Mattress Foundation Frame with Slide Mount for Headboard/Footboard Bracket

Abstract

A mattress foundation frame includes: (a) an upper structure that: (i) is defined by an approximately rectangular perimeter having four corners, and (ii) provides a top surface for supporting a mattress foundation; (b) a plurality of legs attached to the upper structure; (c) two first sliding mechanisms, one provided at each of two adjacent ones the corners; and (d) two headboard/footboard bracket assemblies, each having: (i) a bracket for attaching at least one of a headboard or a footboard, and (ii) a second sliding mechanism that is engaged with the first sliding mechanism of one of the two first sliding mechanisms, such that each of the headboard/footboard bracket assemblies is slidably attached to one of the first sliding mechanisms.

Description

FIELD OF THE INVENTION

The present invention pertains, among other things, to bed components, such as mattress foundation frames and components thereof, as well as to systems, methods and techniques for using, setting up, configuring and/or collapsing such components.

BACKGROUND

A mattress foundation frame, typically made entirely or substantially entirely of steel or another metal, conventionally has been used to support a mattress foundation (such as a box spring), which in turn supports a mattress. The combination of such a frame, foundation and mattress can be used as a bed. In some cases a separate foundation is omitted, and the mattress is placed directly on top of the upper surface of the frame.

Different kinds of mattress foundation frames exist. However, improvements remain desirable, particularly with respect to the ease with which such frames (or portions thereof) can be set up, configured and/or collapsed, as well as the maximum sizes/dimensions to which such frames can be collapsed.

SUMMARY OF THE INVENTION

The present invention addresses the foregoing needs, in one respect, by providing a mattress foundation frame that is includes, or is configured to include, one, two or more brackets slidably attached to the rest of the frame which can be used to detachably attach a headboard or a footboard.

One particular embodiment of the invention is directed to a mattress foundation frame that includes: (a) an upper structure that: (i) is defined by an approximately rectangular perimeter having four corners, and (ii) provides a top surface for supporting a mattress foundation; (b) a plurality of legs attached to the upper structure; (c) two first sliding mechanisms, one provided at each of two adjacent ones the corners; and (d) two headboard/footboard bracket assemblies, each having: (i) a bracket for attaching at least one of a headboard or a footboard, and (ii) a second sliding mechanism that is engaged with the first sliding mechanism of one of the two first sliding mechanisms, such that each of the headboard/footboard bracket assemblies is slidably attached to one of the first sliding mechanisms.

By virtue of the foregoing arrangement, it can be possible to attach a headboard/footboard bracket only if desired, e.g., if a headboard or footboard is desired to be attached to the frame. Moreover, a configuration according to the present invention often can permit the attachment of such a bracket without the need for tools (e.g., screw drivers or wrenches) or small attachment hardware (e.g., screws, bolts or nuts).

Another aspect of the present invention is the provision of a mattress foundation frame that can be folded up into a relatively small (e.g., in terms of maximum dimension) package, e.g., for storage and/or shipment.

One embodiment of this aspect of the invention is directed to a mattress foundation frame that includes: an upper structure that is defined by an approximately rectangular perimeter having two opposite ends and that provides a top surface for supporting a mattress foundation; and a leg assembly attached to the upper structure at each of such two opposite ends. Each such leg assembly preferably includes two legs attached together in a unit and is hingedly attached to the upper structure, so that it is capable of being folded up underneath and substantially parallel to the bottom surface of the top structure or unfolded so that it extends downwardly from, and thereby is capable of supporting, the upper structure. In addition, the upper structure includes two end sections and two middle sections. Each of the end sections is hingedly attached to an adjacent middle section, so that the two sections can be unfolded into an end-to-end configuration or folded so that the bottom surface of the end section is adjacent the bottom surface of the middle section, with the two sections being substantially parallel to each other. The two middle sections are hingedly attached to each other, so that the two sections can be unfolded into an end-to-end configuration or folded so that their bottom surfaces are adjacent to each other and with the two sections being substantially parallel to each other. Preferably, each such leg assembly, when folded up, does not extend beyond the end section to which it is attached. Also, in the preferred embodiments, the two middle sections are hingedly attached through the use of a short intermediate segment that is hingedly attached to each.

