READY TO ASSEMBLE ADJUSTABLE BED

Abstract

A bed assembly includes a pair of expandable structural frame members, each having a compact position with a first frame length and an expanded position with a second frame length longer than the first frame length, a plurality of cross frame members each having a pair of opposing ends and each opposing end releasably attachable to one of the expandable structural frame members in the expanded position and a plurality of decking panels each releasably attachable to the pair of expandable structural frame members in the expanded position.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Patent Application No. 63/071,575 filed Aug. 28, 2020, and U.S. Provisional Patent Application No. 63/115,392 filed Nov. 18, 2020, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

Embodiments of the subject matter disclosed herein relate to bedding including adjustable, articulating bedding platforms and systems.

BACKGROUND

The growth of online, e.g., web-based and direct-to-consumer, shopping creates an opportunity or need for bedding products that can be shipped and delivered directly to consumers using common shipping carriers. The ability to use these common carriers, and the cost associated with shipping, is governed by size and weight restrictions imposed by the carrier. The size and weight of conventional bedding products, and in particular adjustable bedding products, limit the shipping methods or carriers that can be used for delivery due to these size and weight restrictions.

Attempts at creating bedding products, including adjustable bedding products, that meet the size and weight restrictions imposed by shipping carriers include folding bed frames and bed bases and bed frames and bed bases arranged as a few sections that can be disconnected for shipping. While these existing attempts do achieve a degree of size and weight reductions, a need remains for bedding assemblies that provide for an even smaller dimensional weight that meets the size and weight restrictions of common carriers and that can be readily assembled by the consumer.

SUMMARY

Exemplary embodiments are directed to bed assemblies including adjustable bed assemblies that can be disassembled into individual frame members and decking members. These individual frame members include expandable frame members having an expanded position for use in the assembled bed assembly and a compact position for shipping. All of the disassembled frame and decking members, the actuators and control electronics for the adjustable bed assembly and the hardware used to assemble the individual frame members and decking members into the bed assembly can be packaged for shipping in a container that meets or exceeds the shipping standards of common carriers, e.g., United Parcel Service and Federal Express, for small parcels, for example, less than 140 dimensional pounds. The dimensional weight takes into account the actual size or total girth of the parcel being shipped, and the dimensional weight can exceed the actual weight of the package. Each common carrier provides a formula that is used to calculate this dimensional weight, e.g., Dimensional Weight=L+(2 W+2H). Other formulas take the total volume (L×W×H) of the package and divide by a fixed value. The formula used to calculate dimensional weight is also subject to change by each common carrier.

In addition to the compact dimensions associated with the bed assembly, lightweight framing and decking materials can be utilized. The types of framing members include hollow tubular members having circular or rectangular cross sections. Additional weight reduction is achieved with reduced thickness, i.e., wall thickness, of the material of the framing member. Suitable materials for the framing members include, but are not limited to, metals including steel, aluminum, and chrome-molybdenum, plastics, polymers, carbon fiber and combinations thereof. The decking members provide support for a mattress. Suitable materials for the decking members include wood and plastics. In one embodiment, the decking members are constructed from oriented strand board.

Exemplary embodiments are directed to a bed frame having a pair of expandable structural frame members. Each expandable structural frame member has a compact position having a first frame length and an expanded position having a second frame length. The second frame length is longer than the first frame length. The bed frame includes a plurality of cross frame members. Each cross frame member includes a pair of opposing ends, and each opposing end is releasably attachable to one of the expandable structural frame members when in the expanded position. In one embodiment, each expandable structural frame member is a foldable structure.

In one embodiment, each expandable structural frame member includes a plurality of separate frame member portions. The separate frame member portions are connected by hinges and foldable about the hinges to move the expandable structural frame member between the compact position and the expanded position. In one embodiment, the plurality of separate frame member portions includes two frame member portions, and each frame member portion has the first frame length. The first length is about one half the second length.

In one embodiment, the plurality of cross frame members includes three cross frame members. Each expandable structural frame member includes a plurality of hangers shaped to support one of the opposing ends of one of the cross frame members, and the bed frame further has a plurality of clevis pins. Each clevis pin passes through a given hanger in the plurality of hangers and one of the cross frame members adjacent the opposing end supported by the given hanger. In one embodiment, each structural frame member and each cross frame member is constructed from metal tubing. In one embodiment, each structural frame member has a head section frame member portion with a head section fixed frame, a lumbar decking fixed frame mounted on the head section fixed frame and a head section decking frame pivotally connected to the head section fixed frame. Each structural frame member also includes a foot section frame member portion with a foot section fixed frame connected to the head section fixed frame by a hinge, a leg decking frame pivotally connected to the foot section fixed frame, and a foot decking frame pivotally connect to the leg decking frame.

Exemplary embodiments are directed to a bed assembly having a pair of expandable structural frame members. Each expandable structural frame member positionable in a compact position having a first frame length and an expanded position having a second frame length. The second frame length longer than the first frame length. The bed assembly includes a plurality of cross frame members. Each cross frame member includes a pair of opposing ends, and each opposing end is releasably attachable to one of the expandable structural frame members in the expanded position. The bed assembly includes a plurality of decking panels. Each decking panel is releasably attachable to the pair of expandable structural frame members when in the expanded position.

In one embodiment, each expandable structural frame member is a foldable structure. In one embodiment, each structural frame member includes a head section frame member portion and a foot section frame member portion connected to the head section frame member portion by a hinge. The head section frame member portion and the foot section frame member portion foldable about the hinge to move the expandable structural frame member between the compact position and the expanded position. In one embodiment, the head section frame member portion and the foot section frame member portion each have the first frame length. In one embodiment, the head section frame member portion includes a plurality of hangers shaped to support one of the opposing ends of one of the cross frame members, and the foot section frame member portion includes at least one of the plurality of hangers shaped to support one of the opposing ends of one of the cross frame members. In addition, the bed frame also includes a plurality of clevis pins, and each clevis pin passes through a given hanger and one of the cross frame members adjacent the opposing end supported by the given hanger.

In one embodiment, the head section frame member portion includes a head section fixed frame, a lumbar decking fixed frame mounted on the head section fixed frame, and a head section decking frame pivotally connected to the head section fixed frame. In addition, the foot section frame member portion includes a foot section fixed frame connected to the head section fixed frame by the hinge, a leg decking frame pivotally connected to the foot section fixed frame, and a foot decking frame pivotally connect to the leg decking frame. In one embodiment, the plurality of decking panels includes a lumbar decking panel releasably attachable to the lumbar decking fixed frame of each structural frame member, a head decking panel releasably attachable to the head section decking frame of each structural frame member, a leg decking panel releasably attachable to the leg decking frame of each structural frame member, and a foot decking panel releasably attachable to the foot decking frame of each structural frame member.

In one embodiment, the bed assembly also includes a plurality of knurled knob fasteners. Each knurled knob fastener passes through one of the plurality of decking panels and into one of the structural frame members to provide releasable attachment. In one embodiment, the bed assembly also includes a head end actuator disposed between one of the cross frame members and the head decking panel and a foot end actuator disposed between one of the cross frame members and the leg decking panel. In one embodiment, the pair of expandable structural frame members in the expanded position with the plurality of cross frame members and the plurality of decking panels releasably attached constitutes an assembled bed assembly. In addition, the pair of expandable structural frame members with the plurality of cross frame members and plurality of decking panels detached comprises a disassembled bed assembly. The structural frame members, cross frame members and plurality of decking members when in the disassembled bed assembly are arrangeable in packaging that is less than 140 dimensional pounds or 140 dimensional inches.

