CROSS REFERENCES TO RELATED APPLICATION This application claims the benefit of U.S. Provisional Application 63/404,466, filed Sep. 7, 2022, all of which are incorporated by reference.
BACKGROUND Bed foundations are bulky, costly and are heavy and often difficult to transport from one location to another. There is a need in the art to make the transport of bed foundations more efficient and effective.
SUMMARY OF THE INVENTION A compact shippable mattress foundation that quickly assembles without any tools will now be described in accordance with one or more embodiments of the invention. The following exemplary description numerous specific details are set forth to provide a more thorough understanding of embodiments of the invention. It will be apparent, however, to an artisan of ordinary skill that the present invention may be practiced without incorporating all aspects of the specific details described herein. Furthermore, although steps or processes are set forth in an exemplary order to provide an understanding of one or more systems and methods, the exemplary order is not meant to be limiting. One of ordinary skill in the art would recognize that the steps or processes may be performed in a different order, and that one or more steps or processes may be performed simultaneously or in multiple process flows without departing from the spirit or the scope of the invention. In other instances, specific features, quantities, or measurements well known to those of ordinary skill in the art have not been described in detail so as not to obscure the invention. It should be noted that although examples of the invention are set forth herein, the claims, and the full scope of any equivalents, are what define the metes and bounds of the invention.
For a better understanding of the disclosed embodiment, its operating advantages, and the specified object attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated exemplary disclosed embodiments. The disclosed embodiments are not intended to be limited to the specific forms set forth herein. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation.
The term “first”, “second” and the like, herein do not denote any order, quantity or importance, but rather are used to distinguish one element from another, and the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
Spatially relative terms, such as “beneath,” “below,” “lower,” “under,” “above,” “upper,” and the like, may be used herein for ease of explanation to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or in operation, in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” or “under” other elements or features would then be oriented “above” the other elements or features. Thus, the example terms “below” and “under” can encompass both an orientation of above and below. The device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein should be interpreted accordingly.
It will be understood that when an element or layer is referred to as being “on,” “connected to,” or “coupled to” another element or layer, it can be directly on, connected to, or coupled to the other element or layer, or one or more intervening elements or layers may be present. In addition, it will also be understood that when an element or layer is referred to as being “between” two elements or layers, it can be the only element or layer between the two elements or layers, or one or more intervening elements or layers may also be present.
As used herein, the term “substantially,” “about,” and similar terms are used as terms of approximation and not as terms of degree, and are intended to account for the inherent deviations in measured or calculated values that would be recognized by those of ordinary skill in the art. Further, the use of “may” when describing embodiments of the present invention refers to “one or more embodiments of the present invention.” As used herein, the terms “use,” “using,” and “used” may be considered synonymous with the terms “utilize,” “utilizing,” and “utilized,” respectively. Also, the term “exemplary” is intended to refer to an example or illustration.
Unless otherwise defined, all terms (including 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 invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and/or the present specification, and should not be interpreted in an idealized or overly formal sense, unless expressly so defined herein.
Disclosed in this application is a shippable mattress foundation, said shippable mattress comprising 1) a frame having a head element, 2) a foot element, a center support, 3) a right-side element having stamped holes and left-side element having stamped holes 4) cross slats couplable to the frame, 5) stamped holes within the right-side element and left-side element for receipt of the cross slats, 6) an interlocking side flange and 7) an attachment clip on the center support for adjoining the cross slats. Also disclosed is an attachment clip 7) wherein said attachment clip is configured to have a first receptacle and a second receptacle, wherein said first and second receptacle are configured to be on opposing sides, wherein said first and second receptacle are configured to receive said cross slats vertically. In addition, the receptacles of above wherein said receptacles utilize at least two side walls. In addition, the receptacles of above wherein said receptacles utilize a floor. Furthermore, the receptacles of above wherein said receptacles hold said cross slat into position. Also, the shippable mattress foundation mentioned above wherein said frame is attached to vertical support legs providing at least 10 inches of clearance from ground level. In addition, the shippable mattress foundation discussed above wherein said frame can support at least 2,500 lbs of a distributed load. In is worth noting The shippable mattress foundation of discussed above wherein said attachment clip is made of plastic. Additionally, the shippable mattress foundation of discussed above wherein said attachment clip contains a bottom protrusion that fits within a top hole on said center support. Finally, the side flange discussed above wherein said flange side is configured to interlock with a second element portion, wherein interlocking with said second element portion enables for a strong connection between bed frame elements.