The foregoing summary is intended merely to provide a brief description of certain aspects of the invention. A more complete understanding of the invention can be obtained by referring to the claims and the following detailed description of the preferred embodiments in connection with the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following disclosure, the invention is described with reference to the accompanying drawings. However, it should be understood that the drawings merely depict certain representative and/or exemplary embodiments and features of the present invention and are not intended to limit the scope of the invention in any manner. The following is a brief description of each of the accompanying drawings.

FIG. 1 is a top perspective view of a mattress foundation frame in its in-use configuration according to the present invention.

FIG. 2 is an exploded inner perspective view of the corner of a mattress foundation frame corner that includes a first sliding mechanism and a headboard/footboard bracket assembly that includes a second sliding mechanism configured for slidably attaching to the first sliding mechanism.

FIG. 3 is an inner perspective view of the headboard/footboard bracket assembly and the mattress foundation frame corner, with the first and second sliding mechanisms engaged each other so that the headboard/footboard bracket assembly is slidably attached to the mattress foundation frame corner, and with a headboard or a footboard attached to the bracket.

FIG. 4 is an outer perspective view of the corner of the mattress foundation frame with a headboard/footboard bracket assembly attached.

FIG. 5 is a sectional view, along the plane 5-5 shown in FIG. 4, of the corner of the mattress foundation frame with the headboard/footboard bracket assembly attached.

FIG. 6 is a side elevational view of a mattress foundation frame, with its end leg assemblies in the process of being folded up underneath its upper structure.

FIG. 7 is a bottom perspective view of one end of the mattress foundation frame, with its leg assembly fully folded up and with its end section partly folded up underneath its middle section.

FIG. 8 is a perspective view of the mattress foundation frame after being fully folded up (or collapsed).

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

According to one aspect of the present invention, a mattress foundation frame is configured to allow a headboard/footboard bracket assembly to be easily attached to and then detached from each of two adjacent corners (e.g., at the head of the bed) or, in some cases, any of its four corners (e.g., so that such assemblies can be used for attaching either or both of a headboard and/or a footboard). As used herein, a “headboard/footboard bracket” refers to a bracket for attaching either a headboard or a footboard, usually including a plurality of horizontal slots.

FIG. 1 illustrates an exemplary mattress foundation frame 10 according to the present invention. Other than certain relatively small components, discussed below, frame 10 is made primarily, entirely, or almost entirely (e.g., other than some small portions and/or components), of steel and/or other kind(s) of metal. As shown, the upper structure 11 of frame 10 includes a plurality of longitudinal slats 12, separated by gaps, and lateral slats 14, also separated by gaps, all surrounded by an outer perimeter 15, that collectively provide a substantially flat (although not continuous) top surface, e.g., for supporting a mattress foundation. That is, in the current embodiment, the top surfaces of the perimeter 15, longitudinal slats 12 and lateral slats 14 are at least approximately coplanar with each other. As shown, the perimeter 15 is approximately rectangular shaped, but with its four corners rounded (e.g., to minimize the likelihood of injury/damage to people or objects). Slats 12 and 14 are elongated supports and, in the current embodiment, slats 12 are tubular in shape while slats 14 are rectangular panels. However, in alternate embodiments either or both can have either such shape or even a different shape.

In the current embodiment, the only non-metallic components of frame 10 are the feet 16 at the bottom of the legs 17 (i.e., end legs 17E and middle legs 17M), which preferably are made of rubber, plastic or a similar softer material for protecting the surface of the floor upon which frame 10 rests. Alternatively, feet 16 can be omitted, particularly if the bottoms of the legs 17 are formed so as to have only smoothly curved features, in order to avoid scratching or otherwise damaging the floor. As shown in the drawings, in the current embodiment each of the legs 17 is attached to (or otherwise extends from) a different point on the perimeter 15 of the frame 10. In alternate embodiments one or more of the legs 15 might also extend from the longitudinal and/or lateral slat(s) 12, 14.