Exemplary embodiments are directed to a bed assembly containing a pair of expandable structural frame members. Each expandable structural frame member includes a head section frame member portion with a head section fixed frame, a lumbar decking fixed frame mounted on the head section fixed frame and a head section decking frame pivotally connected to the head section fixed frame. Each expandable structural frame member also includes a foot section frame member portion having a foot section fixed frame connected to the head section fixed frame by a hinge, a leg decking frame pivotally connected to the foot section fixed frame and a foot decking frame pivotally connect to the leg decking frame. The head section frame member portion and the foot section frame member portion are foldable about the hinge to move the expandable structural frame member between a compact position having a first frame length and an expanded position having a second frame length. The second frame length longer than the first frame length.

The bed assembly includes a plurality of cross frame members. Each cross frame member includes a pair of opposing ends, and each opposing end is releasably attachable to one of a plurality of hangers attached to each head section fixed frame and each foot section fixed frame and shaped to support one of the opposing ends of one of the cross frame members. The bed assembly includes a plurality of clevis pins. Each clevis pin passes through a given hanger and one of the cross frame members adjacent the opposing end supported by the given hanger. The bed assembly includes a lumbar decking panel releasably attachable to the lumbar decking fixed frame of each structural frame member, a head decking panel releasably attachable to the head section decking frame of each structural frame member, a leg decking panel releasably attachable to the leg decking frame of each structural frame member, a foot decking panel releasably attachable to the foot decking frame of each structural frame member, a head decking panel cross frame member attached to the head decking panel, a leg decking panel cross frame member attached to the leg decking panel, a head end actuator disposed between one of the cross frame members and the head decking panel cross frame member, and a foot end actuator disposed between one of the cross frame members and the leg decking panel cross frame member.

The pair of expandable structural frame members in the expanded position with the plurality of cross frame members, the lumbar decking panel, the head decking panel, the leg decking panel, and the foot decking panel releasably attached is an assembled bed assembly. In addition, the pair of expandable structural frame members in the compact position with the plurality of cross frame members, the lumbar decking panel, the head decking panel, the leg decking panel, and the foot decking panel detached represent a disassembled bed assembly. The expandable structural frame members, cross frame members, the head end actuator, the foot end actuator, the lumbar decking panel, the head decking panel, the leg decking panel, and the foot decking panel in the disassembled bed assembly are arrangeable in packaging comprising less than 129 dimensional pounds or 129 dimensional inches.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate one or more embodiments and, together with the description, explain these embodiments. In the drawings:

FIG. 1 is a top perspective view of an embodiment of a bed assembly;

FIG. 2 is a bottom perspective view of the bed assembly;

FIG. 3 is an elevation view from the side of the bed assembly;

FIG. 4 is a top perspective view of the bed assembly in with the adjustable decking panels raised;

FIG. 5 is an exploded bottom perspective view of the bed assembly;

FIG. 6 is an exploded top perspective view of the bed assembly;

FIG. 7 is a side view from an interior side of an embodiment of a first expandable structural frame member in the expanded position;

FIG. 8 a side view from an exterior side of the first expandable structural frame member in the expanded position;

FIG. 9 is a bottom view of an embodiment of the second expandable structure frame member in the compact position;

FIG. 10 is a side view from an interior side of an embodiment of the head end frame member portion;

FIG. 11 is a side view from an interior side of an embodiment of the foot end frame member portion;

FIG. 12 is a side view of an embodiment of a head section fixed frame;

FIG. 13 is a top view of the head section fixed frame;

FIG. 14 is a side view of an embodiment of the head section decking frame;

FIG. 15 is a top view of the head section decking frame;

FIG. 16 is a top view of an embodiment of a planar leg mounting flange;

FIG. 17 is a side view of the planar leg mounting flange;

FIG. 18 is a front view of an embodiment of a hanger for attaching cross frame members;

FIG. 19 is a side view of the hanger;

FIG. 20 is a front view of an embodiment of a pivot mount;

FIG. 21 is a side view of the pivot mount;

FIG. 22 is a side view of an embodiment of a first part of a butt hinge;

FIG. 23 is an end view of the first part of the butt hinge;

FIG. 24 is a side view of an embodiment of the foot section fixed frame;

FIG. 25 is a top view of an embodiment of the foot decking frame;

FIG. 26 is a side view of the foot decking frame;

FIG. 27 is a top view of an embodiment of the leg decking frame;

FIG. 28 is a side view of an embodiment of a support strut;

FIG. 29 is a top view of an embodiment of an L-shaped leg mounting flange;

FIG. 30 is a side view of the L-shaped leg mounting flange;

FIG. 31 is a side view of an embodiment of a section part of the butt hinge;

FIG. 32 is an end view of the second part of the butt hinge;

FIG. 33 is a top view of an embodiment of a first type of cross frame member;

FIG. 34 is a side view of the first type of cross frame member;

FIG. 35 is a top view of an embodiment of a second type of cross frame member;

FIG. 36 is a side view of the second type of cross frame member;

FIG. 37 is an end view of the second type of cross frame member;

FIG. 38 is a top view of an embodiment of a head decking panel;

FIG. 39 is an end view of the head decking panel;

FIG. 40 is a view through line 40-40 of FIG. 38;

FIG. 41 is a top view of an embodiment of an actuator mounting flange;

FIG. 42 is a front view of the actuator mounting flange;

FIG. 43 is a side view of the actuator mounting flange;

FIG. 44 is a top view of an embodiment of a lumbar decking panel;

FIG. 45 is a top view of an embodiment of a leg decking panel;

FIG. 46 is an end view of the leg decking panel;

FIG. 47 is a top view of an embodiment of a foot decking panel;

FIG. 48 is a top view of an embodiment of a clevis pin;

FIG. 49 is a side view of an embodiment of a knurled knob;

FIG. 50 is an end view of the knurled knob;

FIG. 51 is a top perspective view of an embodiment of a disassembled bed assembly arranged for shipping;

FIG. 52 is a top perspective view of the disassembled bed assembly arranged for shipping and covered with molded pulps;

FIG. 53 is a top perspective view of an embodiment of a box containing the disassembled bed assembly arranged for shipping;

FIG. 54 is an illustration of an embodiment of a bed assembly with the foot decking frame support pillars moved in from the foot end;

FIG. 55 is an illustration of and embodiment of adjusting the gaps between decking panels in the bed assembly;

FIG. 56 is a view of the bottom of the bed assembly illustrating the cross frame members attached to the decking panels;

FIG. 57 is an illustration of an embodiment of the bed assembly in a disassembled and packaged arrangement;

FIG. 58 is an illustration of an embodiment of the dimensions of the bed assembly in a packaged arrangement;

FIG. 59 is an illustration of an embodiment of a queen size embodiment of the bed assembly;

FIG. 60 is an illustration of another embodiment of a queen size embodiment of the bed assembly;

FIG. 61 is an illustration of another embodiment of a queen size embodiment of the bed assembly;

FIG. 62 is an illustration of an embodiment of a foot section fixed frame with the foot decking support pillar moved in from an end;

FIG. 63 is an illustration of an embodiment of decking panels with attached cross frame members;

FIG. 64 is an illustration of an embodiment of decking panels with attached cross frame members; and

FIG. 65 is an illustration of an embodiment of a hanger to attach a cross frame member to an expandable structural frame member.

DETAILED DESCRIPTION

The following description of the embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims.

