Corner Element with Tang Fixation

Abstract

A connector element having a body portion having a substantially planar first abutment surface, a substantially planar second abutment surface, and a corner surface extending between a terminating edge of the first abutment surface and a terminating edge of the second abutment surface, wherein the first abutment surface and the second abutment surface are formed at substantially 90° relative to one another; one or more protrusions extending perpendicular to the first abutment surface; one or more protrusions extending perpendicular to the second abutment surface; at least one first deflectable flexible finger extending from the first abutment surface; and at least one second deflectable flexible finger extending from the second abutment surface, wherein at least a portion of each deflectable flexible finger extends substantially perpendicular to a respective abutment surface, and wherein each deflectable flexible finger comprises a tang that extends to form a camming surface and a shoulder.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation-in-part of co-pending U.S. patent application Ser. No. 29/804,739, filed Aug. 23, 2021, the disclosure of which is incorporated herein in its entirety by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX

Not Applicable.

NOTICE OF COPYRIGHTED MATERIAL

The disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. All trademarks and service marks identified herein are owned by the applicant.

BACKGROUND OF THE PRESENT DISCLOSURE

1. Field of the Invention

The present disclosure relates generally to foundation assemblies. In particular, the present disclosure relates to improved corner elements, foundation assemblies, and a method for constructing foundation assemblies.

2. Description of Related Art

Typically, foundations and bases are constructed by hand from various pieces of pine or other lightweight woods. These built-up foundations are formed in a generally rectangular fashion and are sometimes sawed at each corner in an effort to replicate the rounded corners of conventional mattresses.

Various external jigs and fixtures must be used in order to assemble the numerous components of the foundations. Once aligned, the various pieces or components are typically nailed together.

Any discussion of documents, acts, materials, devices, articles, or the like, which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each claim of this application.

SUMMARY OF THE PRESENT DISCLOSURE

However, constructing foundations using known methods is typically time-consuming, requires relatively skilled workers, requires numerous components and tools, and does not always result in a secure or square foundation. Even with the introduction of certain improved connector elements, assembly typically still requires use of screws or nails to hold the various components of the support assembly together.

Thus, the present disclosure relates generally to improved foundation assemblies. In particular, the present disclosure relates to improved connector elements, foundation assemblies, and a method for constructing a support assembly.

In various exemplary embodiments, the support assembly of the present disclosure is constructed of metal, plastic, and/or wood components. The overall part count is significantly lower than that of other foundations. This low parts count greatly reduces the number of contact points between components in the support assembly, and virtually eliminates the potential for bothersome squeaks caused by friction.

In various exemplary embodiments, the support assembly comprises four perimeter rails (opposing rail elements and opposing header elements), joined to four connector elements. The profile of the perimeter rails provides comparatively smooth, rounded horizontal outer edges, and includes a plurality of paired slat clips that extend from the opposing rail elements to accommodate a plurality of substantially flush-mounted slats.

In various exemplary, non-limiting embodiments, each of the connector elements comprise at least some of a body portion having a substantially planar first abutment surface, a substantially planar second abutment surface, and a corner surface, wherein the first abutment surface extends substantially perpendicularly from a first terminating edge of the corner surface, wherein the second abutment surface extends substantially perpendicularly from a second terminating edge of the corner surface, wherein the corner surface extends between a terminating edge of the first abutment surface to a terminating edge of the second abutment surface, wherein the first abutment surface and the second abutment surface are formed at substantially 90° relative to one another, wherein an upper portion of the first abutment surface terminates at a substantially planar upper corner element surface and a lower portion of the first abutment surface terminates at a substantially planar lower corner element surface, and wherein an upper portion of the second abutment surface terminates at the upper corner element surface and a lower portion of the second abutment surface terminates at the lower corner element surface; one or more protrusions extending perpendicular to the first abutment surface; one or more protrusions extending perpendicular to the second abutment surface, wherein each of the protrusions has a substantially square cross-sectional profile; at least one first deflectable flexible finger extending from the first abutment surface, wherein at least a portion of a primary surface of the at least one first deflectable flexible finger extends substantially perpendicular to the first abutment surface, and wherein the at least one first deflectable flexible finger comprises a tang that extends, proximate a tip of the at least one first deflectable flexible finger, beyond the primary surface of the at least one first deflectable flexible finger, to form a camming surface and a shoulder; and at least one second deflectable flexible finger extending from the second abutment surface, wherein at least a portion of a primary surface of the at least one second deflectable flexible finger extends substantially perpendicular to the second abutment surface, and wherein the at least one second deflectable flexible finger comprises a tang that extends, proximate a tip of the at least one second deflectable flexible finger, beyond the primary surface of the at least one second deflectable flexible finger, to form a camming surface and a shoulder.

In various exemplary, non-limiting embodiments, each of the connector elements further comprises an upper corner element surface extends substantially parallel to the lower corner element surface.

In various exemplary, non-limiting embodiments, the corner surface defines a curved surface.

In various exemplary, non-limiting embodiments, the connector element is formed of a polymeric material, a metal, wood, or a composite material.

In various exemplary, non-limiting embodiments, the camming surface extends substantially perpendicularly from the primary surface.

In various exemplary, non-limiting embodiments, the connector element is formed as an integral unit.

In various exemplary, non-limiting embodiments, the first abutment surface and the second abutment surface each extend substantially perpendicularly from a terminating edge of the upper corner element surface.

In various exemplary, non-limiting embodiments, the first abutment surface and the second abutment surface each extend substantially perpendicularly from a terminating edge of the lower corner element surface.

