Bed base, kit for bed base and method of assembling bed base

Abstract

The bed base includes a frame and one or more panels on top of the frame to define an upper surface of the bed base for supporting the mattress. The frame includes a plurality of rails that, when assembled together, at least partially define the frame. The plurality of rails includes thermoplastic foam that is lighter than wood or other similar or heavier weighted materials that are typically utilized in the construction of the bed base, thereby facilitating easier shipping, lifting, carrying, and assembly of the bed base. The one or more panels may also include a thermoplastic foam. The frame may further include a plurality of brackets to interconnect selected rails of the frame. A kit for a bed base and a method of assembling a bed base are also provided.

Description

Related Applications

[0001] This application claims priority to U.S. Provisional Application Serial No. 63 / 405,029, filed on September 9, 2022, the entire disclosure of which is incorporated herein by reference. Technical Field

[0002] The present invention relates to bed bases, kits for bed bases, and methods of assembling bed bases. In particular, the present invention includes bed bases that utilize thermoplastic components that are lighter than wood and can be press-fitted together to form a base. Background Art

[0003] A bed assembly typically includes a mattress and a base on which the mattress rests. In recent years, it has become increasingly popular to sell mattresses online and to use third-party package delivery companies to deliver mattresses to consumers. In order to facilitate the delivery of mattresses by third-party delivery companies, and to make it easier for consumers to lift and carry mattresses, mattresses are now typically placed in a rolled-up configuration and boxed. This packaging arrangement also serves to reduce the space occupied by the mattress during shipping, and in this way can be used to reduce shipping costs. On the other hand, the various components of the bed base typically must exhibit some form of rigidity in order to properly support the mattress, and therefore cannot be placed in a rolled-up configuration to reduce its space occupation. Therefore, the extent to which the bed base can be easily shipped and subsequently lifted and carried by the consumer in terms of both transportation logistics and costs is primarily related to the weight of the bed base. However, since the structural integrity of the bed base must be sufficient to support the mattress, the main components of the bed base have traditionally been constructed of wood or other weighted materials. As a result, the bed base has typically remained less adaptable for delivery by a third-party delivery company, and difficult for consumers to lift and carry, and then assembled using traditional fasteners (e.g., screws, nails, nuts and bolts). Furthermore, because many conventional bed bases require the use of conventional fasteners in order to hold the various components of the base together, the consumer is required to have certain tools in order to assemble the bed base once it is shipped.

[0004] Therefore, a bed base having features that make the bed base more suitable for shipment by third party shipping companies and facilitate easier lifting, carrying, and assembly of the bed base by the consumer would be both highly desirable and beneficial. Summary of the invention

[0005] The present invention includes bed bases having components comprising materials that are lighter than wood or other similar or heavier weighting materials commonly utilized in the construction of bed bases. In particular, the present invention includes bed bases utilizing a frame that includes thermoplastic foam. The reduction in weight resulting from the use of thermoplastic materials makes the bed base of the present invention more suitable for shipment by third party delivery companies and facilitates easier lifting, carrying, and assembly, as compared to bed bases composed primarily of wood or other similar or heavier weighting materials.

[0006] In an exemplary embodiment of the present invention, a bed base includes a frame and one or more panels, the one or more panels being located on top of the frame to define an upper surface of the base for supporting a mattress. The frame includes a plurality of rails, the plurality of rails including thermoplastic foam, which when assembled together at least partially define the frame.

[0007] In some embodiments, the plurality of rails of the frame include a first set of rails and a second set of rails interlocked with the first set of rails. The first set of rails at least partially defines the perimeter of the frame, and the second set of rails defines an internal structure within the perimeter of the frame, the internal structure being formed by interlocking each rail in the second set of rails with at least one other rail in the second set of rails. To facilitate the interlocking of the second set of rails, each rail in the second set of rails may include a notch for receiving another rail in the second set of rails. In some embodiments, the first set of rails and the second set of rails are interlocked by a mortise and tenon type joint. In this regard, and in some embodiments, each end of each rail in the second set of rails defines a tenon, and each rail in the first set of rails defines one or more openings in which one of the tenons defined by the second set of rails is received.

[0008] In some embodiments, the base further includes a plurality of brackets. Each bracket is configured to interconnect two rails from the first set of rails. In some embodiments, each of the plurality of brackets includes a thermoplastic material to further minimize the weight of the frame attributable to the bracket. In some embodiments, each bracket defines a first slot in which one of the first set of rails is received and a second slot in which another of the first set of rails is received. In one such embodiment, each bracket includes: a first pair of flanges defining the first slot of the bracket; a second pair of flanges defining the second slot of the bracket; and a central body extending from the first pair of flanges and the second pair of flanges. In some embodiments, the central body of each bracket is substantially hollow to further reduce the weight of the frame attributable to the bracket.

[0009] In some embodiments, the bed base includes a plurality of panels to reduce the amount of space required to ship or otherwise transport the bed base in a disassembled configuration. In some embodiments, each panel is removably secured to the frame of the base using a plurality of fasteners, such as press fasteners comprised of recyclable materials, to prevent the panel from separating from or moving relative to the frame during transport or use, while still facilitating preparation for disassembly and subsequent reassembly. In some embodiments, each panel of the base includes a thermoplastic foam. Suitable thermoplastic foams capable of constructing the rails and panels of the frame include polypropylene (PP) foam, polyethylene (PE) foam, polyethylene terephthalate (PET) foam, polyisocyanurate (polyiso) foam, polyvinyl chloride (PVC) foam, and glass fiber reinforced polyurethane (PU) foam.

