| JP3056602 | [Name of device] Separable bed |
CARLSON PAUL (US)
RYAN HOWARD (US)
KONIECZNY MICHAEL (US)
| US20160106222A1 | 2016-04-21 |
| CLAIMS What is claimed is: 1. A bed base comprising: a first side panel; a first end panel interlocked at right angles to the first side panel; a second end panel interlocked at right angles to the first side panel; and a second side panel interlocked at right angles to the second end panel and the first end panel; a first cross rail overlapping the first side panel and the second side panel and coupled to the first side panel, the first end panel, and the second side panel by a first series of wedges that inter fit with a corresponding first series of receivers; a second cross rail overlapping the first side panel and the second side panel and coupled to the first side panel, the second end panel, and the second side panel by a second series of wedges that inter fit with a corresponding second series of receivers; and a third cross rail overlapping the first side panel and the second side panel and coupled to the first side panel and the second side panel by a third series of wedges that inter fit with a corresponding third series of receivers. 2. The bed base of claim 1, wherein the first cross rail, the second cross rail, and the third cross rail are positioned above the first side panel, the first end panel, the second end panel, and the second side panel so that the first cross rail, the second cross rail, and the third cross-rail are load bearing when a bed positioned on the bed base. 3. The bed base of claim 2, wherein the first side panel, the first end panel, the second end panel, and the second side panel are not load bearing when the bed is positioned on the bed base. 4. The bed base of claim 1, wherein each receiver of the first series of receivers, the second series of receivers, and the third series of receivers are formed by a back plate, and inner shell defining a pocket having a first geometry, a foot supporting the inner shell, and an outer shell enclosing the inner shell and the foot. 5. The bed base of claim 4, wherein each wedge of the first series of wedges, the second series of wedges, and the third series of wedges has a second geometry that corresponds with the first geometry of the pocket so that each wedge is securely coupled within each pocket. 6. The bed base of claim 1, wherein each of the first side panel, the first end panel, the second side panel, and the second end panel are formed by an extruded plastic rail having a rectangular cross-section. 7. The bed base of claim 1, wherein each of the first cross rail, the second cross rail, and the third cross rail are formed by a double angle iron extending from a first end to a second end. 8. The bed base of claim 1, further comprising a series of retainers coupled to each end of each of the first cross rail, the second cross rail, and the third cross rail. 9. The bed base of claim 8, wherein each retainer of the series of retainers has an upstanding tab secured to and extending above each end of each of the first cross rail, the second cross rail, and the third cross rail to restrict horizontal movement of any bed positioned on the bed base. 10. The bed base of claim 9, wherein each retainer of the series of retainers includes a pair of retainer halves that interlock with each other and capture the upstanding tab. 11. The bed base of claim 10, wherein the upstanding tab is blunted. 12. The bed base of claim 11, wherein each retainer half is secured to each other and through one of the first cross rail, the second cross rail, and the third cross rail to which the retainer is secured to prevent the upstanding tab from disconnecting from the one of the first cross rail, second cross rail, and third cross rail to which the retainer is secured. 13. The bed base of claim 1, wherein the first end panel is interlocked at right angles to the first side panel by a first corner wedge and a first corner receiver. 14. The bed base of claim 13, wherein the second end panel is interlocked at right angles to the first side panel by a second comer wedge and a second comer receiver. 15. The bed base of claim 14, wherein the second side panel is interlocked at right angles to the second end panel by a third comer wedge and a third comer receiver and at right angles to the first end panel by a fourth comer wedge and a fourth corner receiver. |
HOTEL BED BASE
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
[0001] The present invention relates to a bed base for supporting a mattress set and, more particularly, to a bed specially designed to be assembled without the need for loose hardware and tools.
2. DESCRIPTION OF THE RELATED ART
[0002] The hotel industry uses specialized bed bases for low cost and durability, as well as to block the space under the bed to avoid the need for cleaning of this space and to ensure guests do not leave items behind. A typical bed base consists of four rolled steel panels that are linked together at the corners to form the structure of the base. The base further includes rails at the head and foot and the two sides. The rails form a support structure that is smaller than the perimeter of the foundation of the mattress set. The comers of the frame are typically held together with separate metal plates that are bolted from the top and bottom. This method of assembly of the hotel bed base that requires loose hardware, such as metal plates, that must be manually attached with the appropriate tools is cumbersome and time consuming, and results in a box like structure having very little stability in the comers. In addition, the fasteners often loosen over time, which makes the frame noisy and unstable. The rolled metal panels cannot be formed to a high level of accuracy because of the nature of the rolling process, which complicates assembly and can lead to a misalignment of parts that exposes sharp edges that can injure the assembler or snag fabric.
