CROSS-REFERENCE TO REEATED APPLICATION

This application claims the benefit of U.S. Provisional Application Number 63/064,860, filed August 12, 2020, the entire contents of which is incorporated by reference herein.

FIELD OF THE DISCLOSURE

The present disclosure relates to furniture for supporting a mattress. More specifically, the present disclosure relates to a bed foundation having a framework and platform base for supporting a mattress.

BACKGROUND

Ready to assemble furniture can be purchased by or delivered to consumers in boxes. Ease of assembly, robustness of the design, ease of manufacturing the unassembled components, cost to manufacture, consumer cost, and simplicity are all desirable attributes for ready to assemble furniture articles.

SUMMARY OF THE INVENTION

A bed foundation for supporting a mattress comprises a framework having a rectangular footprint, the framework supporting a platform base. The framework comprising a headboard panel, a footboard panel, and a pair of side bed rails connecting to the headboard panel and footboard panel and defining framework comers. The platform base comprising a spanning pocketed tarp of flexible material with elongate pockets conformingly sized for receiving a plurality of cross slats. Each cross slat having a pair of opposing connecting portions extending out of open ends of the pockets, each connecting portion secured to one of the side bed rails such as by screws into a mounting strip. The slats are spaced to provide a flat planar surface of the pocketed tarp for receiving a mattress.

A bed foundation kit includes framework pieces, a pocketed tarp, and a multiplicity of slats. The framework pieces comprise a footboard panel, a headboard panel, and a pair of side bed rails, the footboard, the headboard, the pair of side bed rails connectable into a rectangular framework defining an area therein. The pocketed tarp has a pair of side margins, and a pair of end margins, the tarp formed of a rectangular shaped sheet material, the tarp having a top side and a bottom side, the pocketed tarp having a multiplicity of pockets formed on the bottom side, the pockets extending from side margin to side margin. The multiplicity of slats are conformingly sized for the multiplicity of slats, each slat having a length longer than a side margin to side margin width of the pocketed tarp.

The bed foundation kit may include a set of instructions and a box. The box may the framework pieces, the pocketed tarp, the multiplicity of slats, and the instructions. The kit may further include a hardware kit. The hardware kit may include a plurality of threaded fasteners, a plurality of angled brackets, and one or more tools. The hardware kit may be included in the box. The bed foundation kit may include one or more center support legs. The bed foundation kit may include one or more center support slats, the one or more center support slats assembleable to extend from the footboard panel to the headboard panel of the rectangular framework.

A bed foundation according to embodiments of the invention may include a footboard panel opposite a headboard panel, the footboard panel having a first end fastened to a first end of a first side bedrail and a second end fastened to a first end of a second side bedrail. The headboard panel has a first end fastened to a second end of the first side bedrail and a second end fastened to the second end of the second side bedrail, such that the footboard panel, headboard panel, and two side bedrails define an approximately rectilinear bed frame having four corners. The foundation further comprising four legs or feet, wherein a respective foot or leg is fastened to each corner elevating the bed frame off the ground, a platform base configured to fit within the bed frame. In embodiments, the platform base may include a slat roll having a plurality of cross slats. In embodiments, the platform base may include a fabric upward facing surface and a plastic downward facing surface, the downward facing surface having a plurality of equidistant traverse pockets, each pocket configured to receive and a cross slat, and a plurality of cross slats received in the plurality of traverse pockets, and wherein each cross slat has a first connecting portion is fastened to the first bedrail and a second connecting portion is fastened to the second bedrail.

In embodiments, the bed foundation may include one or more center supports, each of the one or more center supports having a mounting portion fastened to a cross slat. The mounting portion of the one or more center supports is configured to receive one more center slats such that the center slats are generally perpendicular to the cross slats. The mounting portion may include one or more “U” shaped brackets having a first open end facing the footboard panel and a second open end facing the headboard panel. The bed foundation may have a first center slat extending from a first center support to a second center support, and a second center slat extending from the second center support to a third center support, such that the first and second center slats are on opposite sides of the second center support.