Reference throughout the specification to “one embodiment” or “an embodiment” means that a given feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

Referring initially to FIGS. 1-3, an exemplary embodiment of a bed assembly 100 is illustrated. The bed assembly can be a fixed bed assembly or an adjustable bed assembly. As illustrated, the bed assembly is an adjustable bed assembly. The bed assembly includes a bed frame 102 and a plurality of separate and distinct decking panels 104. The bed frame includes all of the structural members, actuators and control electronics to provide for support of the decking panels and movement among the decking panels from a flat position as illustrated in FIGS. 1-3 and a desired raised or articulated position as illustrated, for example, in FIG. 4. The bed frame is constructed from and includes individual components. All individual components are detachable or releasable from each other. Releasable attachment of the individual components of the bed frame facilitates arranging these individual components for packaging in a bundle or box that meets or exceeds the limits for small parcel dimensional weight, e.g., less than or equal to 140 dimensional pounds or 139 dimensional pounds.

These individual components of the bed frame include a pair of expandable structural frame members 106. The expandable structural frame members are independent of each other and include a first or left, when view from the foot end of the bed assembly, expandable structural frame member 108 and a second or right expandable frame member 110. In one embodiment, the first and second expandable structural frame members are mirror images of each other. As each expandable structural frame member is a mirror image of the other structural frame member but otherwise contains the common components, portions, members and elements, common numbers are used herein to refer to common components, portions, members and elements. The expandable structural frame members are configured to extend along the length of the bed assembly, from the head end 114 to the foot end 116.

Each expandable structural frame member has an overall length that can be changed between a first frame length and a second frame length longer than the first frame length to accommodate the length of the bed assembly while providing for compact packaging that meets the desired dimensional requirements. Suitable expandable structures for each expandable structural frame member include, but are not limited to, telescoping, extensible and folding structures. Preferably, each expandable structural frame member is a foldable structure. In one embodiment, each expandable structural frame member includes a plurality of separate frame member portions, and these separate frame member portions are connected by hinges and foldable about the hinges to change or to move the expandable structural frame member between the first frame length, associated with a compact position of the structural frame member, and the second frame length, associated with the expanded position of the structural frame member. In one embodiment, the separate frame member portions are not connected by hinges, but are releasably attached together, and each structural frame member is disassembled into the plurality of separate frame member portions.

As illustrated, each expandable structural frame member includes two frame member portions, a head end frame member portion 118 and a foot end frame member portion 120 connected by a hinge 122. The head end frame member portion pivots or folds with respect to the foot end frame member portion about the hinge between the expanded position (FIGS. 7 and 8) having the second frame length 112 and the compact position (FIG. 9) having the first frame length 113. As illustrated, the first structural frame member 108 is illustrated in the expanded portion, and the second structural frame member 110 is illustrated in the compact position. In one embodiment, the second frame length is about 70.1 inches (1802 mm). In one embodiment, the first frame length is about one half the second frame length, i.e., 35.5 inches (901 mm). In one embodiment, the first frame length varies from one half the second frame length by up to 1 to 1.2 inches (30 mm). In one embodiment, each frame member portion has the first frame length.

The expandable structural frame members are the structural members to which other components are mounted to form the bed assembly. Referring to FIG. 10, the head section frame member portion 118 of each structural frame member includes a head section fixed frame 124, a lumbar decking fixed frame 126 fixedly mounted on the head section fixed frame, and a head section decking frame 128 pivotally connected to the head section fixed frame. Referring to FIGS. 12 and 13, the head section fixed frame includes a rectangular metal tubing portion 130 extending the length of the head section fixed frame. Suitable metals for the tubing, and all metal tubing and components described herein, include, but are not limited to, hot rolled steel. Tubing is used to provide the desired strength while minimizing weight. In one embodiment, the rectangular metal tubing portion of the head section fixed frame is 1 inch by 2 inch (25 mm×50 mm) rectangular tubing with a wall thickness of about 0.06 inches (1.5 mm).

The head section fixed frame also includes a head section decking frame support pillar 132 and a pair of lumbar decking fixed frame support pillars 134 attached to the top of the rectangular metal tubing portion. All pillars are constructed from metal tubing. In one embodiment, the metal tubing of the support pillars is 1 inch by 1 inch (25 mm×25 mm) square metal tubing with the wall thickness of 0.04 inches (1 mm). The lumbar decking fixed frame is mounted to the lumbar decking fixed frame support pillars. In one embodiment, the lumbar decking fixed frame is constructed from metal tubing. In one embodiment, the metal tubing of the lumbar decking fixed frame is 1 inch by 1 inch (25 mm×25 mm) square metal tubing with the wall thickness of 0.06 inches (1.5 mm). The top surface of the lumbar decking fixed frame includes at least one threaded mounting hole for releasable attachment of a decking panel.

The head section fixed frame also includes a pivot mount 136 attached to the top surface of the rectangular metal tubing portion. The pivot mount provides for pivoting connection of the head section decking frame to the head section fixed frame. In one embodiment the pivot mount is constructed from sheet metal having a thickness of about 0.12 inches (3 mm). Referring to FIGS. 20 and 21, the pivot mount includes a base portion 138 for mounting on the top surface of the rectangular metal tubing portion and a pair of side members 140 extending up from the base portion and defining a channel 142 for accepting the head section decking frame. A mounting hole 144 is passes through each side member to provide passage of a fastener that secures the head section decking frame in the pivot mount while providing for pivoting movement.

Referring now to FIGS. 14 and 15, the head section decking frame 128 includes a rectangular metal tubing portion 142. In one embodiment, the rectangular metal tubing is 1 inch by 1 inch (25 mm×25 mm) square metal tubing with a wall thickness of 0.06 inches (1.5 mm). The top surface of the rectangular metal tubing includes at two threaded mounting holes 146 for releasable attachment of a decking panel. On one end of the rectangular metal tubing portion is a pivoting structure 148 that fits within the channel of the pivot mount. The pivoting structure includes a passage 150 that aligns with the mounting hole through each side member to provide passage of the fastener.

Returning to FIG. 10, the head section frame member portion 118 includes at least one planar leg mounting flange 152 attached to and extending from the rectangular metal tubing portion of the head section fixed frame. The planar leg mounting flange is located closer to an end of the head section frame member portion opposite the lumbar decking fixed frame. Referring to FIGS. 16 and 17, the planar leg mounting flange is constructed from rectangular piece of metal having a thickness of about 0.12 inches (3 mm) and includes at least one threaded mounting hole 160 for releasable attachment of a leg.

Each expandable structural frame member includes a plurality of hangers 153 (FIG. 7). In one embodiment, the hangers are welded onto the structural frame members. In general, welding can be used to attach or to join the various metal components of the bed frame and bed assembly. Referring again to FIG. 10, in one embodiment, the head section frame member portion 118 includes a pair of hangers attached to the head section fixed frame 124. The pair of hangers includes a larger hanger 156 and a smaller hanger 154. In one embodiment, the hangers are constructed from sheet metal having a thickness of about 0.12 inches (3 mm). Referring to FIGS. 18 and 19, each hanger includes a support portion 162 that is aligned with the bottom surface of the rectangular metal tubing portion of the head section fixed frame to provide a horizontal supporting surface for structural elements and a pair of side members 164 extending up from the support portion and defining a channel 168 having a width 170 suitable for accepting the structural elements. For the smaller hanger, this width is about 1.6 inches (41 mm), and for the larger hangers the width is about 2.4 inches (61 mm). A mounting hole 166 passes through each side member to provide passage of a pin or fastener that secures the structural elements within the hanger. In one embodiment, each hanger has the general shape of a clevis.

Returning again to FIG. 10, the head section frame member portion 118 includes a first half 158 of the hinge 122 that is arranged as a butt hinge. Referring to FIGS. 22 and 23, the first half of the butt hinge is formed from 0.08 inch (2 mm) thick metal and includes a leaf 172 and a pair of knuckles 174 spaced from each other and extending from the leaf. The first half is attached to an end of the head section frame member portion 118 by the leaf that extends over the head section fixed frame and one of the pillars.