One feature of frame 10, shown most clearly in FIG. 2, is the inclusion of an inwardly extending mounting structure (sometimes referred to, in reference to the current embodiment, as a corner bracket) 20 at each corner (or at least the two corners at one longitudinal end of frame 10). As shown, in the current embodiment inwardly extending mounting structure 20 includes: (1) an inwardly extending shelf 22 that preferably extends at least ½, ¾or 1 inch inwardly away from the perimeter 15 of the frame 10 and preferably is at least approximately coplanar with the top surfaces of longitudinal slats 12 and lateral slats 14; and (2) a slot-like structure 24 (e.g., at least ½, ¾or 1 inch wide) that extends downwardly (e.g., at least 1 or 2 inches) from shelf 22. More specifically, in the current embodiment, slot-like structure 24 has a cross-section that is, or approximates, a partial rectangle, with an opening in its inwardly facing long side. In the current embodiment, the entire inwardly extending mounting structure 20 is welded to the inner edge of the respective corner of frame 10. However, in alternate embodiments, mounting structure 20 is integrally formed with the rest of frame 10 (e.g., at or near one of its corners).

Also provided in the current embodiment is a headboard/footboard bracket assembly 30 for attaching to one of the corners of frame 10 (e.g., any one of such corners that has a mounting structure 20). As shown, headboard/footboard bracket assembly 30 includes two elongated panels 31 and 32 that are joined together at one of the two long side edges of each, preferably so that the two panels 31 and 32 are arranged at approximately (or exactly) 90° relative to each other, thereby forming a vertically elongated member having an at least approximately L-shaped cross-section. More preferably, panels 31 and 32 have been formed by bending a rectangular metal plate, so that the panels 31 and 32 are integrally formed with each other.

In the current embodiment, each of panels 31 and 32 includes a sequence of horizontal slots 33, similar to the slots in a conventional headboard or footboard bracket, thereby allowing a standard conventional headboard or footboard to be attached to either of panels 31 and 32. In alternate embodiments, only one of panels 31 and 32 is provided with such slots 33 because, in use, typically at most only one of such panels 31 and 32 will be used for attaching a headboard or footboard. However, by providing such slots 33 on both of panels 31 and 32, a single headboard/footboard bracket assembly 30 can be used at any of the four corners of frame 10, thereby reducing the number of different components that must be manufactured. For similar reasons, each mounting structure 20 is provided at one of the corners of frame 10 (although in alternate embodiments, one or more of such mounting structure is 20 are provided at other locations on the frame 10).

Headboard/footboard bracket assembly 30 also includes a shelf 34 extending inwardly from the interior surfaces (i.e., the surfaces forming or abutting the smaller angle, which is less than 180° and, more preferably, approximately 90°) of panels 31 and 32. In the current embodiment, shelf 34 is welded to such inner surfaces (although in alternate embodiments, it could be integrally formed with, or otherwise attached to, such inner surfaces). Extending upwardly from the distal end of shelf 34 (e.g., at least 1 or 2 inches) is a tab-like structure 36 (e.g., at least ½, ¾or 1 inch wide, but in the current embodiment, slightly narrower than the inner width of slot-like structure 24). Preferably, tab-like structure 36 has a shape that is essentially the same as the interior of slot-like structure 24, but slightly narrower so as to just fit within slot-like structure 24. However, in alternate embodiments, the mating surfaces of mounting structure 20 and headboard/footboard bracket assembly 30 can have any of a variety of different shapes, e.g., so long as the two can engage with each other, e.g., so that one can slide vertically relative to the other. Thus, for example, in alternate embodiments, a slot-like structure instead is provided on headboard/footboard bracket assembly 30, while a tab-like structure is provided at the corner of frame 10.

In the current embodiment, if a headboard or footboard bracket is desired at a particular location (i.e., corner) on frame 10, a headboard/footboard bracket assembly 30 is positioned such that tab-like structure 36 is directly beneath slot-like structure 24 and then tab-like structure 36 is slid upwardly into slot-like structure 24, thereby engaging the two components. Preferably, at least one of tab-like structure 36 or slot-like structure 24 is tapered (i.e., narrows in width) as a function of vertical position so that a wedge (or friction) fit is increasingly provided as the two components are more fully engaged with each other. In the current embodiment, as shown in the drawings, slot-like structure 24 (or at least the inner portion thereof) is narrower at the top then at the bottom and tab-like structure 36 (or at least the outer profile thereof) has a uniform width, thereby creating the desired wedge fit. In use, the two components are slid relative to each other in this manner until the top surface of shelf 34 comes into contact with the bottom surface of perimeter 15, resulting in a hard stop with respect to relative motion in that direction. The wedge or friction fit provides resistance to relative motion in the opposite direction; it is noted that such inadvertent separating forces typically occur only rarely in normal use.

