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The present invention relates generally to beds. More particularly, the invention relates to mattress foundations for supporting and elevating mattresses.
A typical bed comprises a mattress, a mattress foundation, and a frame. The frame rests on the floor, and supports and constrains the foundation in the vertical and horizontal directions. Foundations are typically constructed at standard heights of seven or nine inches. The mattress rests on the foundation, and is elevated by the combination of the foundation and the frame.
Certain types of mattresses, such as foam mattresses, can be compressed and packaged in relatively compact shipping containers. The ability to package a mattress in this manner can facilitate shipment of the mattress from the manufacturer to the end user by a commercial package-delivery service.
The design and construction of a typical mattress foundation necessitates shipping the foundation from the manufacturer in its final, i.e., ready to use, configuration. The relatively large volume and the rigidity of a typical mattress foundation can make it prohibitively expensive to ship the foundation to the retailer or the end user using a commercial package-delivery service. Thus, it is usually not feasible to ship the foundation directly from the manufacturing facility to the end user. Moreover, retailers often need to maintain their own delivery service to transport the foundation to the end user, adding substantially to the retailer's operating expenses. Also, maintaining an inventory of mattress foundations can require relatively large amounts of space within a warehouses or other storage facilities of the retailer and the manufacturer, further increasing operating expenses.
Mattress foundations and bed frames may or may not be purchased separately by the end user, from different retailers. Retailers commonly obtain foundations and frames from different manufacturers, and maintain separate inventories of foundations and frames. The need to procure and store foundations and frames separately can increase to the operating expenses of the retailer.
An ongoing need therefore exists for a mattress foundation that can be shipped and stored in a relatively compact configuration, and that is suitable for use with or without a frame.
A mattress foundation has a modular configuration that permits the mattress foundation to be packaged in an unassembled state, in a relatively compact shipping container. The mattress foundation can be used to elevate a mattress with or without the use of a frame.
Embodiments of modular mattress foundations comprise a first and a second header; a first side rail removably attached to the first and second headers; a second side rail removably attached to the first and second headers; and a support removably attached to the first and second side rails.
Methods comprise providing a modular mattress foundation; packaging the modular mattress foundation in an unassembled state at a first location; and sending the modular mattress foundation to a second location in the unassembled state.
Other methods comprise receiving an order for a modular mattress foundation from a purchaser, and sending the modular mattress foundation to the purchaser in an unassembled condition.
Embodiments of mattress foundation kits comprise a header, a side rail capable of being removably attached to the header, and a support capable of being removably attached to the side rail.
The foregoing summary, as well as the following detailed description of embodiments, are better understood when read in conjunction with the appended diagrammatic drawings. For the purpose of illustrating the embodiments, the drawings diagrammatically depict specific embodiments. The appended claims are not limited, however, to the specific embodiments disclosed in the drawings. In the drawings:
FIG. 1 is a top view of an embodiment of a modular mattress foundation in an assembled condition;
FIG. 2 is a top perspective view of the mattress foundation shown in FIG. 1, in the assembled condition;
FIG. 3 is a side view of the mattress foundation shown in FIGS. 1 and 2, in the assembled condition;
FIG. 4 is a front view of the mattress foundation shown in FIGS. 1-3, in the assembled condition;
FIG. 5 is a top view of a header of the mattress foundation shown in FIGS. 1-4;
FIG. 6 is a side view of a side rail of the mattress foundation shown in FIGS. 1-5;
FIG. 7 is a top view of the side rail shown in FIG. 6;
FIG. 8 is a side view of a lateral support of the mattress foundation shown in FIGS. 1-7;
FIG. 9 is a front view of the lateral support shown in FIG. 8;
FIG. 10 is a top view of a center support of the mattress foundation shown in FIGS. 1-9;
FIG. 11 is a side view of the center support shown in FIG. 10;
FIG. 12 is a front view of a bracket of the mattress foundation shown in FIGS. 1-11;
FIG. 13 is a top view of the bracket shown in FIG. 12;
FIG. 14 is a perspective view of a channel of the mattress foundation shown in FIGS. 1-13;
FIG. 15 is a perspective view of an attachment block of the mattress foundation shown in FIGS. 1-14;
FIG. 16 is a perspective view of a support block of the mattress foundation shown in FIGS. 1-15;
FIG. 17 is a top view of a radius block of the mattress foundation shown in FIGS. 1-16;
FIG. 18 is a perspective view of the radius block shown in FIGS. 1-17; and
FIG. 19 is a perspective view of the mattress foundation shown in FIGS. 1-18, in a disassembled condition; and a box that receives the mattress foundation in the unassembled condition.