[0003] The hotel bed base further includes cross rails made of tubing that extend beyond the sides of the frame to create an overhang forming a kick space on both sides of the bed. The cross rails have an upstanding tab on each end to capture and support the foundation of a mattress set. Additional tubing extends down from the cross rails to act as support legs. The support legs of each cross rail are inserted into grooves stamped in the top of the side rails, which adds another location with sharp edges and another junction that will produce noise when the bed is used. The overhang also exposes the rolled metal sides and end rails and thus leaves these parts susceptible to denting by kicking or when vacuuming. The upstanding metal ends of the cross rails that retain the foundation can be sharp and are in a particularly dangerous location for impact with the leg of a user. If the bedding is shifted to one side, the opposite side will extend from the foundation, thereby creating an even more dangerous protrusion that can be obscured by bedding blankets and linen. Thus, there is a need in the art for a bed base that avoids these shortcomings.
BRIEF SUMMARY OF THE INVENTION
[0004] The present invention is a design for a hotel style bed base that can be constructed primarily of extruded plastic panels with plastic end caps and molded foot assemblies along the side and end rails. The plastic end caps interlock by means of a wedge and receiver arrangement. By locking the end rails to the side rail at the comer connection a four-sided box assembly is formed of the extruded panels. The extruded panels have no sharp edges and will not dent easily. The panels are also light weight and do not squeak or rattle when assembled. The corner parts are precisely constructed for a secure fit and the wedges make the pressure of the bed force them together more tightly rather than loosening over time. Cross rails secure to the top of the box support and retain the bedding set. In a preferred embodiment, three double angle iron cross rails span between the sides of the box, one at each end, head and foot, and one in the middle. The cross rails have at least three molded plastic wedges that are inserted into the molded leg assemblies to further secure the extruded panel box assembly. The two cross rails at the foot and head ends of the bed base engage with both the side rails and the leg in the middle of the end rail. These three-point connections stabilize the corners of the panel box and eliminate any parallelograming of the structure. In addition, the parts are precisely constructed for a secure fit and the wedge approach forces the parts together more tightly over time and during use rather than loosening. The middle side rail has a pressed-on leg for support and the side rails pass through notches cut in the extruded side rails and extend beyond. The bedding set rests atop the side rails and is retained with molded plastic retainers. The bedding is thus retained outside of the panel box, so the panels are recessed underneath the bedding. All of the connections of the hotel bed box of the present invention do not require tools or fasteners for assembly. The up turned end of the plastic retainers are blunt and are therefore much safer than metal retainers. The present invention thus provides for easy, tool-free assembly and the interconnected nature of the assembly fosters structural stability that avoid looseness that can lead to undesirable noise when used.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) [0005] The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings, in which: [0006] FIG. l is a perspective view showing the bed base fully assembled and ready for a bedding set.
[0007] FIG. 2 is a perspective view of the bed base disassembled.
[0008] FIG. 3 is a perspective view showing a close-up of the comer assembly disassembled.
[0009] FIG. 4 is a side view of the side rail.
[0010] FIG. 5 is a perspective view showing the component parts of the side rail with one end exploded.
[0011] FIG. 6 is side view of the end rail.
[0012] FIG. 7 is a perspective view showing the component parts of the end rail with one end exploded.
[0013] FIG. 8 is a perspective view showing a cross rail retainer disassembled.
[0014] FIG. 9 is a side view close up of the cross rail retainer disassembled.
[0015] FIG. 10 is an exploded view of the side rail leg
[0016] FIG. 11 is an exploded view of the end rail leg
[0017] FIG. 12 is an exploded view of the cross rail end cap.
[0018] FIG. 13 is an exploded view of alternative embodiment for a side leg assembly.
[0019] FIG. 14 is a cross-sectional view of the embodiment of FIG. 13.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring to the figures, wherein like numerals refer to like parts throughout, there is seen in FIG. 1 a perspective view of a bed base 50 constructed in accordance with the present invention. As can be seen, bed base 50 is assembled and ready for a mattress set and is comprised of two side rails 52 that are attached to two end rails 56. Side rails 52 each have three side leg assemblies 68 and end rails 56 have two end leg assemblies 69. Side rails 52 are connected by three cross rails 60 that secure to each side leg assembly 68. The outer most positioned cross rails 60 also are connected to the end leg assemblies 69. At the ends of each cross rail 60 there are retainers 62 that are shaped to hold a mattress foundation from shifting laterally on bed base 50. Center cross rail 60 has a leg 64 positioned along an intermediate portion to provide a weight bearing member in the middle of bed base 50. As described below, side rails 52 and end rails 56 may comprise solid panels for providing an enclosed perimeter of bed base 50 as is common when bed base 50 is used for hotel bed applications. Because the load bearing structures for bed base 50 are legs 64, side leg assemblies 68, and end leg assemblies 69, side rails 52 and end rails 56 do not need to be load bearing. The material used to form side rails 52 and end rails 56 is therefore not limited to those materials that can provide structural support for a bed positioned on bed base 50, and can be formed from molded plastic and the comparable materials rather than wood, particle board, or metal as is typical for conventional bed base sysatems.