A foundation tarp for a bed assembly includes a sheet of fabric having an upward side opposite a bottom side, a top edge opposite a bottom edge, and a left edge opposite a right edge, and a multiplicity of pockets each configured to receive a slat extending from the left edge to the right edge of the sheet of fabric. The foundation tarp may include a multiplicity of slats, such that each slat has a length greater than a width of the planar sheet, where the width is measured from the left edge to the edge. The upwards side of the planar sheet may comprise a polyester fabric and a bottom side of the planar sheet may comprise a plastic coating. The plastic coating may be a polyvinylchloride plastic coating. Each of the multiplicity of pockets may have a first opening at the left edge of the planar sheet and a second opening at the right edge of the planar sheet. The planar sheet may include one or more apertures approximately centrally located between the left and right edges. The one or more pockets may include corresponding apertures such that a fastener may extend through the planar sheet and the pocket. The slat may include a corresponding aperture such that when the slat is situated within the one or more pockets the fastener may extend through the planar sheet, the slat, and the one or more pockets. The planar sheet may have a length and width generally corresponding the length and width of one of a queen sized mattress, a full sized mattress, a king sized mattress, or a California king sized mattress.

A method of assembling a ready to assemble platform bed kit having framework pieces; a pocketed tarp having a pair of side margins, and a pair of end margins, the tarp formed of a rectangular shaped sheet material, the tarp having a top side and a bottom side, the pocketed tarp having a multiplicity of pockets formed on the bottom side, the pockets extending from side margin to side margin; and a multiplicity of slats conformingly sized for the multiplicity of slats, each slat having a length longer than a side margin to side margin width of the pocketed tarp, the method includes connecting framework pieces into a rectangular framework; inserting each of the multiplicity of slats into corresponding pockets of the pocketed tarp; and securing exposed portions of the multiplicity of slats extending beyond a side margin of the tarp to the pair of side bed rails. The method may further include affixing one or more central support legs to the multiplicity of slats; and sliding one or more central slats through corresponding brackets of the one or more central support legs.

The framework pieces may include a footboard panel, a headboard panel, and a pair of side bed rails. The pocketed tarp may have a top side and a bottom side, the pocketed tarp having a multiplicity of pockets formed on the bottom side, the pockets extending from side margin to side margin. The ready to assemble platform bed kit may include a box. The method may further include removing the framework pieces, the multiplicity of slats, and the pocketed tarp from the box.

A feature and advantage of embodiments is a platform base having slats but also presenting a flat surface of the tarp that receives a mattress. The tarp may be stretched during assembly to have material between adjacent slats be relatively taut.

A feature and advantage of embodiments is an easy to assemble bed foundation kit that has a tarp that provides spacing for connecting slat ends, slat connection portions, to side bed rails.

A feature and advantage of embodiments is an adjustable and easy to assemble central support structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front perspective view of an assembled bed foundation assembly according to embodiments of the invention.

FIG. IB is an exploded front perspective view of a bed foundation assembly according to embodiments of the invention.

FIG. 1C is a perspective view of a box containing a disassembled bed foundation assembly according to embodiments of the invention.

FIG. 2 is a perspective of a footboard panel and legs according to embodiments of the invention.

FIG. 3 is a perspective view of a headboard panel and legs according to embodiments of the invention.

FIG. 4 is a perspective view of a headboard panel and side bedrails according to embodiments of the invention.

FIG. 5 is a perspective view of a footboard panel and side bedrails according to embodiments of the invention.

FIG. 6A is a top view of a pocketed tarp of a platform base according to embodiments of the invention.

FIG. 6B is a close-up view of an aperture through a pocketed tarp of a platform base according to embodiments of the invention.

FIG. 6C is a side view of a pocketed tarp of a platform base according to embodiments of the invention.

FIG. 6D is a side view of a pocket of a pocketed tarp of a platform base according to embodiments of the invention.

FIG. 6E is a top view of a strip of fabric used to form a pocket on a spanning pocketed tarp of a platform base according to embodiments of the invention.

FIG. 7 depicts cross slats being inserted into the pockets of a pocketed tarp of a platform base according to embodiments of the invention.

FIG. 8 depicts center supports being attached to a pocketed tarp of a platform base according to embodiments of the invention.

FIG. 9 depicts support slats being attached to a platform base according to embodiments of the invention.

FIG. 10 depicts a platform base being inserted into a bed frame according to embodiments of the invention.

FIG. 11 depicts a platform base being secured to side bedrails according to embodiments of the invention.