FIGS. 1-19 depict an embodiment of a mattress foundation 10. The mattress foundation 10 can be used to support and elevate a mattress 14. The mattress 14 is shown in phantom in FIG. 3. The mattress foundation 10 and the mattress 14 form a bed 16. The mattress foundation 10 can be used in connection with any type of mattress, including but not limited to foam mattresses, futon mattresses, and spring-unit mattresses.
The mattress foundation 10 comprises a first header 20 and a second header 22. The first and second headers 20, 22 form the ends of the mattress foundation 10, as shown in FIGS. 1-3. The mattress foundation 10 also comprises a first side rail 24 and a second side rail 26 positioned on opposite sides of the mattress foundation 10. Opposing ends of the first side rail 24 are attached to the respective first and second headers 20, 22. Opposing ends of the second side rail 26 likewise are attached to the respective first and second headers 20, 22.
The first and second headers 20, 22 each comprise an upper member 30 and a lower member 32. The upper and lower members 30, 32 are substantially flat, as shown in FIG. 4. Outer corners 34 of the upper and lower members 30, 32 can be rounded, as depicted in FIG. 5.
Directional terms such as “upper,” “lower,” “above,” and “below” are used with reference to the component orientations depicted in FIG. 3. These terms are utilized for exemplary purposes only, and are not intended to limit the scope of the appended claims.
Each of the first and second headers 20, 22 also comprises two support blocks 36 positioned between the upper and lower members 30, 32, as shown in FIGS. 4 and 16. The support blocks 36 are secured to the upper and lower members 30, 32 of the associated first or second header 20, 22 by a suitable means such as screws.
The first and second headers 20, 22 each include an outwardly-facing end support 40 positioned between the upper and lower members 30, 32, as shown in FIGS. 2 and 4. The end support 40 is secured to the upper and lower members 30, 32 of the associated first or second header 20, 22 by a suitable means such as screws.
The first and second headers 20, 22 each include two radius blocks 42, depicted in FIGS. 2-4, 17, and 18. Each radius block 42 is positioned between the upper and lower members 30, 32 of the associated first or second header 20, 22, proximate the corners 34 thereof. The radius blocks 42 are secured to the upper and lower members 30, 32 by a suitable means such as screws. Each radius block 42 includes a substantially straight portion 44, and a curved portion 46 unitarily formed with the straight portion 44. The curved portion 46 of each radius block 42 substantially aligns with the corners 34 of the associated first or second header 20, 22. The curved portions 46 each have a radius of curvature approximately equal to the radius of curvature of the corners 34.
The upper and lower members 30, 32, support blocks 36, end supports 40, and radius blocks 42 are sized so that the first and second headers 20, 22 each have a height, i.e., vertical dimension, of approximately nine inches. Alternative embodiments can be configured so that the first and first and second headers 20, 22 each have a height greater or less than nine inches.
Each of the first and second headers 20, 22 also includes two attachment blocks 50 positioned between the upper and lower members 30, 32, proximate the inwardly-facing, i.e., non-rounded, corners thereof. The attachment blocks 50 are depicted in FIGS. 3 and 15. The attachment blocks 50 can be secured to the upper and lower members 30, 32 of the associated first or second header 20, 22 by a suitable means such as screws. The attachment blocks 50, as discussed below, facilitate attachment of the first and second headers 20, 22 to the first and second side rails 24, 26.
The upper and lower members 30, 32, support blocks 36, end supports 40, radius blocks 42, and attachment blocks 50 of the first and second headers 20, 22 can be formed from a suitable material such as oriented strand board, commonly referred to as “OSB.” Other materials, including engineered and non-engineered woods, plastics, and metallic materials, can be used in the alternative.
Each of the first and second headers 20, 22 also includes three ground-support members, or legs 56. The legs 56 are mounted on the lower members 32 of the first and second headers 20, 22, proximate the outer end thereof. The legs 56 can be secured to the lower members 32 by a suitable means such as T-nuts (not shown) mounted in each leg 56, and complementary bolts (also not shown) that extend through holes formed in the lower member 32. The legs 56 can be formed from wood, plastic, or other suitable materials. Each of the first and second headers 20, 22 can include more, or less than three of the legs 56 in alternative embodiments.
The legs 56 make it possible to place the mattress foundation 10 directly on the floor while elevating the mattress 12 to a standard height above the floor. The mattress foundation 10 can thus function as both a foundation and a frame, i.e., the use of the mattress foundation 10 can obviate the need for a frame. Alternatively, the foundation system 10 can be installed in a frame, without the legs 56. The foundation system 10 can also be placed directly on the floor without the legs 56, in applications where a relatively low mattress height is desired by the end user.
The first and second headers 20, 22 can be configured for use with a headboard and a footboard (not shown). More particularly, the mattress foundation 10 can include four brackets 60 capable of being attached to the first and second headers 20, 22. The brackets 60 are depicted in FIGS. 12 and 13. The brackets 60 can be formed from a suitable material such as aluminum or steel. Each bracket 60 has a curved portion 62. The radius of curvature of the curved portion 62 substantially matches the radius of curvature of the corners 34 of the upper and lower members 30, 32.
Each curved portion 62 has holes 64 formed therein. The holes 64 receive fasteners (not shown) that secure the bracket 60 to the corner 34 of the upper member 30 of an associated first or second header 20, 22. The bracket 60 can be secured to the corner 34 of the lower member 32 in the alternative, in applications wherein the heights of the attachment points on the headboard or footboard are relatively low.
Each bracket 60 also includes a substantially flat intermediate portion 66 that adjoins the curved portion 62, and a substantially flat attachment portion 68. The attachment member 68 adjoins, and is substantially perpendicular to the intermediate member 66. The attachment member 68 has a plurality of horizontally-oriented slots 70 and a round hole 71 formed therein. The slots 70 are stacked vertically, from the perspective of FIG. 12. The slots 70 receive fasteners (not shown) that secure the headboard or footboard to the bracket 60 and the remainder of the mattress foundation 10. The use of multiple, vertically-stacked slots 70 and the hole 71 can accommodate headboards and footboards of different heights. The slots 70 also facilitate adjustment of the relative positions of the mattress foundation 10 and the headboard or footboard in the lateral direction.
The first and second side rails 24, 26 each comprise an elongated main portion 76, as shown in FIGS. 1-3, 6, and 7. Each side rail 24, 26 also includes a sill 78 secured to a lower edge of the main portion 76 by a suitable means such as screws. The height, i.e., vertical dimension, of each side rail 24, 26 is approximately equal to the height of the first and second headers 20, 22.
The side rails 24, 26 also include a plurality of channels 80, depicted in FIGS. 6, 7, and 14. Each channel 80 is secured to an inwardly-facing surface of the main portion 76 of the associated side rail 24, 26, by a suitable means such as screws. The channels 80 can be formed from plastic, or other suitable materials.
Each of the first and second side rails 24, 26 also includes two attachment blocks 82 positioned at the opposing ends thereof. The attachment blocks 82 are substantially identical to the attachment blocks 50, and are depicted in FIGS. 3 and 15. The attachment blocks 82 can be secured to the main portion 76 and the sill 78 of the associated first or second side rail 24, 26 by a suitable means such as screws. Each of the attachment blocks 82 aligns with an associated attachment block 50 of the first or second header 20, 22, as shown in FIG. 3. The attachment blocks 82 can be secured to the associated attachment blocks 50 by a suitable means such as bolts and wing nuts, to removably attach the first and second headers 20, 22 to the first and second side rails 24, 26.