Also in the current embodiment, the length and other dimensions of headboard/footboard bracket assembly 30 are such that when fully engaged with mounting structure 20 (e.g., as discussed above), the bottom of headboard/footboard bracket assembly 30 (i.e., the bottom edge of panels 31 and 32) extends to the same level as the bottom of legs 17, so that headboard/footboard bracket assembly 30, in addition to providing a headboard/footboard bracket, also functions as an additional leg, providing additional support for the frame 10. As a result, a foot 38 (e.g., L-shaped and made of rubber, plastic or a similar soft material) preferably is provided at the bottom of headboard/footboard bracket assembly 30 in order to protect the floor.

It is noted that the attachment process described above can be repeated for each corner of frame 10 at which a headboard or footboard bracket might be desired and/or at which an additional leg support is desired. Once a headboard/footboard bracket assembly 30 has been attached to one of the corners of the perimeter 15 in the foregoing manner, a headboard or footboard 37 can be attached, e.g., by using screws 39 which extended through the slots 33, as shown in FIG. 3. Subsequently, in order to remove a headboard/footboard bracket assembly 30, it is simply pulled away from (i.e., downwardly relative to) the mounting structure 20 with sufficient force to overcome the friction or wedge fit noted above.

The foregoing embodiment uses inwardly extending tab and slot components. As a result, the outer surface of the corner of frame 10 can be smooth and/or continuous (e.g., smoothly curved, as shown in the drawings) if a headboard/footboard bracket assembly 30 is not installed at that corner, or if a bracket assembly 30 is attached to the corner but a headboard or footboard is not attached to bracket assembly 30. In alternate embodiments, one or more sliding component(s) or similar types of mating component(s) is/are provided on the exterior surface of frame 10 and a corresponding one or more mating and/or sliding component(s) is/are provided on the interior surface of headboard/footboard bracket assembly 30 (e.g., directly on panel 31 and/or panel 32). While such an alternate embodiment is a more straightforward implementation of the present invention, one potential disadvantage is that the sliding component on the exterior surface of the corner of frame 10 is exposed if a headboard/footboard bracket assembly 30 has not been installed there, possibly resulting in inadvertent scratching or scraping (e.g., of the user's skin and/or of other furniture, walls, etc.). For that reason, the illustrated embodiment currently is preferred.

Variations on the foregoing embodiments are possible. For instance, rather than including a shelf 22 or 34 (e.g., having a flat top surface) on either or both of mounting structure 20 or headboard/footboard bracket assembly 30, respectively, any other inwardly extending structure instead may be used. Also, in the preceding embodiments, headboard/footboard bracket assembly 30 attaches to mounting structure 20 using a friction fit. In alternate embodiments any of a variety of locking mechanisms (e.g., screws, pins, snap-fit mechanisms, spring-loaded latches, etc.) also, or instead, may be used to secure the two components to each other. However, in the preferred embodiments, it is desirable to avoid the use of small mounting hardware (e.g., screws, nuts, pins, etc.) and the necessity of using tools (e.g., screw drivers or wrenches) for attaching or detaching a headboard/footboard bracket assembly 30.

Another aspect of frame 10 according to the present invention is its unique folding structure which permits frame 10 to be folded down to approximately ¼of its normal (in-use or operational) length.

In the current embodiment, the legs 17E at each of the head and the foot of the frame 10 are attached to each other in a single unit 40 using a cross-bar 42 and are attached to the corresponding end of the frame 10 (more specifically, the corresponding end of the perimeter 15) via hinges 44. In addition, each such end leg 17E is provided with a diagonal support 46 having a pair of hinge pins 47 in its middle section so that it is bendable and also having a locking mechanism 48 (such as a stop or a pin structure) in order to prevent support 46 from over rotating in the direction in which stress is applied in normal use. As a result of this configuration, such end legs 17E can be folded up against the bottom side of upper structure 11 (shown partially folded up in FIG. 6 and fully folded up in FIG. 7) or unfolded into the operational position (shown in FIG. 1), as desired.