REFERENCES The description of the figures provided herein contain references to each depicted component. A list of these components described in the context of each figure is provided below for easy reference.
-
- 1 a frame
- 2 a cover
- 3 legs
- 4 a mounting plate
- 7 box
- 8 an inner-threaded bolt
- 9 a hinge
- 10 a left side vertical support
- 11 a right side vertical support
- 12 a front horizontal support
- 13 a rear horizontal support
- 14 a left bundled slat
- 15 a right bundled slat
- 16 a left slat
- 17 a right slat
- 18 a central vertical support
- 20 a top
- 21 a front
- 22 a right
- 23 a rear
- 25 a bottom
- 30 a first leg segment
- 31 a second leg segment
- 40 a first edge segment
- 41 a second edge
- 42,46 a recessed segment
- 44 a third edge segment
- 45 a fourth edge segment
- 47 a third edge tab segment
- 48 a first edge tab segment
- 50, 52, 53, 54,55,56 bolts
- 60, 61, 62, 63, 64 threaded sockets
- 80 a head
- 81 a body
- 90 a first leaf
- 91 a second leaf
- 92,93 hinges
- 94 a hinge pin
- 95,96 a frame support
- 97 a cotter bolt
- 98 a lock nut
- 100 a left side front support
- 105 a middle-left flange
- 106 a front left flange
- 110 a right side front support
- 115 a middle right flange
- 116 a rear right flange
- 120 a left support piece
- 121 a right support piece
- 125 a front right flange
- 127 a front middle flange
- 131 a right support piece
- 133 a top support piece
- 134 a bottom support piece
- 135 a rear left flange
- 140, 141, 142, 143 150,151, 152, 153 horizontal slats
- 144 a left vertical slat
- 154 a right vertical slat
- 160,170 a rectangular notches
- 161 a notch
- 162 an endpiece
- 183 a resinous left seat
- 184 a resinous right seat
- 185 a top support piece
- 230 a right rear opening
- 231 a left rear opening
- 250 a reinforced opening
- 300 a foot
- 301, 311 a body
- 302, 312 threaded bolt
- 400 an outer first-edge slot
- 401 an inner first-edge slot
- 410 a first-edge-side outer second-edge slot
- 411 an first-edge-side inner second-edge slot
- 412 a third-edge-side outer second-edge slot
- 413 a third-edge-side inner second-edge slot
- 420 a recessed-third-edge slot
- 421 a medial third-edge-recess wall
- 422 a lateral third-edge-recess wall
- 440 an outer third-edge slot
- 441 an inner third-edge slot
- 450 a third-edge-side outer fourth-edge slot
- 451 a third-edge-side inner fourth-edge slot
- 452 a first-edge-side outer fourth-edge slot
- 453 a first-edge-side inner fourth-edge slot
- 460 a recessed-first-edge slot
- 462 a lateral first-edge-recess wall
- 1003 a hole
- 1200 a threaded socket
- 1250, 1050, 1060, 1150 a threaded hole
- 1350 formed in each respective flange
- 4200 an attach clip
- 4202 cross slats
- 4204 a first receptacle
- 4206 a second receptacle
- 4208 a center support
- 4210 two sided walls
- 4212 back walls
- 4214 a floor
- 4216 a stamped hole
- 4218 a top hole
- 4220 a bottom protrusion
- 4300 a head element
- 4302 a foot element
- 4304 a left-side element
- 4305 cross supports element
- 4306 a right-side element
- 4308 vertical support legs
- 4310 a center spine support
- 4311 a side flange
- 4312 a first element portion
- 4314 a second element portion
DESCRIPTION OF THE DRAWINGS FIG. 1 illustrates a top left perspective view of an assembled mattress foundation and a box for shipping an unassembled mattress foundation according to the invention.