[0010] The bed base of the present invention can be provided to the consumer in a disassembled state. Therefore, the present invention further includes a kit for a bed base, the kit including some or all of the components of the various bed base embodiments disclosed herein.

[0011] The present invention further includes a method of assembling a bed base. In one exemplary embodiment, the method of assembling a bed base includes: interlocking a plurality of rails comprising thermoplastic foam to at least partially define a frame of the bed base; and positioning one or more panels on top of the frame to define an upper surface of the bed base for supporting a mattress. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a perspective view of an exemplary bed base made in accordance with the present invention;

[0013] Figure 2 yes Figure 1 A perspective view of the frame of an exemplary bed base of Figure 1 The panel shown in is removed from the base;

[0014] Figure 3 yes Figure 1 An exploded view of the internal structure of the frame of an exemplary bed base;

[0015] Figure 4 yes Figure 1 A top view of a support frame of an exemplary bed base; and

[0016] Figure 5 Yes, you can Figure 1 Side view of a press fastener used in an exemplary bed base. DETAILED DESCRIPTION

[0017] The present invention includes bed bases having components comprising materials that are lighter than wood or other similar or heavier weighting materials commonly utilized in the construction of bed bases. In particular, the present invention includes bed bases that utilize frames that include thermoplastic foam and include components that are capable of being press-fitted together. The reduction in weight resulting from the use of thermoplastic materials makes the bed base of the present invention more suitable for shipment by third party shipping companies and facilitates easier lifting, carrying, and assembly as compared to bed bases composed primarily of wood or other similar or heavier weighting materials.

[0018] When reference is made to the components of the base being "press-fit" together, it is understood that such reference means that the components typically interlock with one another without the use of tools or fasteners. The terms "consisting of" and "composed of" are used interchangeably throughout this disclosure. Thus, unless otherwise specified, the term "consisting of" is open-ended like the term "composed of" and does not exclude the presence of components or materials not expressly recited.

[0019] First reference Figure 1 and Figure 2 A bed base (or foundation) 10 made in accordance with the present invention includes a frame 20 and one or more panels 42, 44, 46 that may be located on top of the frame 20 to define an upper surface of the foundation 10 for supporting a mattress (not shown). Figure 2, the primary structure of the frame 20 is defined by, and can therefore be characterized as including, a plurality of rails 21, 22, 23, 24, 25, 26, 27, 28, which can also be characterized as "slats." Advantageously, in this exemplary embodiment, the plurality of rails 21, 22, 23, 24, 25, 26, 27, 28 and the one or more panels 42, 44, 46 each comprise thermoplastic foam, which is lighter than wood, metal or other weighted materials conventionally utilized in the construction of bed bases.

[0020] Reference now Figures 1 to 3 , the plurality of rails 21, 22, 23, 24, 25, 26, 27, 28 defining the main structure of the frame 20 can be characterized as including two separate groups of rails, namely a first group of rails 21, 22, 23, 24 and a second group of rails 25, 26, 27, 28. In the exemplary embodiment, the frame 20 includes a total of eight rails, of which four rails correspond to the first group of rails 21, 22, 23, 24, and four rails correspond to the second group of rails 25, 26, 27, 28. Specifically, the first group of rails 21, 22, 23, 24 includes a first pair of opposed vertically oriented rails 21, 22 and a first pair of opposed horizontally oriented rails 23, 24, which together define the outer perimeter of the frame 20. Likewise, the second set of rails 25, 26, 27, 28 includes a second pair of opposed vertically oriented rails 25, 26 and a second pair of opposed horizontally oriented rails 27, 28 that together define an internal structure within the perimeter of the frame 20. Figure 2As best shown in the figure, the main structure of the frame 20 is established by means of: (i) each vertically oriented guide rail 21, 22 in the first group of guide rails 21, 22, 23, 24 interlocking with each horizontally oriented guide rail 27, 28 in the second group of guide rails 25, 26, 27, 28; (ii) each horizontally oriented guide rail 23, 24 in the first group of guide rails 21, 22, 23, 24 interlocking with each vertically oriented guide rail 25, 26 in the second group of guide rails 25, 26, 27, 28; and (iii) each vertically oriented guide rail 25, 26 in the second group of guide rails 25, 26, 27, 28 interlocking with each horizontally oriented guide rail 27, 28 in the second group of guide rails 25, 26, 27, 28. In the exemplary embodiment, the vertically oriented rails 21, 22 of the first set of rails 21, 22, 23, 24 and the vertically oriented rails 25, 26 of the second set of rails 25, 26, 27, 28 have a greater length than the horizontally oriented rails 23, 24 of the first set of rails 21, 22, 23, 24 and the horizontally oriented rails 27, 28 of the second set of rails 25, 26, 27, 28. Therefore, the frame 20 in the exemplary embodiment has a generally rectangular shape.