FIG. 12 is a bottom perspective view of a foundation bed assembly according to embodiments of the invention.

DETAILED DESCRIPTION

FIGS. 1A and IB illustrate a foundation bed assembly 100 having a footboard panel 101, a headboard panel 103, two or more side bedrails 105, 107, defining a rectangular bed framework 108 and four or more feet or legs 109 at proximate comers 110 of the framework. Foundation bed assembly 100 may further include platform base 151 comprising a spanning pocketed tarp 120 with a plurality of cross slats 153, a cross slat positioned in each pocket 154 of the tarp. The cross slats having connection portions 160 extending out of each end opening 162 of the tarp pockets 154. In embodiments, a middle support 168 may comprise one or more middle support legs 155, and one or more center slats 157 providing a central support for the spanning pocketed tarp with cross slats. As illustrated in Fig. 1C, all of the components of foundation bed assembly 100, in a disassembled state, may fit conveniently within a box 171 for convenient shipping and delivery. Components may include items required to assemble foundation bed assembly 100. For example, components may include a hardware kit including fasteners and tools. Fasteners may include removable fasteners such as screws, bolts, nuts, and the like. Tools may include wrenches, screwdrivers, or the like. Foundation bed assembly 100 may further include a set of written instructions. Written instructions may be any combination of pictures or words providing direction to a user for transitioning bed assembly 100 from a shipping to a use configuration. Box 171 may be sized to correspond with the size of foundation bed assembly 100 such that all components of foundation bed assembly 100 fit into box 171. For example, a box 171 configured to hold a queen sized foundation bed assembly 100 may be approximately 86 inches long, 10 inches high and 8 inches deep. Foundation bed assemblies 100 may be configured in different sizes to accommodate commonly used mattresses. For example, foundation bed assembly 100 may be sized for a queen mattress, a twin mattress, a full mattress, a king mattress, or a California king mattress. In embodiments, foundation bed assembly 100 may be sized to correspond to custom sized mattresses. In embodiments, box 171 may be shipped directly to a user. In embodiments, box 171 may be readily stored at a retail store for pickup by a user.

In embodiments, platform base 151 may be a slat roll. A slat roll may include slats attached to one another near their ends by ribbons or strings. Slats are generally wooden planks having a width between one and five inches. Slats may also be composite wood materials, polymers, rigid foams, or metals generally known in the art. Slat lengths generally correspond to the width of the mattress being supported. For example, a slat roll to accommodate a Queen sized mattress may have slats with a length of about 80 inches. The number of slats in a slat roll generally correspond to the length of the mattress being supported, with more slats added to the roll for longer mattresses. Slat rolls may be folded or rolled to fit readily within box 171. Slat rolls are illustrated in US Patent Number 9,241,578 and US Patent Publication 2019/0380500, the contents of which are incorporated herein in their entireties for all purposes.

Figs. 2 - 6 illustrate a method of assembly for a framework 108 of foundation bed assembly 100. Referring to Fig. 2, legs 109 may be positioned at opposite ends of footboard panel 101. In embodiments, footboard panel 101 and legs 109 have corresponding apertures configured to receive bolt 223. In embodiments, legs 109 are placed on an interior facing surface 201 of footboard panel 101. In embodiments, each leg

109 is sandwiched between a corner bracket 221 and footboard panel 101. Comer bracket 221 may be secured with nut 225. Legs 109 may be positioned at opposite ends of headboard panel 103. Referring to Fig. 3, in embodiments, headboard panel 103 and legs 109 have corresponding apertures configured to receive bolt 223. In embodiments, legs 109 are placed on an exterior facing surface 303 of headboard panel 103.

In embodiments, headboard panel 103 is sandwiched between a comer bracket 221 and a leg 109. Corner bracket 221 may be secured with nut 225. Referring to Fig.4, a first end of left side bedrail 115 may be secured to headboard panel 103 at comer bracket 221, and a first end of right side bedrail 117 may be secured to an opposite end of headboard panel 103 at comer bracket 221. Referring to Fig. 5, a second end of left side bedrail 115 may be secured to footboard panel 101 at comer bracket 221, and a second end of right side bedrail 117 may be secured to an opposite end of footboard panel 101 at corner bracket 221.