FIG. 2 illustrates a top left perspective view of the assembled mattress foundation shown in FIG. 1
FIG. 3 illustrates the front, bottom, left perspective view of the box shown in FIG. 1.
FIG. 4 illustrates a top rear perspective view of a left side vertical support, right side vertical support, central vertical support, and front horizontal support, each in an unfolded position.
FIG. 5 illustrates a top rear right perspective view of the left side vertical support and the front horizontal support shown in FIG. 4 shown attached to each other.
FIG. 6 illustrates a top elevational view of the central vertical support joined to two slats.
FIG. 7 illustrates a top elevational view of the central vertical support joined to slats and bundled horizontal slats.
FIG. 8 illustrates a top elevational view of the central vertical support joined to slats and bundled horizontal slats.
FIG. 9 illustrates a top, rear, right perspective view of the left side vertical support joined to the rear horizontal support with a cover shown in a draped position.
FIG. 10 illustrates the top, rear, right perspective view of a headboard plate being attached to the rear horizontal support shown in FIG. 9.
FIG. 11 illustrates the top rear perspective view of the headboard plate shown in FIG. 10.
FIG. 12 illustrates a top left perspective view of an assembled mattress foundation with first leg segments installed.
FIG. 13 illustrates the top left perspective view of the assembled mattress foundation shown in FIG. 12 with the first segments and second leg segments installed.
FIG. 14 illustrates the top left perspective view of the assembled mattress foundation shown in FIG. 12 with the first segments, the second leg segments, and third leg segments installed.
FIG. 15 illustrates a front perspective view of an unassembled mattress foundation.
FIG. 16 illustrates a left top perspective view of a king-size mattress foundation with a cover installed over the frame and a box for shipping the mattress foundation.
FIG. 17 illustrates the left rear top perspective view of the mattress foundation shown in FIG. 16 with the cover retracted from a front left corner of the frame.
FIG. 18 illustrates the left rear top perspective view of the mattress foundation shown in FIG. 16 with the first and second leg segments installed.
FIG. 19 illustrates a left top perspective view of a twin-size mattress foundation with a cover partially installed over the frame and a box for shipping the mattress foundation.
FIG. 20 illustrates the partial, left rear top perspective view of the twin-size mattress foundation shown in FIG. 19, with the first and second leg segments installed.
FIG. 21 illustrates a side elevational view of four legs.
FIG. 22 illustrates a table listing dimensions of mattress foundation sizes and respective packaging sizes.
FIG. 23 illustrates a partial rear elevational view of the mattress frame shown in FIG. 9 with the mounting plate in a horizontal position.
FIG. 24 illustrates the partial rear elevational view of the mattress frame shown in FIG. 9 with the mounting plate in a vertical position.
FIG. 25 illustrates a perspective view of a threaded T-nut.
FIG. 26 illustrates a partial top right perspective view of the left vertical support shown in FIG. 4 with a hinge in a locked position.
FIG. 27 illustrates a side elevational view of rails.
FIG. 28 illustrates a partial side elevation view of the rails shown in FIG. 27.
FIG. 29 illustrates a perspective view of a slat separated from a rail.
FIG. 30 illustrates a side elevational view of a leg with two leg segments.
FIG. 31 illustrates an exploded perspective view of the leg shown in FIG. 30.
FIG. 32 illustrates a front top right perspective view of a mattress frame.
FIG. 33 illustrates the partial rear bottom right perspective view of the mattress frame shown in FIG. 32.
FIG. 34 illustrates a bottom perspective view of a cover.
FIG. 35 illustrates a top elevational view of a second embodiment of a mounting plate.
FIG. 36 illustrates a right elevational view of the mounting plate shown FIG. 35.
FIG. 37 illustrates a rear elevational view of the mounting plate shown in FIG. 35.
FIG. 38 illustrates a left elevational view of the mounting plate shown in FIG. 35.
FIG. 39 illustrates the top front left perspective view of the mounting plate shown in FIG. 35.
FIG. 40 illustrates the front elevational view of the mounting plate shown in FIG. 35.
FIG. 41 illustrates the bottom elevational view of the mounting plate shown in FIG. 35.
FIG. 42 illustrates a close-up view of the mattress foundation showing the S-clips.
FIG. 43 illustrates a top perspective view of the mattress foundation.
FIG. 44 illustrates a close-up view of the mattress foundation showing the support as well as how the side elements connect to the side flange throughout the frame.
DETAILED DESCRIPTION FIG. 1-21 illustrate a preferred embodiment of a mattress foundation and the steps of a method for assembling the mattress foundation.
In one or more embodiments of the invention the first step includes a left side vertical support 10 to be unfolded and placed on a floor or an equivalent surface. A right side vertical support 11 is unfolded and placed parallel to the left side vertical support 10. A central vertical support 18 is unfolded and placed between the left side vertical support 10 and the right side vertical support 11. The word “vertical” is meant to mean longitudinal: i.e., running from front to back. The left side vertical support 10 has a left side front support 100. The right side vertical support 11 has a right side front support 110. A front horizontal support 12 is shown unfolded. “Horizontal” is mean to mean latitudinal; i.e., running from left to right. The front horizontal support 12 has a left support piece 120 and a right support piece 121.
FIGS. 4-5 illustrate the next step for assembling the mattress foundation. The front horizontal support 12 is connected to the right side vertical support 11. The left side front support 100 is placed against the left support piece 120. The right side front support 110 is placed against the right support piece 121. In addition, a threaded socket 1200 is formed in the left support piece 120 as well as the right support piece. A hole 1003 is formed in the left side front support 100. A bolt, which is not shown, is to be inserted through the hole 1003 and screwed into the threaded socket 1200. Similarly, the central vertical support 18 and the right side vertical support 11 are joined to the front horizontal support 12. In no particular sequence the rear horizontal support 13 is joined to the left vertical support 10, the right vertical support 11, and the central vertical support 18.
FIG. 6 illustrates a central vertical support 18 which has a resinous left seat 183 and resinous right seat 184. A left slat 16 is held in the left seat 183. A right slat 17 is held in the right seat 184. The left seat 183 and the right seat 184 are at a different height along the central vertical support 18.
In another embodiment, a preferred spacing between adjacent left slats 16 and adjacent right slats 17 is eighteen centimeters (18 cm).
FIG. 7-8 illustrates a left bundled slat 14 and a right bundled slat 15. The left bundled slat 14 includes four horizontal slats 140, 141, 142, 143, a left slat 16, a right slat 17 and a central vertical support 18. A left vertical slat 144 supports the four horizontal slats 140, 141, 142, 143. The right bundled slat 15 includes four horizontal slats 150,151, 152, 153. A right vertical slat 154 supports the four horizontal slats 150, 151, 152, 153.
In another embodiment a preferred spacing between adjacent horizontal slats 140, 141, 142, 143 in a left bundled slat 14 and the four horizontal slats 150, 151, 152, 153 in the right bundled slat 15 is eight and nine-tenths centimeters (8.9 cm).
FIG. 9 illustrate a rear horizontal support 13. The rear horizontal support 13 includes a right support piece 131, top support piece 133, and a bottom support piece 134. Bolts 50, 52, and 53 fasten the rear horizontal support 13 to the right-side vertical support 11. Threaded sockets 60, 61, 62 are disposed in the top support piece 133. Threaded socket 63 is formed in the right support piece 131. Threaded socket 64 is disposed in the bottom support piece 134.
FIGS. 10-11 illustrate a mounting plate 4 attached to the rear horizontal support 13. As explained in conjunction with FIGS. 35-41, the mounting plate 4 is placed with an outer third-edge slot 440 overlying threaded socket 64 and with outer first-edge slot 400 overlying threaded sockets 61 and 62. Bolts 54, 55, and 56 are inserted through outer first-edge slots 400 and outer third-edge 440 and screwed into overlying threaded sockets 62, 61, and 64.
FIGS. 12-14 illustrate a mattress foundation with different heights. Each figure illustrates different height sizes due to the different leg 3 lengths. In FIG. 12, each leg 3 includes a first leg segment 30. The first leg segment 30 includes a foot 300, a body 301, and a bolt (which is not visible in FIG. 12). The body 301 can be cylindrically, or rectangular shaped.