[0021] Although the frame 20 is primarily described herein and is shown in the accompanying drawings as including a total of eight rails and maintaining a generally rectangular shape, it should be understood that the frame 20 is not necessarily limited to such a configuration. Rather, the total number of rails in the frame 20, the distribution of the rails between the first set of rails that largely define the perimeter of the frame 20 and the second set of rails that define the internal structure of the frame 20, and the length of the individual rails can be varied to accommodate mattresses of different sizes, shapes, and / or weights without departing from the spirit and scope of the present invention. For example, the present invention contemplates: an alternative embodiment in which the second set of rails 25, 26, 27, 28 that define the internal structure of the frame 20 includes more than four rails; and an embodiment in which the second set of rails that define the internal structure of the frame 20 includes less than four rails. In addition, alternative embodiments are also contemplated in which the length of the rails of the frame 20 is such that the frame 20 maintains a non-rectangular shape (e.g., a square). Since the benefits and advantages obtained from the rails of the frame 20 being constructed of expanded thermoplastic foam will still be realized in such alternative embodiments, those skilled in the art will readily appreciate that such modifications can be made without departing from the spirit and scope of the present invention.

[0022] Now specific reference Figure 2 and Figure 3In the exemplary embodiment, the second set of rails 25, 26, 27, 28 defining the interior structure of the frame 20 interlocks with the first set of rails 21, 22, 23, 24 via a mortise and tenon type joint. In this regard, each end of each horizontally oriented rail 27, 28 of the second set of rails 25, 26, 27, 28 defines a tenon 27a, 27b, 28a, 28b (i.e., a male member) that can be press-fitted into corresponding openings 22a, 22b defined by the vertically oriented rails 21, 22 of the first set of rails 21, 22, 23, 24. Thus, in this exemplary embodiment, the horizontally oriented guide rails 27, 28 of the second set of guide rails 25, 26, 27, 28 define a total of four tenons, and the vertically oriented guide rails 21, 22 of the first set of guide rails 21, 22, 23, 24 define a total of four openings 22a, 22b, two of which are located at Figure 2 . Similarly, each end of each vertically oriented guide rail 25, 26 of the second set of guide rails 25, 26, 27, 28 defines a tenon 25a, 25b, 26a, 26b that can be press-fit into a corresponding opening 24a, 24b defined by one of the horizontally oriented guide rails 23, 24 of the first set of guide rails 21, 22, 23, 24. Therefore, in this exemplary embodiment, the vertically oriented guide rails 25, 26 of the second set of guide rails 25, 26, 27, 28 define a total of four tenons, and the horizontally oriented guide rails 23, 24 of the first set of guide rails 21, 22, 23, 24 define a total of four openings 24a, 24b, two of which are in the Figure 2 Of course, it is contemplated that a number of other configurations or geometries (including extruded I-beam shaped rails, etc.) may also be utilized and can be used to construct the exemplary bed base without departing from the spirit and scope of the present invention.

[0023] Still reference Figure 2 and Figure 3In addition to interlocking with the first set of guide rails 21, 22, 23, 24, the corresponding guide rails of the second set of guide rails 25, 26, 27, 28 also interlock with each other. To this end, in this exemplary embodiment, the vertically oriented guide rails 25, 26 of the second set of guide rails 25, 26, 27, 28 each define two notches. The vertically oriented guide rails 25, 26 each define a first notch 25c, 26c, which corresponds to one of the two notches 28c, 28d defined by one of the horizontally oriented guide rails 28 of the second set of guide rails 25, 26, 27, 28. The vertically oriented guide rails 25, 26 then each further define a second notch 25d, 26d, which corresponds to one of the two notches 27c, 27d defined by another horizontally oriented guide rail 27 of the second set of guide rails 25, 26, 27, 28. Therefore, the second set of guide rails 25, 26, 27, 28 can be interlocked with each other by aligning the recesses 25c, 25d, 26c, 26d defined by the vertically oriented guide rails 25, 26 with the corresponding recesses 27c, 27d, 28c, 28d defined by the horizontally oriented guide rails 27, 28 and press-fitting the vertically oriented guide rails 25, 26 and the horizontally oriented guide rails 27, 28 together.

[0024] Now refer to it again Figures 1 to 3 As mentioned above, since each rail 21, 22, 23, 24, 25, 26, 27, 28 is constructed of thermoplastic foam, the overall weight of the frame 20 and, therefore, the overall weight of the base 10 as a whole is reduced. Suitable expanded thermoplastic foams that can be utilized in the construction of the rails 21, 22, 23, 24, 25, 26, 27, 28 of the frame 20 include polypropylene (PP) foam, polyethylene (PE) foam, and other types of structural foams, such as polyethylene terephthalate (PET) foam, polyiso (thermosetting) foam, polyvinyl chloride (PVC) foam, and glass fiber reinforced polyurethane (PU) foam, which are 100% recyclable, waterproof, and much lighter than wood or other weighted materials traditionally used in the construction of bed bases. In this exemplary embodiment, the rails 21, 22, 23, 24, 25, 26, 27, 28 of the frame 20 include polyethylene foam. However, regardless of which type of expanding thermoplastic foam is utilized, the reduced weight of the plurality of rails 21, 22, 23, 24, 25, 26, 27, 28 serves not only to reduce costs associated with shipping, but also to enable an individual to more easily lift and carry the base 10 without sacrificing the structural integrity of the base 10.