Referring now to FIG. 11, the foot section frame member portion 120 in each structural frame member includes a foot section fixed frame 176, which is connected to the head section fixed frame by the hinge 122, a leg decking frame 178 pivotally connected to the foot section fixed frame, and a foot decking frame 180 pivotally connect to the leg decking frame. Referring to FIG. 24, the foot section fixed frame includes a rectangular metal tubing portion 182 extending the length of the foot section fixed frame. In one embodiment, the rectangular metal tubing portion of the foot section fixed frame is 1 inch by 2 inch (25 mm×50 mm) rectangular tubing with a wall thickness of about 0.06 inches (1.5 mm).

The foot section fixed frame also includes an end pillar 184, a leg decking frame support pillar 186 and a foot decking frame support pillar 188 attached to the top of the rectangular metal tubing portion. All pillars are constructed from metal tubing. In one embodiment, the metal tubing of the leg decking frame support pillar and foot decking frame support pillar is 1 inch by 1 inch (25 mm×25 mm) square metal tubing with the wall thickness of 0.04 inches (1 mm). In one embodiment, the metal tubing of the end pillar is 2 inch by 2.4 inch (50 mm×60 mm) rectangular metal tubing with a wall thickness of about 0.06 inches (1.5 mm).

The foot section fixed frame also includes a pivot mount 190 attached to the top surface of the rectangular metal tubing portion. The pivot mount provides for pivoting connection of the leg decking frame to the foot section fixed frame. A suitable pivot mount is illustrated in FIGS. 20 and 21.

Referring to FIGS. 25 and 26, the foot decking frame 180 includes a rectangular metal tubing portion 194. In one embodiment, the rectangular metal tubing is 1 inch by 1 inch (25 mm×25 mm) square metal tubing with a wall thickness of 0.06 inches (1.5 mm). The top surface of the rectangular metal tubing includes at least two threaded mounting holes 196 for releasable attachment of a decking panel. The rectangular metal tubing also includes a mounting hole 198 extending through the rectangular metal tubing from the sides. This mounting hole includes a collar 200 extending out from one of the sides. On one end of the rectangular metal tubing portion is a pivoting structure 202 for engagement with a channel in the leg decking frame. The pivoting structure includes a passage 204 to provide passage of the fastener.

Referring to FIG. 27, the leg decking frame 178 includes a rectangular metal tubing portion 206. In one embodiment, the rectangular metal tubing is 1 inch by 1 inch (25 mm×25 mm) square metal tubing with a wall thickness of 0.06 inches (1.5 mm). The top surface of the rectangular metal tubing includes at least two threaded mounting holes 208 for releasable attachment of a decking panel. On one end of the rectangular metal tubing portion is a channel 210 for engagement with the pivoting structure of the foot decking frame. The channel structure includes a passage 214 (FIG. 11) to provide passage of the fastener. On the other end of the rectangular metal tubing portion is a pivoting structure 212 that fits within the channel of the pivot mount. The pivoting structure includes a passage that aligns with the mounting hole through each side member to provide passage of the fastener.

Returning to FIG. 11, the foot section frame member portion 120 in each structural frame member includes a support strut 216 extending between the foot section fixed frame and the leg decking frame to provide support for the foot decking frame on an end opposite the leg decking frame and to provide for proper movement of the foot decking frame when the sections of the adjustable bed are moved or articulated relative to each other. As illustrated in FIG. 28, the support strut 216 has a generally elongated rectangular shape and is formed from a sheet of metal having a thickness of about 0.12 inches (3 mm). A central rib 222 runs along the length of the support strut and has an overall thickness of about 0.24 inches (6 mm). This provides additional rigidity and strength to the support strut. A mounting hole 220 is provided on either end of the support strut. One mounting hole fits over the collar 200 surrounding the mounting hole in the foot decking frame, and other mounting hole aligns with a fastener hole 218 (FIG. 11) in the rectangular tubing of the foot section fixed frame.

Referring to FIG. 11, the foot section frame member portion 120 includes at least one planar leg mounting flange 152 attached to and extending from the rectangular metal tubing portion of the foot section fixed frame. The planar leg mounting flange is located closer to an end of the head section frame member portion opposite the end pillar. A suitable planar leg mounting flange is illustrated in FIGS. 16 and 17. In one embodiment, the foot section frame member portion 120 includes at least one L-shaped leg mounting flange 224 attached to and extending from the rectangular metal tubing portion of the foot section fixed frame. The L-shaped leg mounting flange is at an end of the head section frame member portion containing the end pillar and extends past the end of the foot section fixed frame. Referring to FIGS. 29 and 30, an embodiment of the L-shaped leg mounting flange is illustrated. The L-shaped leg mounting flange is constructed from a piece of metal having a thickness of about 0.12 inches (3 mm) and includes a horizontal portion 228 containing at least one threaded mounting hole 230 for releasable attachment of leg and a vertical portion 226 extending up from the horizontal portion. The vertical portion extends along the foot section fixed frame, and the horizontal portion extends past the end of the foot section fixed frame, overlapping the head section fixed frame when the expandable structural frame member is in the expanded position. Overlap provides lateral support to the hinged connection and positions the threaded mounting hole under the hinge 122. This also places any attached leg under the hinge, providing additional support under the hinged connection.

Returning to FIG. 11, the foot section frame member portion 120 includes at least one hanger 153 attached to the foot section 176. Each hanger is constructed from sheet metal having a thickness of about 0.12 inches (3 mm). As illustrated, the at least one hanger is a larger hanger 156. An embodiment of a larger hanger is illustrated in FIGS. 18 and 19. As illustrated, the hanger overlaps with planar leg mounting flange.

Returning again to FIG. 11, the foot section frame member portion 120 includes a second half 232 of the hinge 122 arranged as a butt hinge. Referring to FIGS. 31 and 32, the second half of the butt hinge is formed from 0.08 inch (2 mm) thick metal and includes a leaf 236 and a single knuckle 234 extending from the leaf. The single knuckle fits between the pair of knuckles in the first half of the hinge, creating a passage for a hinge pin and forming the butt hinge. The second half is attached to an end of the foot section frame member portion 120 by the leaf that extends over a portion of the foot section fixed frame and the end pillar.

Referring to FIGS. 5 and 6, the bed frame includes a plurality of cross frame members 238. In one embodiment, the bed frame includes three cross frame members, although the bed frame can include at least two cross frame members or more than three cross frame members. Each cross frame member is releasably attachable to one of the expandable structural frame members when those members are in the expanded position. This provides a structural connection between the expandable structural frame members. In one embodiment, each cross frame member has a fixed length corresponding to the width of the size of the bed, e.g., twin, full, queen or king. In one embodiment, each cross frame member has a flexible or adjustable length. Therefore, each cross frame member can accommodate multiple sizes of beds. Suitable cross frame members with adjustable lengths include, but are not limited to, tube in tube cross frame members providing slideable or extensible length adjustment, hinged cross frame members each containing two or more portions that are hinged together, and multiple independent pieces, e.g., two piece sections, that can be connected together. In one embodiment, the cross frame member is constructed from multiple sections each having a common size or one of a plurality of sizes, and these sections are connected together to provide the desired bed width when assembled.