In various exemplary, non-limiting embodiments, the main body portion of the connector element includes an at least partially hollow interior portion, defined substantially between the upper corner element surface and the lower corner element surface, wherein one or more ribs are formed within a hollow portion of the interior portion.

In various exemplary, non-limiting embodiments, the one or more first abutment recesses are formed in an area of the first abutment surface and wherein one or more second abutment recesses are formed in an area of the second abutment surfaces.

In various exemplary, non-limiting embodiments, two protrusions extend from the first abutment surface and two protrusions extend from the second abutment surface.

In various exemplary, non-limiting embodiments, each of the connector elements comprise at least some of a body portion having a substantially planar first abutment surface, a substantially planar second abutment surface, and a corner surface, wherein the first abutment surface extends substantially perpendicularly from a first terminating edge of the corner surface, wherein the second abutment surface extends substantially perpendicularly from a second terminating edge of the corner surface, wherein the corner surface extends between a terminating edge of the first abutment surface to a terminating edge of the second abutment surface to define a curved surface, wherein the first abutment surface and the second abutment surface are formed at substantially 90° relative to one another, wherein an upper portion of the first abutment surface terminates at a substantially planar upper corner element surface and a lower portion of the first abutment surface terminates at a substantially planar lower corner element surface, and wherein an upper portion of the second abutment surface terminates at the upper corner element surface and a lower portion of the second abutment surface terminates at the lower corner element surface; two protrusions extending perpendicular to the first abutment surface; two protrusions extending perpendicular to the second abutment surface, wherein each of the protrusions has a substantially square cross-sectional profile; at least one first deflectable flexible finger extending from the first abutment surface, wherein at least a portion of a primary surface of the at least one first deflectable flexible finger extends substantially perpendicular to the first abutment surface, and wherein the at least one first deflectable flexible finger comprises a tang that extends, proximate a tip of the at least one first deflectable flexible finger, beyond the primary surface of the at least one first deflectable flexible finger; and at least one second deflectable flexible finger extending from the second abutment surface, wherein at least a portion of a primary surface of the at least one second deflectable flexible finger extends substantially perpendicular to the second abutment surface, and wherein the at least one second deflectable flexible finger comprises a tang that extends, proximate a tip of the at least one second deflectable flexible finger, beyond the primary surface of the at least one second deflectable flexible finger.

In various exemplary, non-limiting embodiments, each of the connector elements further comprises an upper corner element surface extends substantially parallel to the lower corner element surface.

In various exemplary, non-limiting embodiments, the connector element is formed of a polymeric material, a metal, wood, or a composite material.

In various exemplary, non-limiting embodiments, a camming surface extends substantially perpendicularly from the primary surface.

In various exemplary, non-limiting embodiments, the connector element is formed as an integral unit.

In various exemplary, non-limiting embodiments, the first abutment surface and the second abutment surface each extend substantially perpendicularly from a terminating edge of the upper corner element surface.

In various exemplary, non-limiting embodiments, the first abutment surface and the second abutment surface each extend substantially perpendicularly from a terminating edge of the lower corner element surface.

In various exemplary, non-limiting embodiments, one or more first abutment recesses are formed in an area of the first abutment surface and wherein one or more second abutment recesses are formed in an area of the second abutment surfaces.

In various exemplary, non-limiting embodiments, each of the connector elements comprise at least some of plurality of connector elements, each of the connector elements comprising a body portion having a substantially planar first abutment surface, a substantially planar second abutment surface, and a corner surface, wherein the first abutment surface extends substantially perpendicularly from a first terminating edge of the corner surface, wherein the second abutment surface extends substantially perpendicularly from a second terminating edge of the corner surface, wherein the corner surface extends between a terminating edge of the first abutment surface to a terminating edge of the second abutment surface, wherein the first abutment surface and the second abutment surface are formed at substantially 90° relative to one another, wherein an upper portion of the first abutment surface terminates at a substantially planar upper corner element surface and a lower portion of the first abutment surface terminates at a substantially planar lower corner element surface, and wherein an upper portion of the second abutment surface terminates at the upper corner element surface and a lower portion of the second abutment surface terminates at the lower corner element surface; two protrusions extending perpendicular to the first abutment surface; two protrusions extending perpendicular to the second abutment surface, wherein each of the protrusions has a substantially square cross-sectional profile; at least one first deflectable flexible finger extending from the first abutment surface, wherein at least a portion of a primary surface of the at least one first deflectable flexible finger extends substantially perpendicular to the first abutment surface, and wherein the at least one first deflectable flexible finger comprises a tang that extends, proximate a tip of the at least one first deflectable flexible finger, beyond the primary surface of the at least one first deflectable flexible finger, to form a camming surface and a shoulder; at least one second deflectable flexible finger extending from the second abutment surface, wherein at least a portion of a primary surface of the at least one second deflectable flexible finger extends substantially perpendicular to the second abutment surface, and wherein the at least one second deflectable flexible finger comprises a tang that extends, proximate a tip of the at least one second deflectable flexible finger, beyond the primary surface of the at least one second deflectable flexible finger, to form a camming surface and a shoulder; at least two header elements, wherein each header element includes an upper horizontal header element bar and a lower horizontal header element bar joined by two or more vertical header element bars, wherein each of the horizontal header element bars includes a header element recess within a portion of each terminal end of the horizontal header element bars, wherein each of the header element recesses is a substantially square cross-sectional recess such that at least one of the protrusions is alignable with and at least partially positionable within at least a portion of a mating one of the header element recesses, and wherein the vertical header element bars are positioned proximate the terminal ends of the horizontal header element bars so as to be engaged by at least a portion of the shoulder of at least one of the at least one first deflectable flexible finger or the shoulder of at least one of the at least one second deflectable flexible finger; and at least two rail elements, wherein each rail element includes an upper horizontal rail element bar and a lower horizontal rail element bar joined by two or more vertical rail element bars, wherein each of the horizontal rail element bars includes a rail element recess within a portion of each terminal end of the horizontal rail element bars, wherein each of the rail element recesses is a substantially square cross-sectional recess such that at least one of the protrusions is alignable with and at least partially positionable within at least a portion of a mating one of the rail element recesses, and wherein the vertical rail element bars are positioned proximate the terminal ends of the horizontal rail element bars so as to be engaged by at least a portion of the shoulder of at least one of the at least one first deflectable flexible finger or the shoulder of at least one of the at least one second deflectable flexible finger.