Also, in the present embodiment the upper structure 11 itself is divided into four sections 51-54, with adjacent ones of such sections 51-54 so that they can be folded downwardly or inwardly relative to each other, or unfolded so that they are end-to-end. More specifically, in the current embodiment, each of end sections 51 and 54 is directly hinged to a middle section 52 or 53, respectively, e.g., using just a conventional hinge 57 on each side of frame 10, while middle sections 52 and 53 are hinged to each other using, on each side of frame 10, a rectangular bar (or other connecting element) 58 with a pin 59 at one end attaching the connecting element 58 to middle section 52 and with another pin 59 at the other end attaching the connecting element 58 to middle section 53.

As a result of this configuration, the frame 10 can be folded into approximately one quarter of its operational length in the following manner. First, at each end of the frame 10, each locking mechanism 48 at that end is released (e.g., by retracting a spring-loaded pin or by rotating the two ends of support 46 away from the stop) and then folding the leg unit 40 (or the individual end legs 17E, if not attached in the unit) upwardly and inwardly until such end legs 17E contact or are adjacent to and at least approximately parallel with the bottom surface of the upper structure 11 (i.e., end section 51 or 54), as shown in FIGS. 6 and 7. In order to accommodate the desired folding, each leg unit 40 when folded in this manner does not extend beyond the proximal edge of its corresponding end section 51 or 54. Second, each of the end sections 51 and 54 (together with the folded-up leg unit 40 underneath it) is folded upwardly and inwardly (e.g., in the direction 60 shown in FIG. 7) so that its bottom surface (and/or the folded-up leg unit 40) contacts or is at least approximately parallel with the bottom surface of the adjacent middle section 52 or 53, respectively. Third, the two middle sections 52 and 53 (together with the folded-up structures beneath them) are folded in the direction 62 shown in FIG. 7 so as to bring their bottom surfaces together (with the middle legs 17M between, adjacent to and parallel to their bottom surfaces). The result, shown in FIG. 8, is a very compact unit that can be easily shipped or stored.

Unfolding such a unit, for operational use of the frame 10, essentially involves reversing the steps described in the preceding paragraph. Due to the structural features described above, each unfolding operation includes a natural stop so that the two components being unfolded relative to each other are not capable of being rotated beyond their operational configurations. Also, when unfolding the leg unit 40 (or the individual end legs 17E, if not connected in a unit), the locking mechanism 48 typically will automatically engage at the operational configuration. However, as noted above, manually actuated stops also or instead may be provided.

Additional Considerations

As used herein, the term “attached”, or any other form of the word, without further modification, is intended to mean directly attached, attached through one or more other intermediate elements or components, or integrally formed together. In the drawings and/or the discussion, where two individual components or elements are shown and/or discussed as being directly attached to each other, such attachments should be understood as being merely exemplary, and in alternate embodiments the attachment instead may include additional components or elements between such two components. Similarly, method steps discussed and/or claimed herein are not intended to be exclusive; rather, intermediate steps may be performed between any two steps expressly discussed or claimed herein.

Unless otherwise clearly stated herein, all relative directions (e.g., left, right, top, bottom, above, below) mentioned herein in relation to an article are from the perspective of the article itself and, therefore, are consistent across different views.

Unless clearly indicated to the contrary, words such as “optimal”, “optimize”, “maximize”, “minimize”, “best”, as well as similar words and other words and suffixes denoting comparison, in the above discussion are not used in their absolute sense. Instead, such terms ordinarily are intended to be understood in light of any other potential constraints, such as user-specified constraints and objectives, as well as cost and processing or manufacturing constraints.

In the above discussion, certain methods are explained by breaking them down into steps listed in a particular order. However, it should be noted that in each such case, except to the extent clearly indicated to the contrary or mandated by practical considerations (such as where the results from one step are necessary to perform another), the indicated order is not critical but, instead, that the described steps can be reordered and/or two or more of such steps can be performed concurrently.

In the discussions above, the words “include”, “includes”, “including”, and all other forms of the word should not be understood as limiting, but rather any specific items following such words should be understood as being merely exemplary.