The cross frame members include a first type of cross frame member 240. As illustrated, the first type of cross frame member is located adjacent a head end of the bed frame. Referring to FIGS. 33 and 34, the first type of cross frame member is a length of rectangular tubing. In one embodiment, the metal tubing is a 1.6 inch by 0.8 inch (40 mm×20 mm) rectangular tubing with a wall thickness of 0.08 inches (2 mm). Therefore, the first type of cross frame member has a width 244 along the longer face of about 1.6 inches (40 mm). In one embodiment, the length of the first type of cross frame member 242 is about 36.6 inches (930 mm). The first type of cross frame member includes a pair of opposing ends 264 and a mounting hole 246 located adjacent each end. Each opposing end is placed into one of the hangars in one of the expandable structural members. The width of the longer face corresponds to the width of the channel in the smaller hangers. Therefore, the opposing ends of the first type of cross frame member are placed in one of the smaller hangers 154 such that the mounting holes in the hangers and cross frame member align to accommodate insertion of a fastener through the mounting holes to secure the cross frame member to the expandable structural frame members. Suitable fasteners include threaded fasteners and pins. Preferably, the fastener is a clevis pin. In general, any type of pin or fastener can be used at the various locations where components are connected together such that the pin or fastener provides ease of assembly and secure attachment of the desired members while also providing for removal and disassembly, for example, wing nuts and ball pins among other pins and fasteners.

Returning to FIGS. 5 and 6, in one embodiment, the cross frame members include a second type of cross frame member 248. In one embodiment, the bed frame includes two second type cross frame members. As illustrated, one second type of cross frame member is located adjacent a foot end of the bed frame, and the other second type of cross frame member is located between that second type of cross frame member and the first type of cross frame member. As illustrated, the other second type of cross frame member is located closer the first type of cross frame member and is attached to the head end frame member portion 118. Referring to FIGS. 35-37, the second type of cross frame member is two overlapping lengths of rectangular tubing aligned with the shorter face of a first length of rectangular tubing 260 in contact with a longer face of a second length of rectangular tubing 258. In one embodiment, each metal tubing is 1.6 inch by 0.8 inch (40 mm×20 mm) rectangular tubing with a wall thickness of 0.08 inches (2 mm). Therefore, the longer face of the first length and the short face of the second length define an overall thickness 252 of the second type of cross frame member of about 2.4 inches (60 mm). In one embodiment, the length of the second type of cross frame member 250 is about 36.6 inches (930 mm).

Attached to the longer face of the second length of rectangular tubing opposite the first length of rectangular tubing is a holder 254 for supporting an actuator such as a linear actuator. The holder includes two arms 255 spaced from each other to accommodate placement of an end of an actuator, and each arm includes a passage 256 for placement of a fastener to secure the actuator in the holder. In one embodiment, the fastener is a removable fastener such as a clevis pin. The arrangement of the first and second length of rectangular tubing and the resulting overall thickness provide sufficient structural support for loads introduced into the cross frame member by the actuator. The second type of cross frame member includes a pair of opposing ends 266 and a mounting hole 262 located adjacent each end. Each opposing end is placed into one of the hangars on one of the expandable structural members. The overall thickness 252 corresponds to the width of the channel in the smaller hangers. Therefore, the opposing ends of the second type of cross frame member are placed in one of the larger hangers 156 such that the mounting holes in the hangers and cross frame member align to accommodate insertion of a fastener though the mounting holes to secure the cross frame member to the expandable structural frame members. Suitable fasteners include threaded fasteners and pins. Preferably, the fastener is a clevis pin.

While illustrated with solid lengths of rectangular metal tubing, each cross frame member can also be formed from multiple detachable segments. In addition, each cross frame member can be a foldable or extensible structure. In addition to metal tubing having a rectangular cross section, other types of cross sectional shapes can also be used including, for example, circular, oblong and triangular.

In one embodiment, the bed frame further comprises a plurality of clevis pins. These clevis pins are used through the bed frame to provide releasable attachment of the various frame members and components for assembly of the bed frame. In one embodiment, each clevis pin passes through a given hanger in the plurality of hangers and one of the cross frame members adjacent the opposing end supported by the given hanger. In addition, the plurality of clevis pins include clevis pins that secure operational elements such as actuators to the bed frame and decking panels. Referring to FIG. 48, and embodiment of a clevis pin 270 is illustrated. The clevis pin has a shaft 272 with a length and diameter sufficient to pass through the mounting holes and frame structures. A spring loaded catch 276 is contained in the shaft to secure the clevis pin in the mounting holes and frame structures. A ring 274 is provided at one end of the clevis pin to facilitate insertion and removal of the clevis pin.

As illustrated, for example, in FIGS. 5 and 6, the bed assembly includes a plurality of decking panels 104. Each decking panel is releasably attachable to the pair of expandable structural frame members when the expandable structural frame members are in the expanded position. Therefore, each decking panel provides a structural connection between the pair of expandable structural frame members. The materials of the decking panel are selected to be sufficient to provide this structural connection and to support bedding, e.g., mattresses and users of the bed assembly. Suitable materials include plastics and wood. In one embodiment each decking panel is constructed from oriented strand board (OSB). In one embodiment, each decking panel has a thickness of about 0.6 inches (15 mm). The overall dimensions, length and width, of each decking panel are selected based on the size of the bed assembly, e.g., twin, full, queen, king or California king.

In one embodiment, the plurality of decking panels includes a head decking panel 278 releasably attachable to the head section decking frame of each structural frame member, a lumbar decking panel 280 releasably attachable to the lumbar decking fixed frame of each structural frame member, a leg decking panel 282 releasably attachable to the leg decking frame of each structural frame member, and a foot decking panel 284 releasably attachable to the foot decking frame of each structural frame member. In one embodiment, the lumbar decking panel is a fixed panel, and the head, leg and foot decking panels are adjustable panels.

Referring to FIGS. 38-40, an embodiment of head decking panel is illustrated. The head decking panel includes a plurality of fastener holes 286 for accepting fasteners used to attach the head decking panel to each head decking frame. As illustrated, the head decking panel includes four fastener holes, two for each head decking frame that align with the threaded holes in each head decking frame. Surrounding each fastener hole is a counter bore 288 has a sufficient size and depth to accommodate the proximal end of the fastener so that the fastener extends into the top surface of the head decking panel. In one embodiment, the counter bore has a diameter of about 2 inches (50 mm) and a depth of about 0.16 inches (4 mm). The head decking panel also includes a plurality of holes 290 to accommodate attachment of an actuator mounting flange 292. In one embodiment, each hole contains a threaded insert 291. Referring to FIGS. 41-43, the actuator mounting flange 292 is formed from 0.12 inch (3 mm) sheet metal and includes a flange portion 294 containing a plurality of holes 296 that align with the head decking panel holes 290 and a mounting bracket 297 attached to the flange portion and containing two arms 298 each having a fastener hole 300.

Referring to FIG. 44, an embodiment of lumbar decking panel 280 is illustrated. The lumbar decking panel includes a plurality of the fastener holes 286 for accepting fasteners used to attach the lumbar decking panel to each lumbar decking frame. As illustrated, the lumbar decking panel includes two fastener holes, one for each lumbar decking frame that align with the threaded holes in each lumbar decking frame. Surrounding each fastener hole is the counter bore 286.

Referring to FIGS. 45 and 46, an embodiment of leg decking panel 282 is illustrated. The leg decking panel includes a plurality of the fastener holes 286 for accepting fasteners used to attach the leg decking panel to each leg decking frame. As illustrated, the leg decking panel includes four fastener holes, two for each leg decking frame that align with the threaded holes in each leg decking frame. Surrounding each fastener hole is the counter bore 288. The leg decking panel also includes a plurality of holes 302 to accommodate attachment of the actuator mounting flange 292 as illustrated in FIGS. 41-43. In one embodiment, each hole contains a threaded insert.