In various exemplary embodiments, elements of the support assembly may optionally be fastened together with adhesives, if desired. Alternatively, screws or other fasteners may optionally be used, but are not necessary, to assemble the elements of the foundation. In still other embodiments, both adhesive and screws or other fasteners may be used.

Accordingly, the present disclosure provides a support assembly and support assembly components of improved design.

The present disclosure separately provides a support assembly having a lower overall part count when compared to other foundations.

The present disclosure separately provides a support assembly having improved structural stability.

The present disclosure separately provides a support assembly that can be assembled without the need for external jigs and/or fixtures.

The present disclosure separately provides a support assembly that can be scaled to accommodate any desired size or dimension.

The present disclosure separately provides a support assembly that is less expensive to manufacture.

The present disclosure separately provides a support assembly that can be held together without the use of nails, screws, fasteners, or adhesives.

The present disclosure separately provides a connector element of improved design.

The present disclosure separately provides a connector element that allows for assembly of foundation components without the use of tools.

The present disclosure separately provides a scalable connector element.

The present disclosure separately provides a connector element that is relatively lightweight.

The present disclosure separately provides a connector element that can be produced in mass quantity from plastic, wood, or other any other suitable material.

These and other features and advantages of the present disclosure are described in or are apparent from the following detailed description of the exemplary, non-limiting embodiments.

These and other aspects, features, and advantages of the present disclosure are described in or are apparent from the following detailed description of the exemplary, non-limiting embodiments of the present disclosure and the accompanying figures. Other aspects and features of embodiments of the present disclosure will become apparent to those of ordinary skill in the art upon reviewing the following description of specific, exemplary embodiments of the present disclosure in concert with the figures.

While features of the present disclosure may be discussed relative to certain embodiments and figures, all embodiments of the present disclosure can include one or more of the features discussed herein. Further, while one or more embodiments may be discussed as having certain advantageous features, one or more of such features may also be used with the various embodiments of the systems, methods, and/or apparatuses discussed herein. In similar fashion, while exemplary embodiments may be discussed below as device, system, or method embodiments, it is to be understood that such exemplary embodiments can be implemented in various devices, systems, and methods of the present disclosure.

Any benefits, advantages, or solutions to problems that are described herein with regard to specific embodiments are not intended to be construed as a critical, required, or essential feature(s) or element(s) of the present disclosure or the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

As required, detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the present disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present disclosure.

The exemplary embodiments of the present disclosure will be described in detail, with reference to the following figures, wherein like reference numerals refer to like parts throughout the several views, and wherein:

FIG. 1 illustrates an upper, front, perspective view of an exemplary embodiment of a connector element according to the present disclosure;

FIG. 2 illustrates a lower, front, perspective view of an exemplary embodiment of a connector element according to the present disclosure;

FIG. 3 illustrates an upper, rear, perspective view of an exemplary embodiment of a connector element according to the present disclosure;

FIG. 4 illustrates a lower, rear, perspective view of an exemplary embodiment of a connector element according to the present disclosure;

FIG. 5 illustrates an upper, left side, perspective view of an exemplary embodiment of a connector element according to the present disclosure;

FIG. 6 illustrates a lower, right side, perspective view of an exemplary embodiment of a connector element according to the present disclosure;

FIG. 7 illustrates a left side view of an exemplary embodiment of a connector element according to the present disclosure;

FIG. 8 illustrates a right side view of an exemplary embodiment of a connector element according to the present disclosure;

FIG. 9 illustrates a left view of an exemplary embodiment of a connector element according to the present disclosure;

FIG. 10 illustrates a right view of an exemplary embodiment of a connector element according to the present disclosure;

FIG. 11 illustrates a top view of an exemplary embodiment of a connector element according to the present disclosure;

FIG. 12 illustrates a bottom view of an exemplary embodiment of a connector element according to the present disclosure;

FIG. 13 illustrates a top, cross-sectional view of an exemplary embodiment of a connector element taken along line 13-13 of the connector element of FIG. 7;

FIG. 14 illustrates a top, cross-sectional view of an exemplary embodiment of a connector element taken along line 14-14 of FIG. 7;

FIG. 15 illustrates a partially exploded perspective view of certain components of an exemplary embodiment of a support assembly according to the present disclosure;

FIG. 16 illustrates a partially exploded perspective view of certain components of an exemplary embodiment of a support assembly according to the present disclosure;

FIG. 17 illustrates a partially exploded perspective view of certain components of an exemplary embodiment of a support assembly according to the present disclosure;

FIG. 18 illustrates a perspective view of an exemplary embodiment of a connector element attached to an exemplary header element and an exemplary rail element according to the present disclosure;

FIG. 19 illustrates a partially exploded perspective view of certain components of an exemplary embodiment of a support assembly according to the present disclosure;