FIG. 15 illustrates an unassembled mattress foundation where all of the parts that make up the mattress foundation are unattached and are in a folded position. Included in the figure are the left side vertical support 10, the right-side vertical support 11, and the central vertical support 18 are shown in a folded position unattached to another part. The front horizontal support 12 and the rear horizontal support 13 are shown in a folded position. A plurality of legs 3 are shown. Left slats 16 and right slats 17 are shown. The Figure is intended to illustrate that all of the mentioned parts fit compactly within a box 7.
FIG. 16 illustrates an assembled frame 1 with a cover 2. A box 7 is shown. Also shown in FIG. 16 is a box 7 which houses all components that make up the bed mattress as listed in FIG. 15.
FIG. 17-18 illustrate a king-sized mattress foundation. A cover 2 is placed over the left vertical support 10 and the front horizontal support 12. The cover 2 includes a top 20, a rear 23, and a left 24. The rear 23 has a right rear opening 230 and a left rear opening 231 formed therein. The right rear opening 230 and the left rear opening 231 provide access to the mounting plates 4.
FIG. 19 illustrates a twin-sized mattress foundation. In the figure a left top perspective view of a twin-size mattress foundation is illustrated with a cover partially installed over the frame and a box for shipping the mattress foundation.
FIG. 20 illustrates the partial, left rear top perspective view of the twin-size mattress foundation shown in FIG. 19, with the first and second leg segments installed. The Figure also illustrates a cover 20 that includes a rear 23 and left 24. The rear 23 has a left rear opening 231 formed therein that provides access to the mounting plate 4. A leg 3 is shown with first leg segment 30 and second leg segment 31.
FIG. 21 illustrates legs 3 that include first segment 30 and second segment 31. The first segment 30 includes a foot 300 and a body 301. The second segment 31 includes a body 311 and a threaded bolt 312.
FIG. 22 illustrates a table listing dimensions of mattress foundation sizes and respective packaging sizes. In this table different mattress widths, lengths, heights, and weights are included. In addition, box widths, lengths, and heights are also included. Each of the different dimensions discussed above are included for different respective packaging sizes such as Twin, Twin XL, Full, Queen, King, California King and Split King. The inclusion of different packaging sizes allows for the transport of compact bed mattress Foundations to a variety of users with different weights and heights. The flexibility of compact packings of different mattress foundation sizes allows users access to a bed mattress foundation of their choice no matter their weight and/or height.
FIG. 23 illustrates a mounting plate 4 secured to a rear horizontal support 13. Bolt 54 and bolt 55 are inserted through slots in the mounting plate 4. The mounting plate 4 is oriented but not limited to a landscape position with the larger dimension being horizontal and the shorter dimension being vertical.
FIG. 24 illustrates a mounting plate 4 secured to a rear horizontal support 13. Bolts 61 and 64 are inserted through slots in the mounting plate 4. The mounting plate is in a portrait position, with the larger dimension being vertical, and the smaller dimension being horizontal. The cutout avoids interference with the threaded socket 62.
FIG. 25 illustrates an inner-threaded bolt 8. The inner-threaded bolt 8 has a head 80 and a body 81. A threaded bore 82 is formed axially through the head 80 and the body 81.
FIG. 26 illustrates a hinge 9. The hinge 9 includes a first leaf 90 and a second leaf 91. A plurality of hinges 92 and 93 alternate along the length of the hinge 9. A hinge pin 94 is inserted through the hinges 92 and 93. The first leaf 90 is welded to frame support 95. The second leaf 91 is welded to the frame support 96. When the hinge 9 is open, a cotter bolt 97 is driven through the frame support 95 and frame support 96. A lock nut 98 secures the cotter bolt 97.
FIGS. 27-28 illustrates a left slats 16 and right slats 17. The left stats 16 and the right stats 17 are extruded, hollow rectangular tubes. The slats have a plurality of rectangular notches 160 and 170 formed therein.
FIG. 29 illustrates a top support piece 185 of a central vertical support 18. A left resinous seat 183 and a resinous right seat 184 are held in a form locking connection within rectangular notches in the vertical support 18. The left resinous seat 183 and the right resinous seat 184 are made from a resin. A left slat 16 has an endpiece 162 that rests in the left resinous seat 183. The left slat 16 has a notch 161 that defines the endpiece 162. The notch 161 receives a cutout edge 163. The sides of the notch 161 are exact.