Referring to FIG. 47, an embodiment of a foot decking panel 284 is illustrated. The foot decking panel includes a plurality of the fastener holes 286 for accepting fasteners used to attach the foot decking panel to each foot decking frame. As illustrated, the foot decking panel includes two fastener holes, one for each foot decking frame that align with the threaded holes in each foot decking frame. Surrounding each fastener hole is the counter bore 288.

As illustrated, for example, in FIGS. 2, 5 and 6, the bed assembly includes a plurality of fasteners 304 for insertion into each fastener hole in each decking panel to secure the decking panels to the expandable structural frame members. In one embodiment, the bed assembly includes 14 fasteners. Suitable fasteners include threaded fasteners. Using common fastener holes and counter bores in the decking panels facilitates use of a common fastener. Referring to FIGS. 49 and 50, in one embodiment, each fastener 304 is a threaded knurl knob fastener having a threaded portion 308 and a knob portion 306. The threaded portion is inserted into the fastener holes and engages the threaded holes in the frame members. The knob portion extends into the counter bore around each fastener hole. In one embodiment, the plurality of fasteners are used to grip a mattress placed on top of the decking panels, securing the mattress to the decking panels and eliminating the need for a mattress retaining bar.

Returning to FIGS. 5 and 6, in one embodiment, the bed frame includes a plurality of actuators to provide for adjustable movement of the decking panels. Suitable actuators are known and available in the art and include linear actuators. In one embodiment, the bed frame includes two actuators, a head end actuator 311 and a foot end actuator 310. The head end actuator is disposed between one of the cross frame members and the head decking panel. In one embodiment, the head end actuator is attached to the holder 254 on the second type of cross frame member and the actuator mounting flange 292 attached to the bottom surface of the head decking panel 278. The foot end actuator is disposed between one of the cross frame members and the leg decking panel. In one embodiment, the foot end actuator is attached to the holder 254 on the second type of cross frame member and the actuator mounting flange 292 attached to the bottom surface of the leg decking panel 282.

Therefore, the head end actuator and the foot end actuator are engaged directly on the decking panels and additional cross frame members are not required for movement of the decking panels. Extension of the head end actuator lifts the head decking panel, and extension of the foot end actuator lifts the leg decking panel and the foot decking panel as illustrated in FIG. 4. In addition, the attachment, location and movement of the actuators provide for a bed frame and bed assembly with zero clearance. The actuators, in operation, do not extend below the expandable structural frame members. Therefore, the bed frame and bed assembly do not require legs and can be placed directly on an existing surface or foundation.

In one embodiment, the bed frame and bed assembly include a plurality of removable legs 312. In one embodiment, the bed frame and bed assembly include six removable legs, one for each planar leg mounting flange and each L-shaped leg mounting flange in the bed frame. In one embodiment, each removable leg includes a threaded stem 314 for engagement in the threaded mounting hole of each leg mounting flange. While illustrated as a threaded attachment, other types of releasable attachment mechanisms for the legs can be used.

To create an assembled bed assembly, as illustrated, for example, in FIG. 1, the pair of expandable structural frame members are placed in the expanded position and the ends of the plurality of cross frame members are placed in the appropriate hangars. Clevis pins are then inserted through each hangar and associated end of the cross frame member. The appropriate decking panels are placed over the corresponding decking frame members, and the knurl knob fasteners are inserted into the decking panels and screwed into the decking frame members. The actuators are attached between the cross frame members and the appropriate decking panels using fasteners such as clevis pins. Control electronics are attached to the actuators. In one embodiment, legs are attached to the expandable structure frame members.

The pair of expandable structural frame members with the plurality of cross frame members and the plurality of decking panels detached when detached from each other represent a disassembled bed assembly. The dissembled bed assembly also includes the actuators, legs, clevis pins, knurled knobs and control electronics. Referring to FIGS. 51-53, the extensible structural frame members 106 in the compact position, cross frame members 248, plurality of decking members 104, legs 306, and actuators 306 among the other components of the disassembled bed assembly arranged in packaging that includes a plurality of molded pulps 318 for containing all of the components.

In one embodiment, the bed assembly includes a control module 316 that is configured for releasable attachment to any of the frame members and is included in the packaging. The control module is completely contained between the decking the bottom of the bed frame. The control module is in communication with the actuators, external power sources and wired or wireless controllers of the bed assembly. The control module includes the control electronics, transformers, batteries, wired and wireless communication modules and other components utilized for operation of the adjustable bed assembly. In one embodiment, the bed assembly also includes the wiring or cables for attachment of the control module to the actuators, power sources, wired remotes. In one embodiment, the control module includes communication ports, e.g., USB ports, for communication between the control module and external control and computing resources. Suitable control modules and components for adjustable beds are known and available in the art.

Having placed arranged the components as desired, these components are placed in a container or box 320 having a dimensional weight of less than 140 dimensional pounds, preferably less than or equal to 139 dimensional pounds. In one embodiment, the box has a length 326 of 61 inches (1549.4 mm), a width 324 of 30 inches (762 mm) and a height 322 of 8 inches (203.2 mm).

Referring now to FIG. 54, in one embodiment, the bed assembly 400 has an overall length 402 of 2000 mm (78.74 inches) and a width 404 of 1490 mm (58.67 inches), for example, corresponding to a queen size bed frame, although other size bedframes can be used. The expandable structural frame members are spaced in from the associated edges or sides of the decking panels by a distance 406 of 250 mm (9.84 inches). In addition, the expandable structural frame members are set back from the head end 408 of the head decking panel by a given distance 410 of 154 mm (6.06 inches). For the foot decking panel, a foot decking frame support pillar 412 of the foot section frame member portion is set back from the foot 416 end of the foot decking panel by a distance 414 of 116 mm (4.56 inches).

However, the foot decking frame moves relative to and up from the foot decking support pillar. This creates a point between a fixed frame and a moveable frame in which sheets placed over the bed assembly around the foot decking panel could be caught. Therefore, in one embodiment of the bed assembly 420, all of the dimensions remain the same, but the foot decking frame support pillars 412 of the foot section frame member portion are set back from the foot end of the foot decking by a greater distance 422 of 184 mm (7.24 inches). Referring to FIG. 62, the support pillar 412 is illustrated set in from an end 421 of the foot section fixed frame 413. The is compared to the location of the support pillar 188 of the foot section fixed frame in FIG. 24. Setting the support pillar back from the end provides additional distance at the foot end of the bed to accommodate sheets and bedding.

Referring to FIG. 55, in one embodiment, the dimensions of various decking panels are adjusted to decrease the dimensional weight or dimensional pounds of the bed assembly arranged for shipping. In one embodiment, the dimensional weight=length+(2×depth)+(2×width) and is expressed in dimensions of length, e.g., inches. In one embodiment, the dimensional weight of the bed assembly arranged for shipping is less than or equal to 129 inches. In one embodiment, the head decking panel 430 has a length 431 of 672 mm (26.46 inches), and the lumbar decking panel 432 has a length 433 of 392 mm (15.43 inches). In addition, the leg decking panel 434 has a length 435 of 300 mm (11.81 inches), and the foot decking panel 436 has a length 437 of 485 mm (19.09 inches). Maintaining an overall bed assembly length of 2000 mm yields gaps between adjacent decking panels 438 of 50 mm (1.97 inches). The disassembled bed assembly arranged for shipping 440 has a dimensional weight of about 131 inches. This dimensional weight is driven by the largest length of the decking panels, i.e., the head decking panel length of 672 mm and the combined length of the lumbar and leg decking panels 442, which is 692 mm (27.24 inches).