[0025] Reference again Figure 2 and Figure 3, each rail 21, 22, 23, 24, 25, 26, 27, 28 of the frame 20 can be initially formed via an extrusion process in which a thermoplastic material (such as polypropylene or polyethylene) is melted, mixed with a foaming agent (such as a halogenated hydrocarbon), and then extruded through a die. Of course, the initial formation of each rail 21, 22, 23, 24, 25, 26, 27, 28 can also be achieved using alternative manufacturing techniques without departing from the spirit and scope of the present invention. For example, in some embodiments, the rails 21, 22, 23, 24, 25, 26, 27, 28 can be initially formed using an alternative manufacturing process (such as injection molding). Once initially formed, openings 22a, 22b, 24a, 24b for receiving the tenons 25a, 25b, 26a, 26b, 27a, 27b, 28a, 28b of the second set of guide rails 25, 26, 27, 28 can then be made in the first set of guide rails 21, 22, 23, 24 by removing portions of the middle sections of the first set of guide rails 21, 22, 23, 24. Similarly, once the second set of guide rails 25, 26, 27, 28 are initially formed, by removing portions of the end and middle sections of the second set of guide rails 25, 26, 27, 28, tenons 25a, 25b, 26a, 26b, 27a, 27b, 28a, 28b and recesses 25c, 25d, 26c, 26d, 27c, 27d, 28c, 28d can be made in the second set of guide rails 25, 26, 27, 28.

[0026] Now specific reference Figure 2, each notch defined by the second set of rails 25, 26, 27, 28 preferably extends about 50% of the height of the rail defining the notch. When the second set of rails 25, 26, 27, 28 are interlocked with each other in the manner described above and with such notch configurations, the top of each of the second set of rails 25, 26, 27, 28 resides along a common plane (i.e., the top of each of the second set of rails 25, 26, 27, 28 is coplanar) to provide a uniform, flat surface on which the one or more panels 42, 44, 46 can be positioned to support a mattress. In this exemplary embodiment, the top of the first set of rails 21, 22, 23, 24 also resides along the same plane as the top of the second set of rails 25, 26, 27, 28, so that the flat surface provided by the internal structure of the frame 20 is extended to the perimeter of the frame 20. In this regard, the positioning of the tenons 25a, 25b, 26a, 26b, 27a, 27b, 28a, 28b of the second set of rails 25, 26, 27, 28 and the corresponding openings 22a, 22b, 24a, 24b of the first set of rails 21, 22, 23, 24 in the exemplary embodiment is such that when the first set of rails 21, 22, 23, 24 are interlocked with the second set of rails 25, 26, 27, 28 in the manner described above, the tops of the first set of rails 21, 22, 23, 24 and the second set of rails 25, 26, 27, 28 reside along a common plane. However, alternative frame 20 configurations are contemplated in which the tops of the first set of rails 21, 22, 23, 24 and the second set of rails 25, 26, 27, 28 do not reside along a common plane. For example, in some alternative embodiments, the tops of the first set of guide rails 21, 22, 23, 24 can reside on a plane that is higher than the plane on which the tops of the second set of guide rails 25, 26, 27, 28 reside when the frame 20 is assembled, such that the internal structure of the frame 20 is recessed relative to the periphery of the frame 20.

[0027] Reference again Figure 2 and Figure 3 In the exemplary embodiment, the plurality of openings 60 are also made into the top of the rails where the one or more panels 42, 44, 46 are located, in this case each rail within both the first set of rails 21, 22, 23, 24 and the second set of rails 25, 26, 27, 28. The importance of such openings 60 is further described below.

[0028] The openings 22a, 22b, 24a, 24b of the first set of guide rails 21, 22, 23, 24, the tenons 25a, 25b, 26a, 26b, 27a, 27b, 28a, 28b and recesses 25c, 25d, 26c, 26d, 27c, 27d, 28c, 28d of the second set of guide rails 25, 26, 27, 28, and the openings 60 of both the first set of guide rails 21, 22, 23, 24 and the second set of guide rails 25, 26, 27, 28 can be made using known subtractive manufacturing techniques. Subtractive manufacturing techniques suitable for such applications include, but are not necessarily limited to, drilling, die cutting, water jet cutting, CNC milling, etc. In the case where the first group of guide rails 21, 22, 23, 24 and the second group of guide rails 25, 26, 27, 28 are formed via injection molding, the mold utilized may include several features that, when the initial guide rails are formed, impart: openings 22a, 22b, 24a, 24b to the first group of guide rails 21, 22, 23, 24; tenons 25a, 25b, 26a, 26b, 27a, 27b, 28a, 28b to the second group of guide rails 25, 26, 27, 28; recesses 25c, 25d, 26c, 26d, 27c, 27d, 28c, 28d to the second group of guide rails 25, 26, 27, 28; and / or openings 60 to both the first group of guide rails 21, 22, 23, 24 and the second group of guide rails 25, 26, 27, 28.

[0029] Reference now Figure 1 , Figure 2 and Figure 4 In the exemplary embodiment, the frame 20 further includes a plurality of brackets 32, 34, 36, 38 that interconnect the first set of rails 21, 22, 23, 24 and define corners, and thus partially define the perimeter of the frame 20. In this regard, the brackets 32, 34, 36, 38 can also be characterized as "corner brackets". Figure 2 As best shown in FIG. 1 , each bracket 32, 34, 36, 38 is configured to interconnect two rails from the first set of rails 21, 22, 23, 24. To this end, and in this exemplary embodiment, each bracket 32, 34, 36, 38 defines and can therefore be characterized as including: a central body 32a, 34a, 36a, 38a; a first pair of flanges 32b, 34b, 36b, 38b extending from the central body 32a, 34a, 36a, 38a; and a second pair of flanges 32c, 34c, 36c, 38c extending from the central body 32a, 34a, 36a, 38a, as shown in FIG. Figure 4As best shown in . The first pair of flanges 32b, 34b, 36b, 38b of each respective bracket 32, 34, 36, 38 includes an inner flange and an outer flange. The inner flange and the outer flange are spaced apart from one another so as to define a slot into which an end of one of the first set of rails 21, 22, 23, 24 can be press-fitted. The second pair of flanges 32c, 34c, 36c, 38c of each respective bracket 32, 34, 36, 38 similarly includes an inner flange and an outer flange, the inner flange and the outer flange are spaced apart from one another so as to define a slot into which another of the first set of rails 21, 22, 23, 24 can be press-fitted. As shown in Figure 2 As best shown in FIG. 1 , the height of brackets 32 , 34 , 36 , 38 corresponds to the height of the first set of rails 21 , 22 , 23 , 24 .

[0030] Still refer to Figure 1 , Figure 2 and Figure 3 To help minimize the weight of the brackets 32, 34, 36, 38 and thus the overall weight of the frame 20, in this exemplary embodiment, the central body 32a, 34a, 36a, 38a of each respective bracket 32, 34, 36, 38 is substantially hollow. To further help minimize the weight of the frame 20, each bracket 32, 34, 36, 38, like the rails 21, 22, 23, 24, 25, 26, 27, 28, is preferably at least partially constructed of a thermoplastic material. Suitable thermoplastic materials that can be utilized in the construction of the brackets 32, 34, 36, 38 include polypropylene, polyethylene, or another type of thermoplastic material, such as polyethylene terephthalate, polyiso (thermosetting) plastic, polyvinyl chloride, and polyurethane, which are much lighter than wood or other weighting materials traditionally used in the construction of bed bases. In this exemplary embodiment, each bracket 32, 34, 36, 38 comprises a polyethylene thermoplastic material. Thus, in the exemplary embodiment, each respective component of the frame 20 comprises, in whole or in part, a thermoplastic material. In some cases, the thermoplastics utilized in the construction of the respective components of the frame 20 may be infused with various fibers to provide increased strength and durability to these components.

[0031] Still refer to Figure 1 , Figure 2 and Figure 4, similar to the rails 21, 22, 23, 24 of the frame 20, the brackets 32, 34, 36, 38 in this exemplary embodiment are also formed by an extrusion process, in which the thermoplastic material is melted and then extruded through a die. Therefore, the one die (or several dies) of the extruded brackets 32, 34, 36, 38 makes it possible that when formed, each bracket 32, 34, 36, 38 exhibits the above-mentioned features. Therefore, in this exemplary embodiment, the central body 32a, 32b, 32c, 32d, the first pair of flanges 32b, 34b, 36b, 38b and the second pair of flanges 32c, 34c, 36c, 38c are integrally formed. Of course, without departing from the spirit and scope of the present invention, the brackets 32, 34, 36, 38 may also be formed via different manufacturing processes. For example, in alternative embodiments, the brackets 32, 34, 36, 38 may be formed using different additive manufacturing techniques (such as injection molding and / or 3D printing). Furthermore, it should also be understood that in alternative embodiments, brackets having alternative configurations and / or including features different from the exemplary brackets 32, 34, 36, 38 described above and shown in the figures may be used instead, but still suitable for interconnecting the first set of rails 21, 22, 23, 24. In fact, while the use of brackets is generally preferred in the construction of the frame 20 to increase stability, alternative embodiments are also contemplated herein in which the frame 20 is defined only by the first set of rails 21, 22, 23, 24 and the second set of rails 25, 26, 27, 28.

[0032] Now specific reference Figure 1In the exemplary embodiment, the base 10 includes a total of three panels: a first panel 42, which defines a left portion of the upper surface of the base 10; a second panel 44, which defines a central portion of the upper surface of the base 10; and a third panel 46, which defines a right portion of the upper surface of the base 10. As shown in the exemplary embodiment, the dimensions of the first panel 42, the second panel 44, and the third panel 46 are such that when placed on the frame, the first panel 42, the second panel 44, and the third panel 46 collectively cover the top of each of the first set of rails 21, 22, 23, 24, the second set of rails 25, 26, 27, 28, and the brackets 32, 34, 36, 38. Of course, in an alternative embodiment where the top surface of the internal structure of the frame 20 and the top surface of the perimeter of the frame 20 do not reside along a common plane, the dimensions of the first panel 42, the second panel 44, and the third panel 46 can be modified to collectively cover only the top of the second set of rails 25, 26, 27, 28. Of course, it is further contemplated that while the use of multiple panels to define the surface of the base 10 upon which a mattress can rest may be advantageous in terms of reducing the amount of space required to ship or otherwise transport the base, it is not always required to use multiple panels or a set number of multiple panels when the base is disassembled. Rather, the number of panels utilized may vary without departing from the spirit and scope of the present invention. Thus, alternative embodiments are also contemplated in which less than three panels (e.g., a single panel) are utilized to define the top surface of the base 10 for supporting a mattress; as well as embodiments in which more than three panels are utilized to define the top surface of the base 10 for supporting a mattress.

[0033] Still refer to Figure 1In the exemplary embodiment, each panel 42, 44, 46, like the rails 21, 22, 23, 24, 25, 26, 27, 28 of the frame 20, is also constructed of expanded thermoplastic foam, thereby further reducing the weight of the base 10 compared to a conventional base constructed primarily of wood or other similar or heavier weighting materials. Suitable expanded thermoplastic foams that can be utilized in the construction of the panels 42, 44, 46 of the frame 20 include polypropylene (PP) foam, polyethylene (PE) foam, and other types of structural foams, such as polyethylene terephthalate (PET) foam, polyiso (thermosetting) foam, polyvinyl chloride (PVC) foam, and glass fiber reinforced polyurethane (PU) foam, which are 100% recyclable, waterproof, and much lighter than wood or other weighting materials conventionally used in the construction of bed bases. In the exemplary embodiment, each panel 42, 44, 46 includes polyethylene foam. However, regardless of which type of thermoplastic foam is utilized, the reduced weight of panels 42, 44, 46, as compared to other weighted materials such as wood, again serves not only to reduce costs associated with shipping, but also to make it easier for an individual to lift and carry the base 10 without sacrificing the structural integrity of the base 10.

[0034] Still refer to Figure 1 , like the rails 21, 22, 23, 24, 25, 26, 27, 28 of the frame 20, each corresponding panel 42, 44, 46 can be initially formed via an extrusion process in which a thermoplastic material (such as polypropylene or polyethylene) is melted, mixed with a foaming agent (such as a halogenated hydrocarbon), and then extruded through a mold. Of course, the initial formation of each panel 42, 44, 46 can also be achieved using alternative manufacturing techniques without departing from the spirit and scope of the present invention. For example, in some embodiments, each panel 42, 44, 46 can be initially formed using an alternative manufacturing process (such as injection molding). In this exemplary embodiment, after initial formation, a plurality of openings (not shown) are created in each corresponding panel 42, 44, 46 to correspond to the openings 60 within the tops of the first set of rails 21, 22, 23, 24 and the second set of rails 25, 26, 27, 28. Although not shown in the figures, by Figure 1The positioning of the fasteners 50 in the panel 42, 44, 46 can easily distinguish the presence of such an opening. The openings of the panels 42, 44, 46 can be achieved using known subtractive manufacturing techniques (such as drilling). In the case where the panels 42, 44, 46 are formed via injection molding, such openings can be imparted during the initial formation of the panels 42, 44, 46. In the case where the panels 42, 44, 46 when initially formed do not match the contour of the frame 20 (e.g., those portions of the frame 20 corresponding to the brackets 32, 34, 36, 38), some or all of the panels can be optionally cut to correspond to such contours using known subtractive manufacturing techniques (e.g., water jet cutting, CNC milling, sawing, etc.).

[0035] Reference now Figure 1 and Figure 5 In this exemplary embodiment, in order to prevent the panels 42, 44, 46 from being separated from or moving relative to the frame 20 while in use, while still facilitating the preparation for disassembly and subsequent reassembly of the base 10, each panel 42, 44, 46 is removably secured to the frame 20 by a plurality of fasteners 50. To further enable the preparation for assembly and disassembly of the base 10 as needed and the subsequent recycling of each component of the base 10, each fastener 50 is preferably a press fastener (sometimes also referred to as a "push fastener" or "plastic rivet") comprising a recyclable plastic (e.g., nylon), such as Figure 5 The push fastener shown in FIG. 4 can be easily installed by hand by pushing the fastener 50 through one of the openings in the panels 42 , 44 , 46 and into the opening 60 in the frame 20 .

[0036] Various press fasteners are known in the art and may be utilized to secure the panels 42, 44, 46 to the frame 20. Therefore, it should be understood that the fasteners that may be utilized in the present invention are not limited to Figure 5. It should also be understood that while it is generally preferred to use press fasteners, other fasteners (e.g., snap fasteners, hook and loop fasteners, etc.) that are configured to removably secure the panels 42, 44, 46 to the frame 20 without the use of tools may be used instead without departing from the spirit and scope of the present invention. In addition, since the ease of shipping, lifting, and carrying the base 10 can be primarily attributed to the lightweight construction of the frame 20 and, at least in some embodiments, to the panels 42, 44, 46, it should also be understood that alternative embodiments of fasteners in which tools (e.g., screws) are indeed required for installation are also contemplated herein, and these embodiments are still improved and provide certain advantages over conventional bed bases constructed of wood or other weighted materials. In addition, while securing the panels 42, 44, 46 to the frame 20 may prove to be beneficial in preventing the panels 42, 44, 46 from separating from or moving relative to the frame 20, in some embodiments, the panels 42, 44, 46 may be placed on top of the frame 20 without being secured to the frame 20 and still provide a surface sufficient to support the mattress. Therefore, alternative embodiments are also contemplated herein in which the assembled base 10 does not include the fasteners 50 , and the panels 42 , 44 , 46 and rails 21 , 22 , 23 , 24 , 25 , 26 , 27 , 28 do not include corresponding openings for the fasteners 50 .

[0037] Embodiments in which the plurality of rails 21, 22, 23, 24, 25, 26, 27, 28 and / or panels 42, 44, 46 are entirely composed of thermoplastic foam are contemplated herein; and embodiments in which the plurality of rails 21, 22, 23, 24, 25, 26, 27, 28 and / or panels 42, 44, 46 are partially composed of thermoplastic foam (e.g., combined with fibers or other structural additives to increase strength or durability). Similarly, embodiments in which brackets 32, 34, 36, 38 are entirely composed of thermoplastic materials are contemplated herein; and embodiments in which these brackets are partially composed of thermoplastic materials (e.g., combined with fibers or other structural additives to increase strength or durability).

[0038] The exemplary base 10 described above is configured to accommodate a queen-sized mattress. However, it should be understood that the number and / or size of the rails of the base 10, the recesses defined in the rails, and / or the number or size of the panels may be modified to accommodate mattresses of different sizes. For example, to accommodate a king-sized mattress, the number and / or size of the rails and panels may be increased from the number and / or size described above and shown in the accompanying drawings.

[0039] A preliminary weight comparison between the above-described base 10 and currently commercially available bed bases constructed primarily of wood was conducted to assess the extent to which the exemplary base 10 improves the stress or burden associated with shipping, lifting, and carrying currently commercially available bed bases. As previously described, in the exemplary base 10: the first set of rails 21, 22, 23, 24, the second set of rails 25, 26, 27, 28, and the panels 42, 44, 46 are each constructed of extruded polyethylene foam; the brackets 32, 34, 36, 38 are each constructed of extruded polyethylene; and the fasteners 32 securing the panels 42, 44, 46 to the frame 20 include nylon. The weight comparison indicates that the exemplary bed base made in accordance with the present invention is only twenty-nine pounds (29 lbs.), and is approximately one-third (1 / 3) the weight of a similarly sized wooden bed base currently available for commercial use. Of course, those skilled in the art will appreciate that while in the exemplary base 10 the panels 42, 44, 46 and corresponding parts of the frame 20 are all constructed of thermoplastic materials, alternative embodiments in which only one of the frame 20 or the panels 42, 44, 46 is constructed of thermoplastic materials and / or embodiments in which only certain parts of the frame 20 and / or certain panels 42, 44, 46 are constructed of thermoplastic materials are possible and will still provide the advantage of reduced weight relative to a similarly constructed base constructed of wood or other similar or heavier weighted materials. For example, in one alternative embodiment, each panel 42, 44, 46 of the base 10 may be constructed of fiberboard, while each corresponding part of the frame 20 is constructed of thermoplastic foam.

[0040] In an exemplary embodiment, the base 10 is assembled by first assembling the frame 20 and then securing the panels 42, 44, 46 to the top of the frame 20 using the plurality of fasteners 50. To assemble the frame 20, the second set of rails 25, 26, 27, 28 are preferably first interlocked with each other to form the internal structure of the frame 20, which in this case initially maintains an octagonal shape. As mentioned above, the second set of rails 25, 26, 27, 28 are interlocked by aligning the notches 25c, 25d, 26c, 26d of the vertically oriented rails 25, 26 of the second set of rails 25, 26, 27, 28 with the corresponding notches 27c, 27d, 28c, 28d of the horizontally oriented rails 27, 28 of the second set of rails 25, 26, 27, 28 and press fitting the rails together. Once the second set of guide rails 25, 26, 27, 28 are interlocked with each other, the main structure of the frame 20 is then established by inserting the tenons 25a, 25b, 26a, 26b, 27a, 27b, 28a, 28b defined by the second set of guide rails 25, 26, 27, 28 into the corresponding openings 22a, 22b, 24a, 24b defined by the first set of guide rails 21, 22, 23, 24 and press-fitting the first set of guide rails 21, 22, 23, 24 and the second set of guide rails 25, 26, 27, 28 together, so that the ends of the first set of guide rails 21, 22, 23, 24 are interlocked with the ends of the second set of guide rails 25, 26, 27, 28. The frame 20 is then assembled by inserting the ends of the first set of rails 21, 22, 23, 24 into the slots of one of the brackets 32, 34, 36, 38 and by press-fitting the brackets 32, 34, 36, 38 and the first set of rails 21, 22, 23, 24 together. Once the frame 20 is assembled, the panels 42, 44, 46 are secured to the frame 20 by manually inserting the fasteners 32 through the corresponding openings 60 of the frame 20 and the panels 42, 44, 46 without the use of tools. In this exemplary embodiment and implementation, once fully assembled, the frame 20 defines a three-by-three grid, such as Figure 2 Of course, the shape of the assembled frame 20 can be Figure 2 The shape shown in the figure changes if modified to fit a different size mattress.

[0041] Unless otherwise specified or excluded by context, the method steps disclosed herein for assembling the exemplary base 10 can be performed in any order. In addition, those skilled in the art will understand that in alternative embodiments where brackets 32, 34, 36, 38 and / or fasteners 50 are omitted from the base, the assembly steps associated with the use of such components will also be similarly omitted. In addition, while it is contemplated that the base embodiments described herein are entirely or substantially composed of thermoplastic materials and are generally capable of being assembled without the use of tools, it is further contemplated that certain aspects, features, or portions of the base may also include more traditional materials used in bed bases (such as wood, pallet, medium density fiberboard, etc.) and may be assembled using conventional tools and fastening methods (screws, glue, hook and loop, heat welding, etc.) without departing from the spirit and scope of the present invention.

[0042] Although the base 10 is sometimes described herein in the context of being an assembled article, it should be understood that the base 10 can be provided to the consumer in an unassembled state for subsequent assembly, for example, according to the exemplary assembly method described above. Therefore, another aspect of the present invention relates to a kit for a bed base, which includes some or all components of the base that are consistent with the above-described base in an unassembled state. For example, in some embodiments, the kit can include each of the various components of the exemplary base 10 described above. In other embodiments, the kit can include only the guide rails 21, 22, 23, 24, 25, 26, 27, 28 and panels 42, 44, 46 of the frame 20.

[0043] Those skilled in the art will recognize that additional embodiments and implementations are possible without departing from the teachings of the present invention or the scope of the claims that follow. The detailed description, especially the specific details of the exemplary embodiments disclosed herein, are given primarily for clarity of understanding and should not be construed as unnecessary limitations, as several modifications will be apparent to those skilled in the art after reading this disclosure and may also be made without departing from the spirit or scope of the claimed invention.

Claims

1. A bed base, comprising: a frame comprising a plurality of rails comprising thermoplastic foam; as well as One or more panels are positioned on top of the frame to define an upper surface of the bed base for supporting a mattress.

2. The bed base according to claim 1, wherein: The plurality of guide rails include: a first set of rails at least partially defining a perimeter of the frame; and A second set of rails interlocks with the first set of rails, the second set of rails defining an interior structure within the perimeter of the frame, and each rail in the second set of rails interlocks with at least one other rail in the second set of rails.

3. The bed base according to claim 2, wherein: Each rail of the second set of rails defines a recess for receiving another rail of the second set of rails.

4. The bed base according to claim 2, wherein: Each end of each of the second set of rails defines a tenon, and wherein each of the first set of rails defines one or more openings in which one of the tenons defined by the second set of rails is received.

5. The bed base according to claim 1, wherein: The frame further includes a plurality of brackets, wherein each bracket of the plurality of brackets interconnects two rails of the first set of rails.

6. The bed base according to claim 5, wherein: Each of the plurality of brackets comprises a thermoplastic material.

7. The bed base according to claim 5, wherein: Each of the plurality of brackets defines a first slot in which one of the first set of rails is received and a second slot in which another of the first set of rails is received.

8. The bed base according to claim 7, wherein: Each of the plurality of brackets comprises: a first pair of flanges, the first pair of flanges defining the first slot of the bracket; a second pair of flanges defining the second slot of the bracket; and A central body from which the first pair of flanges and the second pair of flanges extend.

9. The bed base according to claim 8, wherein: The central body is generally hollow.

10. The bed base according to claim 1, wherein: The one or more panels include thermoplastic foam.

11. The bed base according to claim 10, wherein: The plurality of guide rails of the frame include one of polypropylene (PP) foam, polyethylene (PE) foam, polyethylene terephthalate (PET) foam, polyisocyanurate (polyiso) foam, polyvinyl chloride (PVC) foam, and glass fiber reinforced polyurethane (PU) foam, and Wherein, the one or more panels include one of PP foam, PE foam, PET foam, polyiso foam, PVC foam and glass fiber reinforced PU foam.

12. The bed base according to claim 1, wherein: The one or more panels include a plurality of panels.

13. The bed base according to claim 1, wherein: The one or more panels are removably secured to the frame by a plurality of fasteners.

14. The bed base according to claim 1, wherein: The one or more panels include medium density fiberboard.

15. A kit for a bed base, comprising: a plurality of rails configured to interlock with one another to at least partially define a frame of the bed base, the plurality of rails comprising thermoplastic foam; as well as One or more panels, the one or more panels being configured to be placed on top of the plurality of rails when the plurality of rails are interlocked, the one or more panels defining an upper surface of the bed base for supporting a mattress.

16. The kit of claim 15, wherein: The plurality of rails include a first set of rails and a second set of rails configured to interlock with each other, and wherein each rail in the second set of rails is configured to interlock with at least one other rail in the second set of rails to define an interior structure of the frame.

17. The kit of claim 16, wherein: Each rail of the second set of rails defines a recess for receiving another rail of the second set of rails.

18. The kit of claim 16, wherein: Each end of each of the second set of rails defines a tenon, and wherein each of the first set of rails defines one or more openings configured to receive one of the tenons defined by the second set of rails.

19. The kit of claim 16, further comprising a plurality of brackets, each bracket of the plurality of brackets being configured to interconnect two rails of the first set of rails, and the plurality of brackets defining a portion of a perimeter of the frame.

20. The kit of claim 19, wherein: Each of the plurality of brackets comprises a thermoplastic material.

21. The kit of claim 16, wherein: The one or more panels include thermoplastic foam.

22. The kit of claim 21, wherein: The plurality of guide rails include one of polypropylene (PP) foam, polyethylene (PE) foam, polyethylene terephthalate (PET) foam, polyisocyanurate (polyiso) foam, polyvinyl chloride (PVC) foam, and glass fiber reinforced polyurethane (PU) foam, and Wherein, the one or more panels include one of PP foam, PE foam, PET foam, polyiso foam, PVC foam and glass fiber reinforced PU foam.

23. The kit of claim 16, and further comprising a plurality of fasteners configured to removably secure the one or more panels to the frame.

24. The kit of claim 16, wherein: The one or more panels include medium density fiberboard.

25. A method of assembling a bed base, the method comprising: interlocking a plurality of rails to at least partially define a frame of the bed base, the plurality of rails of the frame comprising thermoplastic foam; as well as One or more panels are positioned atop the frame to define an upper surface of the bed base for supporting a mattress.

26. The method according to claim 25, wherein: Interlocking the plurality of rails comprises: interlocking a first set of the plurality of rails with a second set of the plurality of rails, the first set of rails at least partially defining a perimeter of the frame; and A second set of the plurality of rails are interlocked together to define an interior structure within the perimeter of the frame.

27. The method according to claim 26, wherein: Interlocking the first set of rails with the second set of rails and interlocking the second set of rails together is performed by press fitting the first set of rails and the second set of rails together.

28. The method of claim 25, further comprising interconnecting the first set of rails together using a plurality of corner brackets, the first set of rails and the plurality of corner brackets defining a perimeter of the frame.

29. The method of claim 25, further comprising removably securing the one or more panels to the frame using a plurality of fasteners.

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