FIG. 20 illustrates a side view of certain components of an exemplary embodiment of an assembled support assembly according to the present disclosure;

FIG. 21 illustrates a side view of certain components of an exemplary embodiment of an assembled support assembly according to the present disclosure;

FIG. 22 illustrates a top view of certain components of an exemplary embodiment of an assembled support assembly according to the present disclosure; and

FIG. 23 illustrates a bottom view of certain components of an exemplary embodiment of an assembled support assembly according to the present disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

For simplicity and clarification, the design factors and operating principles of the connector elements and foundation assemblies according to the present disclosure are explained with reference to various exemplary embodiments of a connector element and/or support assembly according to the present disclosure. The basic explanation of the design factors and operating principles of the connector elements and/or foundation assemblies is applicable for the understanding, design, and operation of the connector elements and/or foundation assemblies of the present disclosure. It should be appreciated that the connector elements and/or foundation assemblies can be adapted to many applications where a connector elements and/or foundation assemblies can be used.

As used herein, the word “may” is meant to convey a permissive sense (i.e., meaning “having the potential to”), rather than a mandatory sense (i.e., meaning “must”). Unless stated otherwise, terms such as “first” and “second”, “right” and “left”, “top” and “bottom”, “upper” and “lower”, and “horizontal” and “vertical” are used to arbitrarily distinguish between the exemplary embodiments and/or elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such exemplary embodiments and/or elements.

As used herein, and unless the context dictates otherwise, the term “coupled” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). The term coupled, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. The terms “a” and “an” are defined as one or more unless stated otherwise.

Throughout this application, the terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include”, (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are used as open-ended linking verbs. It will be understood that these terms are meant to imply the inclusion of a stated element, integer, step, or group of elements, integers, or steps, but not the exclusion of any other element, integer, step, or group of elements, integers, or steps. As a result, a system, method, or apparatus that “comprises”, “has”, “includes”, or “contains” one or more elements possesses those one or more elements but is not limited to possessing only those one or more elements. Similarly, a method or process that “comprises”, “has”, “includes” or “contains” one or more operations possesses those one or more operations but is not limited to possessing only those one or more operations.

Furthermore, the terms “front”, “rear”, “right”, “left”, “upper”, and “lower”, as used in reference to the attachment interface and the rear attachment interface portion, are used for basic explanation and understanding of the operation of the presently disclosed systems, methods, and/or apparatuses and are to be seen as a naming convention used to help differentiate between certain of the components of the present disclosure and are not to be construed as limiting the systems, methods, and/or apparatuses of the present disclosure.

It should also be appreciated that the terms “connector element”, “support assembly”, “rail element”, “header element”, and “slat” are used for basic explanation and understanding of the operation of the systems, methods, and apparatuses of the present disclosure. Therefore, the terms “connector element”, “support assembly”, “rail element”, “header element”, and “slat” are not to be construed as limiting the systems, methods, and apparatuses of the present disclosure.

For simplicity and clarification, the connector elements of the present disclosure will be shown and/or described as being used in conjunction with an exemplary support assembly being utilized as a bedding foundation. However, it should be appreciated that these are merely exemplary embodiments of the connector elements and foundation assemblies are not to be construed as limiting the present disclosure. Thus, the connector elements and/or foundation assemblies of the present disclosure may be utilized in conjunction with any bedding component or support platform.

Turning now to the appended drawing figures, FIGS. 1-14 show an exemplary embodiment of a connector element 105 according to the present disclosure. In an illustrative, non-limiting embodiment of the present disclosure, as illustrated in FIGS. 1-14, the connector element 105 comprises at least some of a main body portion 110, an upper corner element surface 115, a corner surface 130, a substantially planar first abutment surface 131, a substantially planar second abutment surface 132, and a lower corner element surface 116.

As illustrated in FIGS. 1-14, the main body portion 110 extends from the substantially planar upper corner element surface 115 to the substantially planar lower corner element surface 116.

The first abutment surface 131 extends substantially perpendicularly from a first terminating edge of the corner surface 130. Likewise, the second abutment surface 132 extends substantially perpendicularly from a second terminating edge of the corner surface 130. The corner surface 130 extends between a terminating edge of the first abutment surface 131 to a terminating edge of the second abutment surface 132. In various exemplary embodiments, the corner surface 130 is defined by a curved surface.

In various exemplary, nonlimiting embodiments, the first abutment surface 131 and the second abutment surface 132 are formed at substantially 90° relative to one another.

An upper portion of the first abutment surface 131 and an upper portion of the second abutment surface 132 each terminate at the upper corner element surface 115, while a lower portion of the first abutment surface 131 and a lower portion of the second abutment surface 132 each terminate at the lower corner element surface 116.

In various exemplary embodiments, the first abutment surface 131 and the second abutment surface 132 each extend substantially perpendicularly from a terminating edge of the upper corner element surface 115. Similarly, the first abutment surface 131 and the second abutment surface 132 each extend substantially perpendicularly from a terminating edge of the lower corner element surface 116.

In various exemplary embodiments, as illustrated in FIGS. 1-14, the main body portion 110 of the connector element 105 includes an at least partially hollow interior portion, defined substantially between the upper corner element surface 115 and the lower corner element surface 116. In these exemplary embodiments, one or more ribs 155 may optionally be formed within a hollow portion 150 of the interior portion. The one or more ribs 155 may provide additional strength and/or rigidity to the main body portion 110.

In various exemplary embodiments, one or more first abutment recesses 133 are optionally formed in an area of the first abutment surface 131. Similarly, one or more second abutment recesses 134 are optionally formed in an area of the second abutment surfaces 132. The one or more first abutment recesses 133 and/or second abutment recesses 134 may provide additional strength and/or rigidity to the corner connector 105.