Several different embodiments of the present invention are described above, with each such embodiment described as including certain features. However, it is intended that the features described in connection with the discussion of any single embodiment are not limited to that embodiment but may be included and/or arranged in various combinations in any of the other embodiments as well, as will be understood by those skilled in the art.

Thus, although the present invention has been described in detail with regard to the exemplary embodiments thereof and accompanying drawings, it should be apparent to those skilled in the art that various adaptations and modifications of the present invention may be accomplished without departing from the intent and the scope of the invention. Accordingly, the invention is not limited to the precise embodiments shown in the drawings and described above. Rather, it is intended that all such variations not departing from the intent of the invention are to be considered as within the scope thereof as limited solely by the claims appended hereto.

Claims

1. A mattress foundation frame, comprising:

(a) an upper structure that: (i) is defined by an approximately rectangular perimeter having four corners, and (ii) provides a top surface for supporting a mattress foundation;

(b) a plurality of legs attached to the upper structure;

(c) two first sliding mechanisms, one provided at each of two adjacent ones said corners; and

(d) two headboard/footboard bracket assemblies, each having: (i) a bracket for attaching at least one of a headboard or a footboard, and (ii) a second sliding mechanism that is engaged with the first sliding mechanism of one of said two first sliding mechanisms, such that each of said headboard/footboard bracket assemblies is slidably attached to one of said first sliding mechanisms.

2. A mattress foundation frame according to claim 1, wherein each of said first sliding mechanisms is provided at a distal end of a first structure that extends inwardly, starting from a proximal end of said first structure, from a corresponding one of said two adjacent corners.

3. A mattress foundation frame according to claim 2, wherein each of said headboard/footboard bracket assemblies also includes a vertically elongated member that provides said bracket and a second structure that extends away from said vertically elongated member, starting from a proximal end of said second structure, and wherein the second sliding mechanism is provided at a distal end of said second structure.

4. A mattress foundation frame according to claim 3, wherein each of said second sliding mechanisms has been slidably engaged with a corresponding one of said first sliding mechanisms until said second structure comes into contact with a bottom surface of at least one of said first structure or said perimeter.

5. A mattress foundation frame according to claim 3, wherein said vertically elongated member has an at least approximately L-shaped cross-section formed by two elongated panels that are joined together at a common edge.

6. A mattress foundation frame according to claim 5, wherein at least one of said two elongated panels includes a sequence of horizontal slots for attaching at least one of a headboard or a footboard.

7. A mattress foundation frame according to claim 5, wherein each of said two elongated panels includes a sequence of horizontal slots for attaching at least one of a headboard or a footboard.

8. A mattress foundation frame according to claim 3, wherein when one of said headboard/footboard bracket assemblies is slidably attached to one of said first sliding mechanisms until a stop has been reached, said vertically elongated member extends downwardly to approximately a same distance as a bottom surface of each of said legs, so that said vertically elongated member also functions as an additional leg.

9. A mattress foundation frame according to claim 1, wherein said first sliding mechanism comprises a vertically oriented slot.

10. A mattress foundation frame according to claim 9, wherein said second sliding mechanism comprises a tab that is disposed within said vertically oriented slot.

11. A mattress foundation frame according to claim 10, wherein each of said first sliding mechanism and said second sliding mechanism has a cross-section in a shape of a rectangle with a portion of one side missing.

12. A mattress foundation frame according to claim 1, wherein at least one of said first sliding mechanism and said second sliding mechanism narrows in width as a function of vertical position, so as to provide a wedge fit between said first sliding mechanism and said second sliding mechanism.

13. A mattress foundation frame according to claim 1, wherein said upper structure and said plurality of legs are made primarily of metal.

14. A mattress foundation frame according to claim 1, wherein said upper structure and said plurality of legs are made primarily of steel.

15. A mattress foundation frame according to claim 1, wherein said top surface also includes a plurality of longitudinal slats, separated from each other by gaps, and a plurality of lateral slats, also separated from each other by gaps.

16. A mattress foundation frame according to claim 15, wherein said plurality of longitudinal slats and said plurality of lateral slats have top surfaces that are approximately coplanar with each other.

17. A mattress foundation frame according to claim 1, wherein said legs are hingedly attached to different points on said perimeter.