Maintaining the same overall bed assembly length of 2000 mm and increasing the gaps between adjacent decking panels 444 to 65 mm, provides for a decrease in the lengths of each individual decking panel. In one embodiment, the head decking panel 446 has a length of 654 mm (25.75 inches), and the lumbar decking panel 448 has a length of 300 mm (11.81 inches). In addition, the leg decking panel 450 has a length of 274 mm (10.79 inches), and the foot decking panel 452 has a length of 497 mm (19.57 inches). With the adjusted lengths of the decking panels, the disassembled bed assembly arranged for shipping 454 has a reduced dimensional weight of about 129 inches. This dimensional weight is driven by the largest length of the decking panels, i.e., the head decking panel length with the reduced length of 654 mm and the combined length of the lumbar and leg decking panels 456, which is also 654 mm.

Referring to FIGS. 56 and 63-65, in one embodiment the bed assembly 460 includes the first type of cross frame member 462 and the two second types of cross frame member 464 spanning between the expandable structural frame members as discussed herein. In addition, the bed assembly includes a plurality of decking panel cross frame members that also span between the expandable structural frame members. Unlike the other cross frame members, the decking panel cross frame members are fixedly secured to the decking panels, for example, using a plurality of fasteners. The decking panel cross frame members provide additional structural support to the decking panels and also provide support for the actuators 472. Therefore, the actuator mounting flanges are not used.

The decking panel cross frame members include a head decking panel cross frame member 466 attached to the back or underside of the head decking panel, for example, using fasteners passing through the head decking panel. The head decking panel cross frame member 466 is attached to the expandable structural members by hangers 468 attached to the expandable structural members. Suitable hangers are disclosed herein. The head decking panel cross frame member fits into the hangers when the head decking panel is placed on the expandable structural members. The head decking panel cross frame member can be secured in the hangers using clevis pins or other types of fasteners. In one embodiment, the fasteners used to secure the head decking panel to the expandable structural members are used to secure the head decking panel cross frame member in the hanger. These fasteners pass through fastener holes 463 in the head decking panel, the head decking panel cross frame member and the hanger. As is illustrated in FIG. 65, each hanger 468 includes holes 481 for the clevis pin and a hole 483, for example a threaded hole, to engage the fasteners inserted through the fastener holes in the head decking panel. As the hangers are located inside the expandable structural members, the fastener holes 463 and counter bores 465 passing through the head decking panel and associated with these fasteners are shifted inward relative to the other fastener holes 467 and counter bores 469 that are located over the expandable structural members. The head decking panel cross frame member also includes a bracket 470 to engage the actuator 472 for providing lift to the head decking panel. Suitable actuators include, but are not limited to, Richmat actuators, which are commercially available from Qingdao Richmat Intelligence Technology Inc.

The decking panel cross frame members include a lumbar decking panel cross frame member 474 attached to the back or underside of the lumbar decking panel, for example, using fasteners passing through the lumbar decking panel. The lumbar decking panel cross frame member 474 is attached to the expandable structural members by hangers 476 attached to the expandable structural members. Suitable hangers are disclosed herein. The lumbar decking panel cross frame member fits into the hangers when the lumbar decking panel is placed on the expandable structural members. The lumbar decking panel cross frame member can be secured in the hangers using clevis pins or other types of fasteners. These fasteners, however, preferably are not used to secure the lumbar decking panel to the lumbar decking panel cross frame member. Additional structural rigidity is not required as the lumbar decking panel cross frame member does not directly operatively engaged with an actuator. In one embodiment, the actuator control box 478 is secured to the bottom surface of the lumbar decking panel.

The decking panel cross frame members include a leg decking panel cross frame member 480 attached to the back or underside of the leg decking panel. The leg decking panel cross frame member 480 is attached to the expandable structural members by hangers 484 attached to the expandable structural members. Suitable hangers are disclosed herein. The leg decking panel cross frame member fits into the hangers when the leg decking panel is placed on the expandable structural members. The leg decking panel cross frame member can be secured in the hangers using clevis pins or other types of fasteners. In one embodiment, the fasteners used to secure the leg decking panel to the expandable structural members are used to secure the leg decking panel cross frame member in the hanger. These fasteners pass through fastener holes 471 in the leg decking panel, the leg decking panel cross frame member and the hanger. As the hangers are located inside the expandable structural members, the fastener holes 471 and counter bores 473 passing through the leg decking panel and associated with these fasteners are shifted inward relative to the other fastener holes 475 and counter bores 477 that are located over the expandable structural members. The leg decking panel cross frame member also includes a bracket 487 to engage the actuator 472 for providing lift to the leg decking panel and the foot decking panel. Suitable actuators include, but are not limited to, Richmat actuators.

In one embodiment, the decking panel cross frame members include a foot decking panel cross frame member 464 attached to the back or underside of the foot decking panel, for example, using fasteners passing through the foot decking panel. The foot decking panel cross frame member 464 is attached to the expandable structural members by hangers 479 attached to the expandable structural members. Suitable hangers are disclosed herein. The foot decking panel cross frame member fits into the hangers when the lumbar decking panel is placed on the expandable structural members. The lumbar decking panel cross frame member can be secured in the hangers using clevis pins or other types of fasteners. These fasteners, however, preferably are not used to secure the lumbar decking panel to the lumbar decking panel cross frame member. Additional structural rigidity is not required as the lumbar decking panel cross frame member is not directly operatively engaged with an actuator.

Referring to FIG. 57, an embodiment of the bed assembly arranged for shipping 490 is illustrated. The bed assembly when arranged for shipping has a thickness or height 492 of 220 mm (8.66 inches), a width of 665.5 mm (26.20 inches) and a length of 1504 mm (59.21 inches), which accommodates a bed assembly width of 1490 mm (58.66 inches). Referring to FIG. 58, this yields an estimated total weight of less than 150 lbs, e.g., 146.2 lbs, and a dimensional weight of less than 165 inches, e.g., 129 inches.

Referring to FIG. 59, the dimensions along the length of a conventional queen size adjustable bed frame 500 for the head 502, lumbar 504, leg 506 and foot 508 sections are illustrated. These dimensions cover both the decking panels and a portion of the space between adjacent decking portion. The head section has a length of about 690 mm (27.17 inches), and the lumbar section has a length of about 456 mm (17.95 inches). The leg section has a length of about 350 mm (13.78 inches), and the foot section has a length of about 510 mm (20.08 inches). Referring to FIG. 60, the dimensions along the length of a queen size adjustable bed assembly 510 as disclosed herein for the head 512, lumbar 514, leg 516 and foot 518 sections are illustrated before the decking panels and gaps between adjacent decking panels are adjusted. These dimensions cover both the decking panels and a portion of the space between adjacent decking portion. The head section has a length of about 668 mm (26.3 inches), and the lumbar section has a length of about 354 mm (14.33 inches). The leg section has a length of about 343 mm (13.5 inches), and the foot section has a length of about 625 mm (24.61 inches). Based on these dimensions, the head section 512 of the bed assembly has a length that is 22 mm (0.87 inches) shorter than the head section 502 of the conventional queen adjustable bed frame. In addition, the lumbar section 514 of the bed assembly has a length that is 92 mm (3.62 inches) shorter than the lumbar section 504 of the conventional queen adjustable bed frame. These dimensional differences affect the comfort of the bed assembly.

Referring to FIG. 61, the dimensions along the length of a queen size adjustable bed assembly 520 for the head 522, lumbar 524, leg 526 and foot 528 sections when the lengths of the decking panels are adjusted are illustrated. These dimensions cover both the decking panels and a portion of the space between adjacent decking portion and eliminate the differences between the head section and lumbar section lengths when compared to the sections of a conventional queen adjustable bed frame. The head section has a length of about 690 mm (27.17 inches), and the lumbar section has a length of about 456 mm (17.95 inches). The leg section has a length of about 343 mm (13.5 inches), and the foot section has a length of about 511 mm (20.12 inches). Therefore, even the leg section and foot section lengths differ only slightly from the lengths associated with a conventional queen adjustable bed frame.