One or more protrusions 135 extend, along a longitudinal axis, perpendicularly from the first abutment surface 131. Likewise, one or more protrusions 135 extend, along a longitudinal axis, perpendicularly from the second abutment surface 132. As illustrated in FIGS. 1-14, the connector element 105 includes two protrusions 135 extending from the first abutment surface 131 and two protrusions 135 extending from the second abutment surface 132. It should be appreciated that the number of protrusions 135 is a design choice based on the desired appearance and functionality of the connector element 105.

In various exemplary, nonlimiting embodiments, each of the protrusions 135 has a substantially square cross-sectional profile, when viewed along a plane perpendicular to the longitudinal axis of the protrusion 135 and perpendicular to the first abutment surface 131 or perpendicular to the second abutment surfaces 132, respectively.

In various exemplary, nonlimiting embodiments, each header element recess 167 and each rail element recess 177 is a substantially square cross-sectional recess.

Thus, the protrusions 135 are alignable with and at least partially positionable within at least a portion of the mating header element recesses 167 formed in the header elements 160 or the mating rail element recesses 177 formed in the rail elements 170. In this manner, an appropriate connector element 105 can be more readily aligned with the appropriate header element 160 and/or rail element 170 when the support assembly 100 is assembled.

It should be appreciated that while the protrusions 135 and the header element recesses 167 and rail element recesses 177 are shown and described as having substantially square cross-sections, it should be appreciated that the present disclosure is not so limited. Thus, the protrusions 135 and the header element recesses 167 and rail element recesses 177 may optionally have any desired cross-sectional profile, including, for example, a substantially circular, rectangular, square, or triangular profile.

At least one first deflectable flexible finger 140 extends from the first abutment surface 131. At least a portion of a primary surface 143 of the at least one first deflectable flexible finger 140 extends substantially perpendicular to the first abutment surface 131, and wherein the at least one first deflectable flexible finger 140 comprises a tang 149 that extends, proximate a tip 144 of the at least one first deflectable flexible finger 140, beyond the primary surface 143 of the at least one first deflectable flexible finger 140, to form a camming surface 146 and a shoulder 148.

At least one second deflectable flexible finger 140 extends from the second abutment surface 132. At least a portion of a primary surface 143 of the at least one second deflectable flexible finger 140 extends substantially perpendicular to the second abutment surface 132, and wherein the at least one second deflectable flexible finger 140 comprises a tang 149 that extends, proximate a tip 144 of the at least one second deflectable flexible finger 140, beyond the primary surface 143 of the at least one second deflectable flexible finger 140, to form a camming surface 146 and a shoulder 148.

Each deflectable flexible finger 140 comprises a stem 142, which terminates at a tip 144, a shoulder 148, and a camming surface 146, which extends from a side portion of the stem 142.

In various exemplary embodiments, the connector element 105 is substantially rigid and is formed of a polymeric material such as a polymeric composite. Alternate materials of construction may include one or more of the following: wood, steel, aluminum, titanium, and/or other metals, as well as various alloys and composites thereof, glass-hardened polymers, polymer or fiber reinforced metals, carbon fiber or glass fiber composites, continuous fibers in combination with thermoset and thermoplastic resins, chopped glass or carbon fibers used for injection molding compounds, laminate glass or carbon fiber, epoxy laminates, woven glass fiber laminates, impregnate fibers, polyester resins, epoxy resins, phenolic resins, polyimide resins, cyanate resins, high-strength plastics, nylon, glass, or polymer fiber reinforced plastics, thermoform and/or thermoset materials, and/or various combinations of the foregoing. Thus, it should be understood that the material or materials used to form the connector element 105 is a design choice based on the desired appearance and functionality of the connector element 105.

It should be appreciated that the connector element 105 may be integrally formed. Alternatively, suitable materials can be used and sections are elements made independently and attached or coupled together, such as by adhesives, staples, screws, nails, or other fasteners, to form the connector element 105.

It should be understood that the overall size and shape of the connector element 105, and the various portions thereof, is a design choice based upon the desired functionality and/or appearance of the connector element 105. Additionally, it should be appreciated that the connector element 105 is formed such that multiple connector elements 105 may be positioned and used as each of the four corners of a support assembly 100. Therefore, multiple connector elements do not have to be formed for a specific location at a specific corner of a support assembly 100.

As illustrated in FIGS. 15-23, the connector element 105 may be used to construct an exemplary support assembly 100. As illustrated in FIGS. 15-23, the exemplary support assembly 100 comprises at least some of connector elements 105, header elements 160, rail elements 170, and elongate slats 180.

Each of the header elements 160 includes an upper horizontal header element bar 163 and a lower horizontal header element bar 163 joined by two or more vertical header element bars 165. Each of the horizontal header element bars 163 includes a header element recess 167 at least within a portion of each terminal end of the horizontal header element bars 163. In various exemplary embodiments, each horizontal header element bar 163 comprises a portion of square tubing having a header element recess 167 formed therethrough, along its entire length.

The horizontal header element bars 163 are spaced apart from one another and at least one vertical header element bar 165 is attached or coupled to and between the horizontal header element bars 163, perpendicular to the longitudinal axis of the header element 160, proximate each terminal end of the horizontal header element bars 163. In various exemplary, nonlimiting embodiments, at least one additional vertical header element bar 165 is attached or coupled to and between the horizontal header element bars 163, between the terminal ends of the vertical header element bars 165.