Footboard panel 101, headboard panel 103, side bedrails 115, 117, and legs 109 may be made from wood or wood products such as particle board, plywood, compressed board or the like. Inward facing surfaces are typically not seen by a consumer. Accordingly, to save on expense, inward facing surfaces may be finished with inexpensive materials such as laminate, or left unfinished. In embodiments, inward facing surfaces may be finished. Outward facing surfaces may be finished or unfinished. For example, outward facing surfaces may be veneered, stained, painted, or the like. In embodiments, legs 109 may have both inward and outward facing surfaces finished. In embodiments, legs 109 are uniform. In embodiments, legs 109 may have different shapes or designs. For example, legs 109 attached to footboard panel 101 may be angular and legs 109 attached to headboard panel 103 may be uniform. In embodiments, left and right side bedrails 115, 117 include mounting rails 116, 118. Mounting rails 116, 118 may be affixed to interior facing sides of side bedrails 115, 117. Mounting rails 116, 118 may be comprised of wood or wood products. In embodiments, mounting rails 116, 118 may include pre-drilled holes.

Referring to Figs. 6A - 6E, pocketed tarp 120 comprises a planar fabric tarp 601. In embodiments, fabric tarp 601 is a woven material. For example, fabric tarp 601 may be a polyester fabric. In embodiments, fabric tarp 601 is non self-supporting. In embodiments, fabric tarp 601 has a left side 603 opposite a right side 605. In embodiments, fabric tarp 601 is generally rectilinear and has dimensions generally corresponding to a mattress. For example, fabric tarp 601 may have a length of about 1844 mm and a width of about 1480 mm, generally corresponding to a queen size mattress. In embodiments, fabric tarp 601 may have a thickness of less than 2 mm. In embodiments, fabric tarp 601 may have a thickness less than 5 mm. Fabric tarp 601 may have a plurality of mounting apertures 623. Mounting apertures 623 may be generally equidistant from left side 603 and right side 601. As shown in Fig. 6B, mounting apertures may 623 be generally rectangular in shape. In embodiments, mounting apertures 623 may have rounded comers. In embodiments, mounting apertures 623 may have a length of about 25 mm and a width of about 10 mm.

In embodiments, fabric tarp 601 includes a plurality of transverse pockets 621 extending from left side 603 to right side 605. Fig. 6C depicts a side view of a pocketed tarp 120 with a plurality of transverse pockets 621 having openings 625 and the rights and left sides 603, 605 of fabric tarp 601. Fabric tarp 601 has an upward facing side 607 and a downward facing side 609. In embodiments, downward facing side 609 has a plastic coating. For example, downward facing side 609 may have a pvc plastic coating. In embodiments, plastic coating may have a thickness less than 2 mm. In embodiments, plastic coating may have a thickness less than 5 mm. Plastic coating may be non self- supporting. Plastic coating may be flexible and easily folded or rolled. Plastic coating may be impervious. For example, liquid may not readily pass through plastic coating. Likewise fabric tarp 601 may be tightly woven such that liquids, dust, or other fine particulate matter does not readily pass through.

Fig. 6D depicts a close up of a side view of a pocket 621 secured to downward facing side 609 of fabric tarp 601. Referring to Fig. 6E, pocket 621 is formed from fabric strip 629. In embodiments, fabric strip 629 is the same or similar material to fabric tarp 601. In embodiments, fabric strip 629 may have a woven polyester fabric side opposite a side with a plastic coating. In embodiments, fabric strip 629 has a length corresponding the width of fabric sheet 601. In embodiments, fabric strip 629 has a length of about 1480 mm. In embodiments, fabric strip 601 has a width about 99 mm. Fabric strip 601 has flange portions 627 that are fixedly attached to fabric sheet 601. For example, flange portions 627 may be stitched and/or glued to fabric sheet 601. In embodiments, flange portion 627 may be between 10 and 17 mm. When flange portions 627 are attached to fabric sheet 601, fabric strip 629 defines an opening 625 that is about 42 mm wide and 15 mm in height. Fabric strip 629 may have a centrally located aperture corresponding to mounting aperture 623 of fabric tarp 601. In embodiments, fabric strip 629 is affixed such that a plastic coated side abuts with bottom facing side 609 of fabric sheet 601. In embodiments, a plurality of fabric strips 629 are spaced between 200 and 250 mm from one another. In embodiments, a plurality of fabric strips 629 are spaced between 210 and 270 mm from one another. In embodiments, a plurality of fabric strips 629 are spaced between 220 mm from one another. In embodiments, a plurality of fabric strips 629 are spaced between 262 mm from one another. In embodiments a fabric strip 269 is placed such that the center is