FIGS. 30-31 illustrate a leg 3, which includes a first leg segment 30 and a second leg segment 31. The first leg segment 30 has a foot 300, a body 301, and a bolt extending vertically from the cylindrical body 301.
FIGS. 32-33 illustrate an assembled frame 1. See also FIG. 4. A rear left flange 135 is connected to the bottom support piece 134. A middle-left flange 105 is connected to the bottom support piece 104. A front left flange 106 is connected to the bottom support piece 134. A front right flange 125 is connected to the bottom support piece 134. A front middle flange 127 is connected to the bottom support piece 134. The middle right flange 115 is connected to the bottom support piece 134. The rear right flange 116 is connected to the bottom support piece 134. Each flange 105, 106, 115, 116, 125, 127, and 135 is horizontal (i.e., parallel to the ground) and extends inward. A threaded hole is drilled in 1050, 1060, 1150, 1250, and 1350 is formed in each respective flange 105, 106, 115, 116, 125, and 135.
FIG. 34 illustrates a preferred embodiment of a cover 2. The cover has a front 21, a right 22, and a bottom 25. The bottom has a reinforced opening 250. The reinforced opening 250 is centered 2.5 cm from the front 21 and right 22 so the opening overlies the threaded hole 1250 in the front right flange 125. After the frame 1 is assembled but before the legs 3 are attached, the cover 2 is placed over the frame 1. The threaded bolt 312 of the leg 3 is fed through the reinforced opening 250 and screwed into the threaded hole 1250.
FIGS. 35-41 illustrate a second preferred embodiment of a mounting plate 4. The mounting plate 4 is preferably made of steel and has a generally (except for the recessed segments 42 and 46) rectangular shape. FIG. 40 shows a perimeter of the mounting plate 4, which includes a first edge segment 40, which connects to a second edge 41, which connects to a third edge tab segment 47, which connects to a lateral third-edge-recess wall 422, which connects to a recessed third edge segment 42, which connects to a medial third-edge-recess wall 421, which connects to a third edge segment 44, which connects to a fourth edge segment 45, which connects to a first edge tab segment 48, which connects to a lateral first-edge-recess wall 462, which connects to a first edge recessed segment 46, which connects to a medial first-edge-recess wall, which connects to the first edge segment 40. The mounting plate 4 has the following discorectangular (also referred to as stadium-shaped) slots formed therein: outer first-edge slot 400, inner first-edge slot 401, first-edge-side outer second-edge slot 410, first-edge-side inner second-edge slot 411, third-edge-side outer second-edge slot 412, third-edge-side inner second-edge slot 413, recessed-third-edge slot 420, outer third-edge slot 440, inner third-edge slot 441, third-edge-side outer fourth-edge slot 450, third-edge-side inner fourth-edge slot 451, first-edge-side outer fourth-edge slot 452, first-edge-side inner fourth-edge slot 453, and recessed-first-edge slot 460.
FIGS. 42-44 illustrate a mattress All-In-One metal foundation that assembles quickly without any tools, ships in a small Fedex/UPS package, fits easier on a skid in a retail store, and allows an end customer to take it home in a car. It holds at least 2500 lbs. of weight, allows for easy attachment of a headboard of various dimensions, has an attractive optionable, washable and detachable outer stylish cover, and is designed to allow of up to 12″ of underneath storage. Also has stamped holes 4216 for receipt of the cross slats and a bespoken plastic clip for adjoining the cross slats.