The header element recesses 167 of the horizontal header element bars 163 are spaced apart from one another a distance that is equal to or substantially equal to the distance that the protrusions 135 are spaced apart from one another on each respective side of the connector elements 105.

The vertical header element bars 165 are positioned proximate the terminal ends of the horizontal header element bars 163 so as to be engaged by at least a portion of a shoulder 148, as described herein.

Each of the rail elements 170 includes an upper horizontal rail element bar 173 and a lower horizontal rail element bar 173 joined by two or more vertical rail element bars 175. Each of the horizontal rail element bars 173 includes a rail element recess 177 at least within a portion of each terminal end of the horizontal rail element bars 173. In various exemplary embodiments, each horizontal rail element bar 173 comprises a portion of square tubing having a rail element recess 177 formed therethrough, along its entire length.

The horizontal rail element bars 173 are spaced apart from one another and at least one vertical rail element bar 175 is attached or coupled to and between the horizontal rail element bars 173, perpendicular to the longitudinal axis of the rail element 170, proximate each terminal end of the horizontal rail element bars 173. In various exemplary, nonlimiting embodiments, at least one additional vertical rail element bar 175 is attached or coupled to and between the horizontal rail element bars 173, between the terminal ends of the vertical rail element bars 175.

The rail element recesses 177 of the horizontal rail element bars 173 are spaced apart from one another a distance that is equal to or substantially equal to the distance that the protrusions 135 are spaced apart from one another on each respective side of the connector elements 105.

The vertical rail element bars 175 are positioned proximate the terminal ends of the horizontal rail element bars 173 so as to be engaged by at least a portion of a shoulder 148, as described herein.

Each of the rail elements 170 includes a plurality of spaced apart slat clips 178 that extend from the upper horizontal rail element bar 173. Each of the slat clips 178 is formed so as to support or cradle at least a portion of a terminal end portion of a slat 180 therein. The slat clips 178 extend such that when the rail elements 170 are aligned with one another, opposing slat clips 178 of opposing rail elements 170 are adjacent one another so that opposing terminal ends of each slat 180 are able to be positioned at least partially within opposing slat clips 178 such that the slats 180 are spaced apart from one another along the support assembly 100 and are substantially parallel to one another along the support assembly 100.

It should be appreciated, that the features of the rail elements 170 correspond to the elements of the header elements 160 and may, in fact, be identical to the elements of the header elements 160. However, typically the rail elements 170 are longer in length than the length of the header elements 160.

Due to the shape and placement of the protrusions 135, so long as the header elements 160 are of an equal length and the rail elements 170 are of an equal length, and so long as each of the header elements 160 and the rail elements 170 has a terminating end that is parallel and perpendicular to the longitudinal axis of the element, when the respective protrusions 135 are positioned within the header element recesses 167 and the rail element recesses 177 and the terminal ends of the header element 160 and the rail elements 170 are abutted against the corresponding first abutment surface 131 and the second abutment surface 132, the header elements 160 are parallel to one another and the rail elements 170 are parallel to one another.

In order to construct a foundation support assembly 100, four connector elements 105 are positioned at locations proximate the four corners of the finished foundation support assembly 100.

When properly positioned, the header elements 160 and the rail elements 170 are each guided, by the interaction of the protrusions 135 with the respective header element recesses 167 of the header element 160 and further interaction between the protrusions 135 with the respective rail element recesses 177 of the rail elements 170, respectively.

In this manner, as a corner connector 105 is properly aligned with and urged toward a header element 160 or a rail element 170, inner surfaces of a vertical header element bar 165 proximate a terminal end of the header element 160 and inner surfaces of a vertical rail element bar 175 proximate a terminal end of the rail elements 170 contact the camming surfaces 146 of the respective tangs 149.

As the corner connector 105 continues to be urged toward the header element 160 or the rail element 170, inner surfaces of a vertical header element bar 165 and inner surfaces of a vertical rail element bar 175 contact the camming surfaces 146 and the deflectable flexible finger 140 are flexed inwardly so as to ride along the inner surfaces of a vertical header element bar 165 and inner surfaces of a vertical rail element bar 175.

The deflectable flexible fingers 140 continues to be flexed inwardly until shoulders 148 pass beyond an edge of the vertical header element bar 165 and the vertical rail element bar 175, whereupon the spring bias of the stressed stem 142 causes the deflectable flexible fingers 140 to snap outwardly and the tang 149 is urged past the edge of the vertical header element bar 165 and the vertical rail element bar 175, to assume a locked or engaged position, as illustrated, for example, in FIGS. 17-23.

When the tang 149 is in the locked or engaged position, the shoulder 148 contacts and engages a sidewall surface of the vertical header element bar 165 and the vertical rail element bar 175, firmly attaching or coupling the header elements 160 and the rail elements 170 to the corner connectors 105. When assembled, the interaction of the tang 149 with the vertical header element bar 165 and the vertical rail element bar 175 restraining withdrawal of the vertical header element bar 165 and the vertical rail element bar 175 from the respective corner connector 105. More specifically, when a withdrawing force is applied to the corner connector 105 with respect to the header element 160 or the rail element 170, the abutting relation of the shoulders 148 and the vertical header element bar 165 and the vertical rail element bar 175 will preclude longitudinal movement, thereby precluding the disengagement of the corner connector 105 from the vertical header element bar 165 and the vertical rail element bar 175.

It is further noted that if the angle of the shoulder 148 includes an undercut, the greater the withdrawing force applied the header element 160 or the rail element 170, the stronger the engagement between the tangs 149 and the vertical header element bar 165 and the vertical rail element bar 175 becomes, as the withdrawing force will cause tangs 149 to further flex inward restraining the movement of the header element 160 or the rail element 170.