The term “removably attached,” as used throughout the specification and claims with reference to two or more components, means that the components are secured to each other in a manner that permits the components to be separated without damaging or permanently deforming the components or any fasteners, brackets, etc. used to secure the components to each other.
The first and second headers 20, 22 can be removably attached to the first and second side rails 24, 26 by interlocking joints in alternative embodiments.
The main portions 76, sills 78, and attachment blocks 82 of the first and second side rails 24, 26 can be formed from a suitable material such as oriented strand board. Other materials, including engineered and non-engineered woods, plastics, and metallic materials can be used in the alternative.
The first and second side rails 24, 26 can each include two of the legs 56. The legs 56 can be mounted on the sill 78 of the associated first and second side rails 24, 26, in the manner discussed above in relation to the legs 56 of the first and second headers 20, 22. Each of the first and second headers 20, 22 can include more, or less than three of the legs 56 in alternative embodiments. The mattress foundation 10, as discussed above, can be utilized without the legs 56 at the discretion of the end user.
The mattress foundation 10 also comprises a plurality of lateral supports 83, depicted in FIGS. 1, 2, 8, and 9. Each lateral support 83 includes an elongated slat 84, and a brace 85. A groove 86 can be formed in the bottom of each slat 84, as shown in FIG. 9. The groove 86 receives an upper end of an associated brace 85. The brace 85 is attached to the slat 84 by a suitable means such as screws.
The lateral supports 83 can be removably attached to the first and second side rails 24, 26. In particular, the ends of each brace 85 can be placed in an associated channel 80 of the first or second rail 24, 26. The channels 80 are sized to receive and constrain the ends of the braces 85. The bottom of each end rests on the sill 78 of the associated first or second side rail 24, 26 when the ends are fully inserted into the channels 80.
The number of channels 80 mounted on each of the first and second side rails 24, 26 matches the number of lateral supports 83 used in the mattress foundation 10. The number of channels 80 mounted on first and second side rails 24,26 of alternative embodiments can be greater than the number of lateral supports 83. This arrangement can provide the end user with greater flexibility in placing the lateral supports 83 in the optimal positions for a particular type of mattress 14.
The lateral supports 83 and the first and second headers 20, 22 provide the surfaces that support the mattress 12. The lateral supports 83 also function as cross braces that add rigidity to the mattress foundation 10.
The main portions 76 of first and second side rails 24, 26 can have inwardly-facing slots formed therein in lieu of the channels 80, for receiving and constraining the ends of the braces 85.
The mattress foundation 10 is depicted with six of the lateral supports 83 for exemplary purpose only. The optimal number of lateral supports 83 is application-dependent, and can vary with factors such as the overall dimensions of the mattress foundation 10, and the anticipated maximum weight that the mattress foundation 10 will support.
The mattress foundation 10 further comprises a center support 90, depicted in FIGS. 1, 10, and 11. The center support 90 is removably attached the bottoms of some or all of the bracing members 84, by a suitable means such as screws. The center support 90 extends substantially parallel to the first and second side rails 24, 26, and adds rigidity to the mattress foundation 10. One or more of the legs 56 can be attached to the center support 90, in the manner discussed above in relation to the legs 56 of the first and second headers 20, 22.
The lateral supports 83 and the center support 90 can be formed from a suitable material such as oriented strand board. Other materials, including engineered and non-engineered woods, plastics, and metallic materials can be used in the alternative.
The mattress foundation 10 can optionally be configured with drawers 102. The drawers 102 are depicted in phantom in FIG. 3. The drawers 102 can be suspended from the first and second side rails 24, 26 or the first and second headers 20, 22 by a suitable means such as sliding brackets 104. Alternatively, the drawers 98 can be rest directly on the floor, without any support from the remainder of the mattress foundation 10.
