedge coupled to one of the pair of cross rails that inter fits with the third receiver and a fourth wedge coupled to the other of the pair of cross rails that inter fits with the fourth receiver. In a third aspect, each of the pair of cross rails can telescope between a series of lengths, each of which corresponds to one of a series of predetermined bed widths. In a fourth aspect, the center rail is positioned equidistantly from each of the pair of side rails when the pair of cross rails are telescoped into each of the series of lengths. In a fifth aspect, the series of extensions include at least two that can selectively engage the third receiver and the fourth receiver of the center rail.