[0021] Referring to FIG. 2, bed base 50 is shown with cross rails 60 and center leg 64 removed and side rails 52 and end rails 56 disassembled. Each end of each side rail 52 has one of a set of upstanding comer wedges 112. On each end of each side rail 56 there is one of a set of downward facing receivers 114. Receivers 114 are shaped to engage with wedges 112 and to lock side rails 52 to end rails 56 at the corners of bed base 50. Each cross rail 60 includes a series of cross rail wedges 136 positioned to inter fit with the side rail leg assembly 68 and end rail legs 69 into a receiver pocket 138 positioned adjacently to comer wedges 112. In this way, end rail 56 and side rails 52 are locked together at each comer and at the six leg assemblies 66 and two leg assemblies 69 by cross rails 60, thereby completely securing bed base 50 without the need for tools. Receivers 114 and comer wedges 112 thus form an interlock at each corner of bed base 50 to couple side rail 52 to end rail 56. It should be recognized that each pair of receivers 114 and corner wedges 112 could be reversed so that comer wedge 112 is facing downward to couple with receiver 14 facing upward, and comer wedge 112 could be positioned on the end of end rail 56 with receiver 114 positioned on the end of side rail 52.
[0022] Referring to FIG. 3 the connection of side rail 52 and end rail 56 is formed by comer wedge 112 of side rail 52 inter fitting with receiver 114 of end tail 56 to form a unified and stable comer without the need for fasteners or tools.
[0023] Referring to FIG. 4, side rail 52 has slots 78 for positioning of cross rail 60 (not shown). Side leg assemblies 68 are positioned at each end and in the center for support. Corner wedges 112 are positioned at each end of side rail 52.
[0024] Referring to FIG. 5, side rail 52 may be constructed from an extruded plastic rail 57 having a rectangular cross section. Slots 78 pass thru the upper portion of the rectangular form of side rail 57. Corner wedge 112 is shown disconnected from side rail 52 to reveal the shape of the extrusion of plastic rail 57. A mounting portion 134 of corner wedge 112 is seen on the end of side rail 52. Side leg assemblies 68 are shown exploded from side rail 52 to show that bosses 132 may be used to engage both plastic rail 57 and mounting portion 134 of corner wedge 112 and may held in place with screws 46. A cap 130 may be used to on the bottom of comer wedge 112. Screws 46 along the upper edge of panel 52 may be positioned so that the overlapping portions of cross rails 60 cover the screw heads. [0025] Referring to FIG. 6, end rail 56 has receivers 114 are positioned at each end and an end rail leg 69 positioned in the center.
[0026] Referring to FIG. 7, end rail 56 may be constructed of an extruded plastic rail 57 having a rectangular cross section. It can further be seen that receiver 114 is shown exploded off one end to see the shape of extruded plastic rail 57. A mounting portion 134 of receiver 114 can be seen on the exploded end of end rail 56. Receiver 114 is held in place with screws 46. End rail legs 69 is shown exploded from end rail 56 to show that bosses 132 engage plastic rail 57 and may be held in place with screws 46.
[0027] Referring to FIG. 8, cross rail 60 and side rail 52 are shown in a disassembled configuration. The end of the cross rail 60 includes a plastic retainer 62 that serves to hold the mattress set (not shown) from moving laterally on bed base 50. The ends of cross rail 60 also create an overhang that provides clearance for the feet of user of a bed on bed base 50.
Plastic retainer 62 includes an up-turned tab 67 that is generally round for safety. Screws 46 may be used to secure side leg assembly 68 and corner wedge 112 to extruded plastic rail 57. The end of side rail 60 includes side rail wedge 136, is shown disassembled from side leg assembly 68. Wedge 136, when assembled, is secured to side leg assembly 68 in receiver pocket 138. This inter fitting securely locks cross rail 60 to the side rail 52.
[0028] Referring to FIG. 9, cross rail 60 with retainer 62 is shown disassembled from side rail 52 with side rail wedge 136 positioned above pocket 138 prior to be inter fit therein to form leg assembly 68. The upturned tab 67 of retainer 62 is blunted blunt for safety and is shaped to hold the mattress set (not shown).