Although the features and elements of the present exemplary embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein. Any methods or flowcharts provided in the present application may be implemented in a computer program, software, or firmware tangibly embodied in a computer-readable storage medium for execution by a dedicated computer or a processor.

This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.

Claims

1. A bed frame comprising:

a pair of expandable structural frame members, each expandable structural frame member comprising a compact position having a first frame length and an expanded position having a second frame length, the second frame length longer than the first frame length; and

a plurality of cross frame members, each cross frame member comprising a pair of opposing ends and each opposing end releasably attachable to one of the expandable structural frame members in the expanded position.

2. The bed frame of claim 1, wherein each expandable structural frame member comprises a foldable structure.

3. The bed frame of claim 2, wherein each expandable structural frame member comprises a plurality of separate frame member portions, the separate frame member portions connected by hinges and foldable about the hinges to move the expandable structural frame member between the compact position and the expanded position.

4. The bed frame of claim 3, wherein the plurality of separate frame member portions comprises two frame member portions, each frame member portion comprising the first frame length.

5. The bed frame of claim 1, wherein the first length is about one half the second length.

6. The bed frame of claim 1, wherein the plurality of cross frame members comprises three cross frame members.

7. The bed frame of claim 1, wherein:

each expandable structural frame member comprises a plurality of hangers shaped to support one of the opposing ends of one of the cross frame members; and

the bed frame further comprises a plurality of clevis pins, each clevis pin passing through a given hanger in the plurality of hangers and one of the cross frame members adjacent the opposing end supported by the given hanger.

8. The bed frame of claim 1, wherein each structural frame member and each cross frame member comprises metal tubing.

9. The bed frame of claim 1, wherein each structural frame member comprises:

a head section frame member portion comprising: a head section fixed frame; a lumbar decking fixed frame mounted on the head section fixed frame; and a head section decking frame pivotally connected to the head section fixed frame; and

a foot section frame member portion comprising: a foot section fixed frame connected to the head section fixed frame by a hinge; a leg decking frame pivotally connected to the foot section fixed frame; and a foot decking frame pivotally connect to the leg decking frame.

10. A bed assembly comprising:

a pair of expandable structural frame members, each expandable structural frame member comprising a compact position having a first frame length and an expanded position having a second frame length, the second frame length longer than the first frame length;

a plurality of cross frame members, each cross frame member comprising a pair of opposing ends and each opposing end releasably attachable to one of the expandable structural frame members in the expanded position; and

a plurality of decking panels, each decking panel releasably attachable to the pair of expandable structural frame members in the expanded position.

11. The bed assembly of claim 10, wherein each expandable structural frame member comprises a foldable structure.

12. The bed assembly of claim 10, wherein each structural frame member comprises:

a head section frame member portion; and

a foot section frame member portion connected to the head section frame member portion by a hinge, the head section frame member portion and the foot section frame member portion foldable about the hinge to move the expandable structural frame member between the compact position and the expanded position.

13. The bed assembly of claim 12, wherein the head section frame member portion and the foot section frame member portion each comprise the first frame length.

14. The bed assembly of claim 12, wherein:

the head section frame member portion comprises a plurality of hangers shaped to support one of the opposing ends of one of the cross frame members;

the foot section frame member portion comprises at least one of the plurality of hangers shaped to support one of the opposing ends of one of the cross frame members; and

the bed frame further comprises a plurality of clevis pins, each clevis pin passing through a given hanger and one of the cross frame members adjacent the opposing end supported by the given hanger.

15. The bed assembly of claim 12, wherein:

the head section frame member portion comprises: a head section fixed frame; a lumbar decking fixed frame mounted on the head section fixed frame; and a head section decking frame pivotally connected to the head section fixed frame; and

the foot section frame member portion comprises: a foot section fixed frame connected to the head section fixed frame by the hinge; a leg decking frame pivotally connected to the foot section fixed frame; and a foot decking frame pivotally connect to the leg decking frame.

16. The bed assembly of claim 15, wherein the plurality of decking panels comprises:

a lumbar decking panel releasably attachable to the lumbar decking fixed frame of each structural frame member;

a head decking panel releasably attachable to the head section decking frame of each structural frame member;

a leg decking panel releasably attachable to the leg decking frame of each structural frame member; and

a foot decking panel releasably attachable to the foot decking frame of each structural frame member.

17. The bed assembly of claim 16, further comprising a plurality of knurled knob fasteners, each knurled knob fastener passing through one of the plurality of decking panels and into one of the structural frame members to provide releasable attachment.

18. The bed assembly of claim 16, further comprising:

a head end actuator disposed between one of the cross frame members and the head decking panel; and

a foot end actuator disposed between one of the cross frame members and the leg decking panel.

19. The bed assembly of claim 10, wherein the pair of expandable structural frame members in the expanded position with the plurality of cross frame members and the plurality of decking panels releasably attached comprises an assembled bed assembly and the pair of expandable structural frame members with the plurality of cross frame members and plurality of decking panels detached comprises a disassembled bed assembly, the structural frame members, cross frame members and plurality of decking members in the disassembled bed assembly arrangeable in packaging comprising less than 140 dimensional pounds.

20. A bed assembly comprising:

a pair of expandable structural frame members, each expandable structural frame member comprising: a head section frame member portion comprising: a head section fixed frame; a lumbar decking fixed frame mounted on the head section fixed frame; and a head section decking frame pivotally connected to the head section fixed frame; and a foot section frame member portion comprising: a foot section fixed frame connected to the head section fixed frame by a hinge; a leg decking frame pivotally connected to the foot section fixed frame; and a foot decking frame pivotally connect to the leg decking frame, the head section frame member portion and the foot section frame member portion foldable about the hinge to move the expandable structural frame member between a compact position having a first frame length and an expanded position having a second frame length, the second frame length longer than the first frame length;

a plurality of cross frame members, each cross frame member comprising a pair of opposing ends and each opposing end releasably attachable to one of a plurality of hangers attached to each head section fixed frame and each foot section fixed frame and shaped to support one of the opposing ends of one of the cross frame members;

a plurality of clevis pins, each clevis pin passing through a given hanger and one of the cross frame members adjacent the opposing end supported by the given hanger;

a lumbar decking panel releasably attachable to the lumbar decking fixed frame of each structural frame member;

a head decking panel releasably attachable to the head section decking frame of each structural frame member;

a leg decking panel releasably attachable to the leg decking frame of each structural frame member;

a foot decking panel releasably attachable to the foot decking frame of each structural frame member;

a head decking panel cross frame member attached to the head decking panel;

a leg decking panel cross frame member attached to the leg decking panel;

a head end actuator disposed between one of the cross frame members and the head decking panel cross frame member; and

a foot end actuator disposed between one of the cross frame members and the leg decking panel cross frame member;

wherein the pair of expandable structural frame members in the expanded position with the plurality of cross frame members, the lumbar decking panel, the head decking panel, the leg decking panel, and the foot decking panel releasably attached comprises an assembled bed assembly and the pair of expandable structural frame members in the compact position with the plurality of cross frame members, the lumbar decking panel, the head decking panel, the leg decking panel, and the foot decking panel detached comprises a disassembled bed assembly, the expandable structural frame members, cross frame members, the head end actuator, the foot end actuator, the lumbar decking panel, the head decking panel, the leg decking panel, and the foot decking panel in the disassembled bed assembly arrangeable in packaging comprising less than 129 dimensional pounds.