Thus, it should be appreciated that the corner connector 105 may be attached or coupled to the header element 160 or the rail element 170 in the same manner.

When the header elements 160 and the side wall elements 170 are attached, coupled, or secured to an appropriate connector element 105, the slats 180 can be positioned between opposing slat clips 178 of opposing rail elements 170 to form the support assembly 100.

Once assembled, the foundation support assembly 100 can be placed in a bed frame (not shown) for receiving a mattress.

While the present disclosure has been described in conjunction with the exemplary embodiments outlined above, the foregoing description of exemplary embodiments of the present disclosure, as set forth above, are intended to be illustrative, not limiting and the fundamental disclosure should not be considered to be necessarily so constrained. It is evident that the present disclosure is not limited to the particular variation set forth and many alternatives, adaptations modifications, and/or variations will be apparent to those skilled in the art.

Furthermore, where a range of values is provided, it is understood that every intervening value, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the present disclosure. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and is also encompassed within the present disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the present disclosure.

It is to be understood that the phraseology of terminology employed herein is for the purpose of description and not of limitation. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present disclosure belongs.

In addition, it is contemplated that any optional feature of the inventive variations described herein may be set forth and claimed independently, or in combination with any one or more of the features described herein.

Accordingly, the foregoing description of exemplary embodiments will reveal the general nature of the present disclosure, such that others may, by applying current knowledge, change, vary, modify, and/or adapt these exemplary, non-limiting embodiments for various applications without departing from the spirit and scope of the present disclosure and elements or methods similar or equivalent to those described herein can be used in practicing the present disclosure. Any and all such changes, variations, modifications, and/or adaptations should and are intended to be comprehended within the meaning and range of equivalents of the disclosed exemplary embodiments and may be substituted without departing from the true spirit and scope of the present disclosure.

Also, it is noted that as used herein and in the appended claims, the singular forms “a”, “and”, “said”, and “the” include plural referents unless the context clearly dictates otherwise. Conversely, it is contemplated that the claims may be so-drafted to require singular elements or exclude any optional element indicated to be so here in the text or drawings. This statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely”, “only”, and the like in connection with the recitation of claim elements or the use of a “negative” claim limitation(s).

Claims

1. A connector element, comprising:

a body portion having a substantially planar first abutment surface, a substantially planar second abutment surface, and a corner surface, wherein said first abutment surface extends substantially perpendicularly from a first terminating edge of said corner surface, wherein said second abutment surface extends substantially perpendicularly from a second terminating edge of said corner surface, wherein said corner surface extends between a terminating edge of said first abutment surface to a terminating edge of said second abutment surface, wherein said first abutment surface and said second abutment surface are formed at substantially 90° relative to one another, wherein an upper portion of said first abutment surface terminates at a substantially planar upper corner element surface and a lower portion of said first abutment surface terminates at a substantially planar lower corner element surface, and wherein an upper portion of said second abutment surface terminates at said upper corner element surface and a lower portion of said second abutment surface terminates at said lower corner element surface;

one or more protrusions extending perpendicular to said first abutment surface;

one or more protrusions extending perpendicular to said second abutment surface, wherein each of said protrusions has a substantially square cross-sectional profile;

at least one first deflectable flexible finger extending from said first abutment surface, wherein at least a portion of a primary surface of said at least one first deflectable flexible finger extends substantially perpendicular to said first abutment surface, and wherein said at least one first deflectable flexible finger comprises a tang that extends, proximate a tip of said at least one first deflectable flexible finger, beyond said primary surface of said at least one first deflectable flexible finger, to form a camming surface and a shoulder; and

at least one second deflectable flexible finger extending from said second abutment surface, wherein at least a portion of a primary surface of said at least one second deflectable flexible finger extends substantially perpendicular to said second abutment surface, and wherein said at least one second deflectable flexible finger comprises a tang that extends, proximate a tip of said at least one second deflectable flexible finger, beyond said primary surface of said at least one second deflectable flexible finger, to form a camming surface and a shoulder.

2. The connector element of claim 1, further comprising an upper corner element surface extends substantially parallel to said lower corner element surface.

3. The connector element of claim 1, wherein said corner surface defines a curved surface.

4. The connector element of claim 1, wherein said connector element is formed of a polymeric material, a metal, wood, or a composite material.

5. The connector element of claim 1, wherein said camming surface extends substantially perpendicularly from said primary surface.

6. The connector element of claim 1, wherein said connector element is formed as an integral unit.

7. The connector element of claim 1, wherein said first abutment surface and said second abutment surface each extend substantially perpendicularly from a terminating edge of said upper corner element surface.

8. The connector element of claim 1, wherein said first abutment surface and said second abutment surface each extend substantially perpendicularly from a terminating edge of said lower corner element surface.

9. The connector element of claim 1, wherein said main body portion of said connector element includes an at least partially hollow interior portion, defined substantially between said upper corner element surface and said lower corner element surface, wherein one or more ribs are formed within a hollow portion of said interior portion.

10. The connector element of claim 1, wherein one or more first abutment recesses are formed in an area of said first abutment surface and wherein one or more second abutment recesses are formed in an area of said second abutment surfaces.

11. The connector element of claim 1, wherein two protrusions extend from said first abutment surface and two protrusions extend from said second abutment surface.