[0029] Referring to FIG. 10, side leg assembly 68 includes an outer shell 140, an inner shell 142 that contains a pocket 138 for accepting and inter fitting with wedge 136, and a receiver foot 152 for bearing any weight applied to leg assembly 69 by cross rails 60, such as when a foundation and mattress is supported by bed frame 50. A back plate 154 includes bosses 132 extending outwardly for mounting to side rail 52 using screws 46.
[0030] Referring to FIG. 11, end leg assembly 69 includes an outer shell 144 and an inner shell 146 that contains a receiver pocket 138 as well as a receiver foot 152 for bearing any weight applied to leg assembly 69 by the centermost cross rail 60. Inner shell 146 includes bosses 132 for mounting so that leg assembly 69 may be held together by screws 46. [0031] Referring to FIG. 12, cross rail 60 assembly includes retainer 62 formed by a right half 149 and a left half 148 that contain up turned tab 67. Right half 149, left half 148, and tab 67 may be assembled using rivets 158 to form the overlapping ends of cross rail 60 adjacent to wedge 136. Retainer 62 is thus securely held in place on the end of cross rail 60 because of the interconnection with right half 149, left half 148 and rivets 158. As a result, retainers 62 are significantly less likely to disconnect from cross rails 60 as is the case with conventional end caps that are placed over the crimped tube cross rails of conventional bed bases.
[0032] Referring to FIGS. 13 and 14, there is seen an alternative embodiment for a side leg assembly 168 that may be used so that screws 46 used to secure side leg assembly 168 to side rail 52 are not visible along the outside of the bottom of side rails 52. Side leg assembly 168 comprises an outer shell 240, an inner shell 242 that contains the standard receiver pocket 138 used to accept wedge 136, and a receiver foot 252 for supporting inner shell 242. A back plate 254 includes upper bosses 232 for coupling to side rail 52 via screws 46. The bottom of back plate 254 contains a foot 256. As seen in FIG. 14, foot 256 can be positioned under a lip 258 on the inside of the lower edge of side rail 52 and secured to the bottom of side rail 52 by a screw 46 to hold side leg assembly 168 without screw heads being visible from the outside of side rail 52.
[0033] As detailed above, a first aspect of the invention is a bed base comprising: a first side rail; a first end rail interlocked with the first side rail; and a first cross rail interlocked with the first side rail and the first end rail and overlapping the first side rail to provide a first support. In a second aspect, the first end rail is interlocked with the first side rail by a first corner wedge coupled to one of the first side rail and the first end rail and a first retainer coupled to the other of the first side rail and the first end rail. In a third aspect, the first cross rail is interlocked with the first side rail and the first end rail by a first cross rail wedge that inter fits with a first receiver coupled to the first side rail and second cross rail wedge that inter fits with a second receiver coupled to the first end rail. In a fourth aspect, the bed base has a second end rail interlocked with the first side rail by a second comer wedge coupled to one of the first side rail and the second end rail that inter fits with a second retainer associated with the other of the first side rail and the second corner wedge. In a fifth aspect, the bed base has a second cross rail interlocked with the first side rail and the second end rail and overlapping the first side rail to provide a second support, wherein the second cross rail is interlocked with the first side rail by a third cross rail wedge that inter fits with a third receiver coupled to the first side rail and is interlocked to the second end rail by a fourth cross rail wedge that inter fits with a fourth receiver coupled to the second end rail. In a sixth aspect, the bed base has a second side rail interlocked with the second end rail and the first end rail. In a seventh aspect, the second side rail is interlocked with the second end rail by a third comer wedge coupled to one of the second side rail and the second end rail and a third retainer coupled to the other of the first side rail and the first end rail. In an eight aspect, the second side rail is interlocked with the first end rail by a fourth comer wedge coupled to one of the second side rail and the first end rail and a fourth retainer coupled to the other of the second side rail and the first end rail. In a ninth aspect, the second cross rail is interlocked with the second side rail by a fifth wedge that inter fits with a fifth receiver coupled to the second side rail and the second cross rail overlaps the second side rail to provide a third support. In a tenth aspect, the first cross rail is interlocked with the second side rail by a sixth wedge that inter fits with a sixth receiver coupled to the second side rail and the first cross rail overlaps the second side rail to provide a fourth support. In an eleventh aspect, the bed base has a third cross rail interlocked with the first side rail by a seventh wedge that inter fits with a seventh receiver coupled to the first side rail and interlocked with the second side rail by an eighth wedge that inter fits with an eight receiver coupled to the second side rail, wherein the third cross rail overlaps the first side rail to provide a fifth support and the second side rail to provide a sixth support. In a twelfth aspect, each of the first support, the second support, the third support, the fourth support, the fifth support, and the sixth support include a tab extending upwardly. In a thirteenth aspect, each of the first support, the second support, the third support, the fourth support, the fifth support, and the sixth support include a pair of opposing members securing the tab in place.
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