The modular construction of the mattress foundation 10 can permit the mattress foundation 10 to be packaged in an unassembled state. More particularly, the first and second headers 20, 22, the first and second side rails 24, 26, the lateral supports 83, the center support 90, and the various associated fasteners can be placed in a relatively compact shipping container, such as a cardboard box 92 having an appropriate load rating. The box 92 is depicted in FIG. 19. Packing materials such as polystyrene can be used to immobilize and cushion the components of the mattress foundation 10 within the box 92.
Shipping containers other than cardboard boxes can be used in the alternative. For example, a plastic case can be used as the shipping container. Alternatively, the unassembled components of the mattress foundation 10 can be packaged by wrapping the components together in shrink wrap or other suitable materials.
The first and second headers 20, 22, the first and second side rails 24, 26, the lateral supports 83, and the drawers 102 (if applicable) can be assembled by the manufacturer prior to being boxed or packaged, with the exception of the legs 56. The legs 56 can be placed in the box 70 separately, to help reduce the overall volume of the unassembled mattress foundation 10. The center support 90 can likewise be packed without the associated legs 56 attached thereto.
The end user or another individual can assemble the mattress foundation 10 after the mattress foundation 10 has been transported to the end user's home or other location of use. Following unpacking, the first and second headers 20, 22, the first and second side rails 24, 26, the lateral supports 83, and the center support 90 can be removably attached to each other as discussed above, and the legs 56 can be installed on their associated components. Assembly instructions can be provided with the mattress foundation 10 to assist the assembly thereof. It should be noted that the mattress foundation can also be shipped in an assembled condition, if desired.
The components of the mattress foundation 10 can be stacked or otherwise arranged within the box 92 so as to minimize the combined overall dimensions of its component parts. The size of the box 92 can therefore be substantially less than the size of the assembled mattress foundation 10. Thus, the volume of warehouse or other storage space needed to accommodate an inventory of the mattress foundations 10 is relatively low in comparison to that required to accommodate an equivalent number of conventional mattress foundations.
The ability to package the unassembled mattress foundation 10 in a relatively compact shipping container such as the box 92 can facilitate shipping the mattress foundation 10 via a commercial package-delivery service. The use of the mattress foundation 10 can thereby eliminate the need for a retailer or other supplier to maintain its own delivery service.
The use of a commercial package-delivery service to ship the mattress foundation 10 to the end user can potentially lessen delivery time, i.e., the time period between the order and delivery of the mattress foundation 10. Moreover, the use of a commercial package-delivery service can eliminate the need for a retailer or other supplier to maintain regional distribution facilities. Instead, the mattress foundations 10 can be shipped directly from a single distribution point, such as a centrally-located distribution center or the place of manufacture, to any location served by the package-delivery service. The ability to ship from a single, centralized distribution point via a commercial package-delivery service can be particularly beneficial to retailers that rely on e-commerce/internet-based sales for a substantial portion of their business.
The use of the mattress foundation 10 can also eliminate the need for a separate frame. In particular, the legs 56 can elevate the upper surfaces of the mattress foundation 10 to a level suitable for supporting the mattress 12 at a desired height. The end user can be given the option of purchasing the mattress foundation 10 with legs 56 sized to provide a particular elevation for the mattress 14. Alternatively, the mattress foundation 10 can be packaged with two or more sets of legs 56, where the legs 56 of each set have a length different than the legs 56 of the other set. The user can select and install the set of legs 56 that elevate the mattress 12 to the particular height desired by the user.
The foregoing description is provided for the purpose of explanation and is not to be construed as limiting. While the embodiments have been described with reference to specific embodiments or methods, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Furthermore, although particular embodiments and methods have been described herein, the appended claims are not intended to be limited to the particulars disclosed herein. Those skilled in the relevant art, having the benefit of the teachings of this specification, may effect numerous modifications to the embodiments and methods as described herein, and changes may be made without departing from the scope of the appended claims.
For example, the mattress foundation 10 depicted herein is suitable for use with a queen-size mattress 14. Alternative embodiments can be configured for use with mattresses of other sizes.