More specifically, FIG. 42 illustrates an attachment clip 4200 on the center support 4208 for adjoining the cross slats 4202 as such is configured in accordance with one or more embodiments of the invention. The attachment clip 4200 is configured to fit into punched holes or other anchoring elements within a center support 4208. The attachment clip 4200 contains a bottom protrusion 4220 that fits within a top hole 4218. In addition, the attachment clip 4200 contains a first receptacle 4204 and a second receptacle 4206 within which cross slats (4202) fit. It should be noted that the first receptacle 4204 and the second receptacle 4206 are configured to be on opposing sides. The first and second receptacles (4204 and 4206) are oriented to vertically receive the cross slats 4202 in one or more embodiments of the invention. The receptacles may, however, be configured to receive cross slats 4202 horizontally if desired. Each receptacle utilizes two side walls 4210, a back wall 4212 and floor 4214 to hold the cross slat 4202 in position. The cross slat 4202 is placed into the receptacle via an open top albeit in an alternative embodiment of the invention the top may be close such that the cross slat 4202 is inserted into the receptacle. The receptacle openings are placed on opposing sides to enable cross slats 4202 to be placed in them on a first side and second side or right and left when the bed frame is horizontal.
Each attachment clip 4200 may utilize flanges on each side to minimize side to side movement once the cross slat 4202 is placed into position. Downward flanges may also be incorporated into the attachment clip 4200 to better secure the clip onto the center support 4208. The attachment clip 4200 which couples with the center support 4208 is formed of durable plastic in one embodiment of the invention maybe formed using any material suitable for supporting the cross slats 4202. The advantage of having the configuration described herein is that because the attachment clips 4200 are removeable and the cross slats 4202 and other components of the bed frame 1 can be broken down into a shippable length, freight costs, storage needs, and other important business aspects are furthered in a desirable manner.
FIG. 43 illustrates a bed frame with a cross slats 4202, head element 4300, foot element 4302, a left-side element 4304, a cross support element 4305, a right-side element 4306, and stamped holes 4216 as it is configured in accordance with one or more embodiments of the invention. The head element 4300, cross slats 4202 and foot element 4302 are bisected and have ends placed over vertical support legs 4308 located at each corner of the assembled bed frame. A a center spine support 4310 also links into additional vertical support legs 4308 to provide extra support for the middle portion of the frame. These vertical support legs 4308 are placed under the head element 4300, foot element 4302, left-side element 4304, cross support element 4305, and right-side element 4306 as needed for support. In one or more embodiments of the invention such vertical support legs 4308 are on each corner of the frame and also placed along the center support spine 4310 which is oriented in the center of the frame. These center support 4208 members serve to elevate the bed frame to a desired height and support the body weight of a user. The head element 4300, cross support element 4305 and foot element 4302 couple with or rest upon the vertical support legs 4308 and sit flush with the height of the attachment clips 4200 and cross slats 4202 so that a flat surface is created. The attachment clips 4200 attach to the cross slats 4202 in a vertical manner thereby providing a structural strength to the overall frame 1 The head element 4300, foot element 4302, left-side element 4304, cross support element 4305, and right-side element 4306 may be shipped in a first element portion 4312 and a second element portion 4314 so that there are separate pieces which adjoin at the center support spine 4310 and the cross support element 4305. The pieces may be separable or hinged together but in either instance can be broken down to minimize the package size required to ship the frame. The vertical support legs 4308 may be constructed with a side flange 4311 upon which the second element portion 4314 sits. The side flange 4311 is configured to interlock with the second element portion 4314 thereby providing a strong connection between right-side element 4306, the left-side 4304 element, the head element 4300 and the foot element 4302. This interlocking connection between the side flange and the second element portion is illustrated in FIG. 4 This strong connection in turn mitigates undesired movement of the frame 1 when a person is shifting their weight on the bed. Alternatively, the vertical support legs 4308 may be configured in other ways to receive the elements of the bedframe required for support. In one embodiment the support legs 4308 can be welded onto the frame corners of the frame 1. This means that in this embodiment there will be nine support legs 4308 that are welded to the frame 1. A hole or receptacle may be placed in the vertical support structure 4308 within which an end of the bed frame element may fit. A yoke or other such way to secure the bed frame elements may also be utilized. A core aspect of the invention is that the pieces are easily disassembles and assembled for shipment. When assembled the bed frame utilizes support legs that provide at least 10 inches of clearance from the ground level. The assembled frame 1 is able so support at least 2,500 pounds of distributed load when weight is placed upon it.
Thus, shippable mattress foundation has been described. The reader should note however that the claims set forth below and the full scope of their equivalents are what define the scope of the invention.