12. A connector element, comprising:

a body portion having a substantially planar first abutment surface, a substantially planar second abutment surface, and a corner surface, wherein said first abutment surface extends substantially perpendicularly from a first terminating edge of said corner surface, wherein said second abutment surface extends substantially perpendicularly from a second terminating edge of said corner surface, wherein said corner surface extends between a terminating edge of said first abutment surface to a terminating edge of said second abutment surface to define a curved surface, wherein said first abutment surface and said second abutment surface are formed at substantially 90° relative to one another, wherein an upper portion of said first abutment surface terminates at a substantially planar upper corner element surface and a lower portion of said first abutment surface terminates at a substantially planar lower corner element surface, and wherein an upper portion of said second abutment surface terminates at said upper corner element surface and a lower portion of said second abutment surface terminates at said lower corner element surface;

two protrusions extending perpendicular to said first abutment surface;

two protrusions extending perpendicular to said second abutment surface, wherein each of said protrusions has a substantially square cross-sectional profile;

at least one first deflectable flexible finger extending from said first abutment surface, wherein at least a portion of a primary surface of said at least one first deflectable flexible finger extends substantially perpendicular to said first abutment surface, and wherein said at least one first deflectable flexible finger comprises a tang that extends, proximate a tip of said at least one first deflectable flexible finger, beyond said primary surface of said at least one first deflectable flexible finger; and

at least one second deflectable flexible finger extending from said second abutment surface, wherein at least a portion of a primary surface of said at least one second deflectable flexible finger extends substantially perpendicular to said second abutment surface, and wherein said at least one second deflectable flexible finger comprises a tang that extends, proximate a tip of said at least one second deflectable flexible finger, beyond said primary surface of said at least one second deflectable flexible finger.

13. The connector element of claim 1, further comprising an upper corner element surface extends substantially parallel to said lower corner element surface.

14. The connector element of claim 1, wherein said connector element is formed of a polymeric material, a metal, wood, or a composite material.

15. The connector element of claim 1, wherein a camming surface extends substantially perpendicularly from said primary surface.

16. The connector element of claim 1, wherein said connector element is formed as an integral unit.

17. The connector element of claim 1, wherein said first abutment surface and said second abutment surface each extend substantially perpendicularly from a terminating edge of said upper corner element surface.

18. The connector element of claim 1, wherein said first abutment surface and said second abutment surface each extend substantially perpendicularly from a terminating edge of said lower corner element surface.

19. The connector element of claim 1, wherein one or more first abutment recesses are formed in an area of said first abutment surface and wherein one or more second abutment recesses are formed in an area of said second abutment surfaces.

20. A connector element support assembly, comprising:

a plurality of connector elements, each of said connector elements comprising a body portion having a substantially planar first abutment surface, a substantially planar second abutment surface, and a corner surface, wherein said first abutment surface extends substantially perpendicularly from a first terminating edge of said corner surface, wherein said second abutment surface extends substantially perpendicularly from a second terminating edge of said corner surface, wherein said corner surface extends between a terminating edge of said first abutment surface to a terminating edge of said second abutment surface, wherein said first abutment surface and said second abutment surface are formed at substantially 90° relative to one another, wherein an upper portion of said first abutment surface terminates at a substantially planar upper corner element surface and a lower portion of said first abutment surface terminates at a substantially planar lower corner element surface, and wherein an upper portion of said second abutment surface terminates at said upper corner element surface and a lower portion of said second abutment surface terminates at said lower corner element surface;

two protrusions extending perpendicular to said first abutment surface;

two protrusions extending perpendicular to said second abutment surface, wherein each of said protrusions has a substantially square cross-sectional profile;

at least one first deflectable flexible finger extending from said first abutment surface, wherein at least a portion of a primary surface of said at least one first deflectable flexible finger extends substantially perpendicular to said first abutment surface, and wherein said at least one first deflectable flexible finger comprises a tang that extends, proximate a tip of said at least one first deflectable flexible finger, beyond said primary surface of said at least one first deflectable flexible finger, to form a camming surface and a shoulder;

at least one second deflectable flexible finger extending from said second abutment surface, wherein at least a portion of a primary surface of said at least one second deflectable flexible finger extends substantially perpendicular to said second abutment surface, and wherein said at least one second deflectable flexible finger comprises a tang that extends, proximate a tip of said at least one second deflectable flexible finger, beyond said primary surface of said at least one second deflectable flexible finger, to form a camming surface and a shoulder;

at least two header elements, wherein each header element includes an upper horizontal header element bar and a lower horizontal header element bar joined by two or more vertical header element bars, wherein each of said horizontal header element bars includes a header element recess within a portion of each terminal end of said horizontal header element bars, wherein each of said header element recesses is a substantially square cross-sectional recess such that at least one of said protrusions is alignable with and at least partially positionable within at least a portion of a mating one of said header element recesses, and wherein said vertical header element bars are positioned proximate said terminal ends of said horizontal header element bars so as to be engaged by at least a portion of said shoulder of at least one of said at least one first deflectable flexible finger or said shoulder of at least one of said at least one second deflectable flexible finger; and

at least two rail elements, wherein each rail element includes an upper horizontal rail element bar and a lower horizontal rail element bar joined by two or more vertical rail element bars, wherein each of said horizontal rail element bars includes a rail element recess within a portion of each terminal end of said horizontal rail element bars, wherein each of said rail element recesses is a substantially square cross-sectional recess such that at least one of said protrusions is alignable with and at least partially positionable within at least a portion of a mating one of said rail element recesses, and wherein said vertical rail element bars are positioned proximate said terminal ends of said horizontal rail element bars so as to be engaged by at least a portion of said shoulder of at least one of said at least one first deflectable flexible finger or said shoulder of at least one of said at least one second deflectable flexible finger.