262 mm from an edge of fabric tarp 601. Referring to Fig. 7, cross slats 153 may be slid into corresponding pockets 621 of pocketed tarp 120. Having a plastic surface of fabric strip 629 facing a plastic surface of fabric tarp 601 advantageously facilitates the insertion of cross slat 153 while further preventing snagging or ripping of fabric sheet 601. Cross slats 153 may have a central mounting portion 701 that corresponds with mounting aperture 623. Cross slats have connecting portions 703 extending beyond edges of pocketed tarp 120. In embodiments, connecting portion 703 may extend between 25 and 100 mm from an edge of pocketed tarp 120.

As seen in Fig. 8, middle support leg 155 may be affixed to pocketed tarp 120.

Middle support leg 155 has mounting surface 803 that abuts pocketed tarp 120 at mounting aperture 623. Mounting surface 803 is configured to receive screw 801. Screw 801 may pass partially through both pocketed tarp 120 and central mounting portion 701 of cross slat 153 thereby securing middle support leg 155, pocketed tarp 120, and cross slat 153 to one another. Referring to Fig. 9, middle support leg 155 may include one or more support brackets 901 configured to receive center slat 157. In embodiments, support brackets 901 have a “U” shape. In embodiments, support brackets 901 have a rectilinear cross-section. In embodiments, support brackets 901 surround at least three sides of center slat 157. In embodiments, support brackets 901 is formed by affixing an “L” shaped piece to a side of middle support leg 155. In embodiments, middle support leg 155 may have a support bracket 901 affixed such that support bracket 901 has a first open end facing a footboard panel and an opposite open end facing a headboard panel. In embodiments, support bracket 901 may be affixed to middle support leg 155 such that a closed side faces and is generally parallel to a side bedrail panel. In embodiments, platform base 151 may have three middle support legs 155 and two center slats 157. In embodiments, a first center slat 157 may be slid into position extending from a first middle support leg 155 to a second middle support leg 155. In embodiments, a second center slat 157 may be slid into position extending from a second middle support leg 155 to a third middle support leg 155. In embodiments, center slat 157 is generally perpendicular to cross slat 153. In embodiments, center slat 157 abuts pocketed tarp 120.

Referring to Figs. 10-12, platform base 151 is inserted within bed framework 108 such that mounting portions 703 of cross slats 153 rest atop mounting rails 116, 118 of left and right bedrail panels 115, 117. Mounting portions 703 are secured to mounting rails 116, 118. For example, as depicted in Fig. 11, a plurality of screws 1101 may secure mounting portion 703 to mounting rails 116, 118. Once secured, platform base 151 provides a taught platform configured to receive a further bed components such as a mattress. Fig. 12 depicts an under side of view of an assembled foundation bed assembly 100. Legs 109 and middle support legs 155 are generally sized such that each will make contact with a surface such as a floor while maintaining platform base 151 in a generally level position.

The following references are incorporated herein for all purposes: US Patents 5,564,140, 9,538,851, and 6,701,551, and US Pat. Pubs. 2005/0039258 and 2013/0086743.

For purposes of this disclosure, stated measurements or dimensions are accurate within 10% of the stated values. Similarly, measurements or dimensions stated to be “generally” or “about” a specific value are considered accurate within 10% of the stated value.

The above references in all sections of this application are herein incorporated by references in their entirety for all purposes. Components illustrated in such patents may be utilized with embodiments herein. Incorporation by reference is discussed, for example, in MPEP section 2163.07(B).

All of the features disclosed in this specification (including the references incorporated by reference, including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including references incorporated by reference, any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any incorporated by reference references, any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed The above references in all sections of this application are herein incorporated by references in their entirety for all purposes.

Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples shown. This application is intended to cover adaptations or variations of the present subject matter. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents, as well as the following illustrative aspects. The above described aspects embodiments of the invention are merely descriptive of its principles and are not to be considered limiting. Further modifications of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention.