Child support assembly

Abstract

The present disclosure is directed to a child support assembly including a frame assembly and a soft goods assembly. The child support assembly may provide one or more additional modes, such as a bassinet mode or a mattress-only mode, and the child support assembly is foldable into a collapsed configuration for transport and storage. The child support assembly can include a plurality of wooden legs, with each leg including an attachable upper corner and lower foot for supporting components of the child support assembly. The present disclosure also relates to a method of producing the plurality of wooden legs, and a method of attaching the upper corners and lower feet to the plurality of wooden legs.

Description

CHILD SUPPORT ASSEMBLYCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 656,399 filed June 5, 2024, U.S. Provisional Application No. 63 / 570,190 filed March 26, 2024, U.S. Provisional Application No. 63 / 561 ,789 filed March 6, 2024, U.S. Provisional Application No. 63 / 557,984 filed February 26, 2024, U.S. Provisional Application No. 63 / 620,287 filed January 12, 2024, U.S. Provisional Application No. 63 / 613,030 filed on December 20, 2023, U.S. Provisional Application No. 63 / 580,866 filed on September 6, 2023, which are incorporated by reference as if fully set forth.FIELD OF INVENTION

[0002] The present disclosure generally relates to a child support assembly, and more particularly relates a convertible child support assembly including wooden legs and an improved soft goods assembly.BACKGROUND

[0003] A playard is a type of framed enclosure that provides a safe and comfortable space for an infant or young child (hereinafter referred to as a “child”) to both sleep and play. A bassinet is a framed enclosure that generally is configured to provide a safe and comfortable space for a child, and support occupants while sleeping or laying down. Playards generally have a greater depth or higher sidewalls than bassinets. Playards and bassinets generally have a mattress providing a support surface for the child. Soft goods assemblies, such as fabric, mesh, or other material can be used to enclose an interior space in a bassinet or a playard. The soft goods assemblies can include sidewalls having some transparency such that caregivers can watch children inside of the bassinet or playard.

[0004] It would be desirable to provide a child support assembly that is capable of converting between a bassinet mode and a playard mode, that is also foldable for storage and transport, and which is aesthetically pleasing and functional.SUMMARY

[0005] According to one aspect, a playard for a child is disclosed. The playard can include a frame assembly and a soft goods assembly connected to the frame assembly. The frame assembly can include a plurality of legs each extending from a supporting surface to a plurality of top rails of the frame assembly, each of the plurality of legs are formed from a wooden material. A bottom X-frame can be disposed adjacent the supporting surface below the soft goods assembly, and the bottom X-frame isconnectable to the plurality of legs. The bottom X-frame can include a hub positioned at a central location below the soft goods assembly, a plurality of tubes rotationally coupled to the hub, and a release mechanism including a hub lock coupled to the hub. The hub lock is configured to transition between a locked state and an unlocked state to secure and release for rotation, respectively, the plurality of tubes.

[0006] According to another aspect, a child support assembly is disclosed. The child support assembly can include a frame assembly and a soft goods assembly connected to the frame assembly, the frame assembly can include a plurality of wooden legs. A bassinet can be removably connected to at least one of the frame assembly and the soft goods assembly. The bassinet can include a mattress configured to fit within the bassinet, and the mattress is removeable from the bassinet. A toy bar is configured to selectively attach to either a top rail of the frame assembly or the mattress, and the toy bar is attachable to the mattress when the mattress is removed from the bassinet.

[0007] According to yet another aspect, a child support assembly is disclosed. The child support assembly can include a frame assembly and a soft goods assembly connected to the frame assembly, and the frame assembly can include a plurality of legs. A bassinet can be removably connected to at least one of the frame assembly and the soft goods assembly. The bassinet can include a bassinet upper panel extending about an upper perimeter of the bassinet. A bassinet clip can be coupled to the bassinet upper panel at each corner of the bassinet. The bassinet clip can include a retainer portion that is sized to receive and detachably lock onto one leg of the plurality of legs to couple to the bassinet upper panel to the plurality of legs.

[0008] According to yet another aspect, a playard for a child is disclosed. The playard can include a frame assembly and a soft goods assembly connected to the frame assembly, the soft goods assembly defining an interior space. The frame assembly can include a plurality of legs each extending from a supporting surface to a plurality of top rails of the frame assembly, each of the plurality of legs can be formed from a wooden material. Further, each of the plurality of legs can be angled outwards extending from the plurality of top rails to the supporting surface, at an angle away from a center of the frame assembly. A cross-sectional area of the interior space can be constant from the plurality of top rails to a base of the soft goods assembly.

[0009] According to yet another aspect, a method of manufacturing a playard with a wooden leg for supporting a soft goods assembly is disclosed. The method can include providing a soft goods assembly having a narrow portion and a wide portion extending from the narrow portion. Making a first lengthwise cut along the wooden leg with a cutting tool using a cutting implement, the first lengthwise cut forming a groove in the wooden leg. Making a second lengthwise cut along the wooden leg with the cutting tool using the cutting implement, the second lengthwise cut widening an inner portion of thegroove. Attaching the soft goods assembly to the wooden leg by sliding the wide portion of the soft goods assembly into the inner portion of the groove.

[0010] According to yet another aspect, a playard for a child is disclosed. The playard can include a frame assembly and a soft goods assembly connected to the frame assembly. The frame assembly can include a plurality of legs each extending from a supporting surface to a plurality of top rails of the frame assembly, and at least some of the plurality of legs are formed from a wooden material. A bottom X-frame can be disposed adjacent the supporting surface below the soft goods assembly. An upper corner can be coupled to each of the plurality of legs at an upper distal end of each of the plurality of legs, and each of the upper corners can be configured to couple to two top rails of the plurality of top rails. A lower foot can be coupled to each of the plurality of legs at a lower distal end of each of the plurality of legs, and each of the lower feet can be configured to couple to at least a portion of the bottom X-frame.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The foregoing Summary as well as the following Detailed Description will be best understood when read in conjunction with the appended drawings, which illustrate embodiments of the disclosure. In the drawings:

[0012] FIG. 1 is a perspective view of a child support assembly of the present disclosure in a bassinet mode.

[0013] FIG. 2 is an exploded perspective view of the child support assembly of FIG. 1 .

[0014] FIG. 3 is a bottom perspective view of the child support assembly of FIG. 1 .

[0015] FIG. 4 is a front elevation view of the child support assembly of FIG. 1 .

[0016] FIG. 5 is a partial exploded view of the child support assembly of FIG. 1 .

[0017] FIG. 6 is a partial cross-sectional view of the child support assembly of FIG. 1 taken along Section Line 6—6 in FIG. 5.

[0018] FIG. 7 is a bottom perspective view of a bottom X-frame for the child support assembly of FIG. 1.

[0019] FIG. 8A is a perspective view of a child support assembly in a bassinet mode with certain components omitted.

[0020] FIG. 8B is a magnified partial view of the assembly of Figure 13A.

[0021] FIG. 9A is a perspective view of an embodiment of a child support assembly in a playmat mode.

[0022] FIG. 9B is a magnified partial view of the assembly of Figure 14A.

[0023] FIG. 10A is a front elevation view of a toy bar for a child support assembly in a rail mode.

[0024] FIG. 10B is a magnified partial view of the toy bar of Figure 15A.

[0025] FIG. 11 A is a front elevation view of a toy bar for another embodiment of a child support assembly in the playmat mode.

[0026] FIG. 11 B is a magnified partial view of the toy bar of Figure 16A.

[0027] FIG. 12A is a magnified view of a leg of the child support assembly.

[0028] FIG. 12B is a perspective view of the child support assembly in a playard mode.

[0029] FIG. 12C is a perspective view of the child support assembly in a bassinet mode.

[0030] FIGS. 13A-13C are perspective views illustrating attachment of the bassinet to the frame assembly.

[0031] FIGS. 14A-14C are magnified perspective views illustrating attachment of the bassinet to the frame assembly with a bassinet clip.

[0032] FIGS. 15A-15B illustrate the bassinet connected to the frame assembly without and with the bassinet clip, respectively.

[0033] FIG. 16 is a perspective view of an alternative embodiment of the soft goods assembly.

[0034] FIGS. 17A-17C illustrate details of the alternative embodiment of the soft goods assembly in FIG. 16.

[0035] FIGS. 18A-18G illustrate a method of cutting a channel in the legs of the child support assembly.

[0036] FIG. 19A is a perspective view of the leg including a channel with a first shape.

[0037] FIG. 19B is a perspective end view of the leg including a channel with a second shape.

[0038] FIGS. 19C-19D illustrate a fixture that can be used to produce the channel with the second shape, as illustrated in FIG. 19B.

[0039] FIGS. 20A-20D illustrate a method of cutting the channel of FIG. 19B in the legs of the child support assembly.

[0040] FIGS. 21 A-22C illustrate another method of cutting the channel of FIG. 19B in the legs of the child support assembly.

[0041] FIGS. 23A-23E illustrate another method of cutting the channel of FIG. 19B in the legs of the child support assembly.

[0042] FIGS. 24A-24C illustrate yet another method of cutting the channel of FIG. 19B in the legs of the child support assembly.

[0043] FIGS. 25A-25G illustrate various views of the leg, lower feet, and upper corners of the child support assembly.

[0044] FIGS. 26A-26I illustrate various views of another embodiment of the leg, lower feet, and upper corners of the child support assembly.

[0045] FIGS. 27A-27G illustrate various views of another embodiment of the leg, lower feet, and upper corners of the child support assembly.

[0046] FIGS. 28A-28B illustrate a method of producing the legs of the child support assembly.

[0047] FIGS. 29A-29C illustrate another method of producing the legs of the child support assembly.

[0048] FIGS. 30A-30D illustrate another method of producing the legs of the child support assembly.

[0049] FIGS. 31A-31 B illustrate another method of producing the legs of the child support assembly.

[0050] FIGS. 32A-32E illustrate various views of another embodiment of coupling the upper corners to the legs of the child support assembly.

[0051] FIGS. 33A-33D illustrate various views of another embodiment of coupling the upper corners to the legs of the child support assembly.

[0052] FIGS. 34A-34B illustrate various views of another embodiment of coupling the upper corners to the legs of the child support assembly.

[0053] FIGS. 35A-35D illustrate various views of another embodiment of coupling the upper corners to the legs of the child support assembly.

[0054] FIG. 36 is a perspective view of another embodiment of coupling the upper corners to the legs of the child support assembly.

[0055] FIGS. 37A-37B illustrate various views of another embodiment of coupling the upper corners to the legs of the child support assembly.

[0056] FIGS. 38A-38B illustrate various views of another embodiment of coupling the upper corners to the legs of the child support assembly.

[0057] FIGS. 39A-39C illustrate various views of another embodiment of coupling the lower feet to the legs of the child support assembly.

[0058] FIGS. 40A-40E illustrate various views of another embodiment of coupling the lower feet to the legs of the child support assembly.

[0059] FIGS. 41 A-41D illustrate various views of another embodiment of coupling the lower feet to the legs of the child support assembly.

[0060] FIGS.42A-42C illustrate various views of another embodiment of coupling the lower feet to the legs of the child support assembly.

[0061] FIGS.43A-43D illustrate various views of another embodiment of coupling the lower feet to the legs of the child support assembly.

[0062] FIGS. 44A-44C illustrate various views of another embodiment of coupling the lower feet to the legs of the child support assembly.

[0063] FIGS. 45A-45B illustrate cross-section views of the lower feet of FIGS. 44A-44B.DETAILED DESCRIPTION

[0064] Certain terminology is used in the following description for convenience only and is not limiting. The words “front”, “rear”, “upper”, and “lower” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly” refer to directions towards and away from parts referenced in the drawings. “Axially” refers to a direction along the axis of a shaft (or shaft-like structure), or a direction along a rotation axis. A reference to a list of items that are cited as “at least one of a, b, or c” (where a, b, and c represent the items being listed) means any single one of the items a, b, or c, or combinations thereof. The terms “about” and “approximately” are to be construed as within 10% of a stated value or ratio. The terminology includes the words specifically noted above, derivatives thereof, and words of similar import.

[0065] As shown in Figures 1-4, a child support assembly 10 is disclosed herein, which child support assembly 10 may also be referred to as a playard. Therefore, it is to be understood that the “child support assembly 10” and “playard 10” can be used interchangeably. The child support assembly 10 generally includes a frame assembly 12 and a soft goods assembly 14 that is connected to the frame assembly 12. The combined frame assembly 12 and softgoods assembly 14 (i.e., child support assembly 10) are configured to define an interior space 16 for supporting a child therein. The term interior space 16 can generally refer to an enclosed perimeter within the soft goods assembly 14. An upper portion of the interior space 16 can be open or enclosed, for example by a canopy. A mattress (not shown) may be provided within the soft goods assembly 14 near a lower or bottom surface to provide a support surface for the child. In embodiments, the mattress may be removable.

[0066] The frame assembly 12 can include a plurality of legs 18 that each extend from a supporting surface (e.g. ground surface) to a plurality of top rails 20 of the frame assembly 12. The plurality of legs 18 can be constructed from a solid wood material, and the plurality of legs 18 can be configured to support the child support assembly 10 in a standing configuration. A lower foot 22 can be coupled to a lower or bottom distal end of each of the plurality of legs 18, positioned closest and contacting the supporting surface. An upper corner 24 can be coupled to an upper distal end of each of the plurality of legs 18, and the upper corners 24 are configured to couple to the plurality of top rails 20. Therefore, the upper corners 24 interconnect the plurality of legs 18 to the plurality of top rails 20. In some examples, as illustrated, the child support assembly 10 can include four of each of the plurality of legs 18, the plurality of top rails 20, the lower feet 22, and the upper corners 24.

[0067] The connection between each of the plurality of legs 18, the plurality of top rails 20, the lower feet 22, and the upper corners 24 creates the frame assembly 12, which frame assembly 12 can generally define a support frame or structure for supporting the soft goods assembly 14. A bassinet 26 can be positioned within and coupled to either the soft goods assembly 14 or the frame assembly 12. In some examples, the bassinet 26 can be coupled to the soft goods assembly 14 through a zipper connection between the bassinet 26 and the soft goods assembly 14, such that the bassinet 26 is vertically offset from a lower or bottom surface of the soft goods assembly 14, discussed further below. The bassinet 26 can include a bassinet upper panel 28 that wraps around the plurality of top rails 20 and the upper corners 24 to aid in securing the bassinet 26 as well as creating an aesthetically pleasing appearance.

[0068] Referring to FIGS. 5-6, in some embodiments, each of the plurality of legs 18 can be formed from solid wood (i.e., formed entirely or substantially from wood throughout the thickness and height). Further, each of the plurality of legs 18 can include a channel 30 that extends radially into the leg 18 from an outer circumference towards a central axis of the leg 18. Additionally, the channel 30 extends in a height direction from one distal end to the other distal end of the leg 18. The channel 30 within each of the plurality of legs 18 is configured to receive a portion of the soft goods assembly 14. Specifically, the soft goods assembly 14 can include a soft goods sheath 32 positioned at each corner of the soft goods assembly 14. The soft goods sheath 32 is sized and configured to receive a stiffener 34 within each of the soft goods sheaths 32, which stiffener 34 can be a plastic or metal rod, among other options not specifically listed. As such, a stiffener 34 can be inserted into each of the soft goods sheaths 32 of the soft goods assembly 14, and then each of the plurality of legs 18 can be inserted onto and coupled to the soft goods sheaths 32 and stiffeners 34 through the channel 30 within each of the plurality of legs 18. Therefore, each of the plurality of legs 18 can be coupled to the soft goods assembly 14 through the soft goods sheaths 32 and stiffeners 34 connection, discussed in detail in following disclosure.

[0069] As shown best in FIGS. 3 and 7, the frame assembly 12 can further include a bottom X- frame 36, and at least one outrigger 38 can be coupled to an underside of the lower surface of the soft goods assembly 14, adjacent the support surface. The outriggers 38 can be additional supports that are utilized to further stabilize the child support assembly 10 when in use. The bottom X-frame 36 can be disposed adjacent the supporting surface and below or on an underside of the soft goods assembly 14. The bottom X-frame 36 is connectable to each of the plurality of legs 18 through the lower feet 22, adding further support and stability to the frame assembly 12 and overall child support assembly 10. The bottom X-frame 36 includes a hub 40, a plurality of tubes 42, and a release mechanism 44.

[0070] The hub 40 is positioned at a central location below the soft goods assembly 14, with respect to both a widthwise and lengthwise direction. The hub 40 includes a height in a vertical direction, with respect to the orientation of the hub 40 when the child support assembly 10 is in the upright, in-use position (FIG. 4). Each of the plurality of tubes 42 are rotationally coupled to the hub 40, such as through a pin or other pivot connection. Further, each of the plurality of tubes 42 extend outwards away from the hub 40, forming an X-shaped configuration. The plurality of tubes 42 includes at least one locking tube 42A and at least one non-locking tube 42B. The at least one locking tube 42A is configured to be locked in an expanded configuration, as shown in FIG. 7, by a hub lock 46. As such, the bottom X-frame 36 is configured to aid in keeping the child support assembly 10 in an upright, expanded configuration during use. Further, a user can pull up on the release mechanism 44 to release the hub lock 46 from a locked state, allowing the bottom X-frame 36 to fold into a collapsed configuration for transport and storage.

[0071] Referring to FIGS. 8A-11 B, a toy bar 48 may be provided with the child support assembly 10. The toy bar 48 may be selectively attached to the child support assembly 10 at various locations and in various modes. More specifically, the toy bar 48 is configured to selectively attach to either the top rail 20 of the frame assembly 12 or the mattress 50 from the bassinet 26, when the mattress 50 is removed from the bassinet 26. Referring to FIGS. 8A-8B, the toy bar 48 is shown clipped onto the top rail 20 via a clip 52. Referring to FIGS. 9A-9B, the toy bar 48 is shown in various embodiments clipped onto the mattress 50 via the clip 52, for use in the playmat mode (also referred to as a toy gym or activity mat). Further, FIGS. 10A-10B show the clip 52 oriented generally downward for mounting to the top rail 20, e.g. in the bassinet mode or in the playard mode. FIGS. 11 A-11 B show the clip 52 pivoted inward to the arrangement of FIG. 9A, oriented generally inward for mounting to the mattress 50.

[0072] The toy bar 48 includes a toy bar stalk 54 with a clip 52 disposed at each distal end of the toy bar stalk 54. The clip 52 includes a main clip 56 and a pivoting clip 58, which pivoting clip 58 pivots relative to the main clip 56 about a pivoting clip pivot 62. The main clip 56 and the pivoting clip 58 are configured to couple to the top rail 20 or the mattress 50, to couple the toy bar 48 to the respective component. As shown best in FIG. 11 B, the main clip 56 can pivot about a main clip pivot 60, such that the clip 52 is pivoted inwards to couple to the mattress 50. The toy bar stalk 54 includes a cam face 64 that pushes the pivoting clip 58 downward so that it can clamp onto the sides of the mattress 50. Once the clip 52 is rotated inward, it is ready to be attached to the mattress 50 to be used as a playmat. The toy bar 48 is a device or component in which toys can be hung from or attached to for the entertainment of the child. As discussed, the toy bar 48 can be attached to either the child support assembly 10 or the mattress 50, providing a multi-functional component.

[0073] FIG. 12A is a magnified view of the leg 18 of the child support assembly 10. FIG. 12B is a perspective view of the child support assembly 10 in a playard mode. FIG. 12C is a perspective view of the child support assembly 10 in a bassinet mode. FIGS. 12A-12C will be discussed together.

[0074] When the child support assembly 10 is in the bassinet mode (FIG. 12C), the bassinet 26 provides a raised floor or surface for conveniently placing the occupant at a higher height above the supporting surface for easier ingress and egress from the child support assembly 10. As illustrated in FIGS. 12B-12C, the bassinet 26 can be coupled to the child support assembly 10 through a zipper connection 66 that is coupled to or integrated in the soft goods assembly 14. In some examples, the zipper connection 66 can be sewn into an upper mesh seam of the soft goods assembly 14, about an upper internal perimeter of the soft goods assembly 14. Therefore, the bassinet 26 includes a mating zipper connection with the zipper connection 66, allowing the bassinet 26 to be coupled to the soft goods assembly 14. The zipper connection 66 provides an aesthetically clean and cost-effective solution.

[0075] The bassinet 26 further includes the bassinet upper panel 28, which bassinet upper panel 28 extends about and outwards from a perimeter of the bassinet 26. The bassinet upper panel 28 can be constructed from a material similar to the soft goods assembly 14, which material is soft to the touch for the comfort of the child placed within the bassinet 26. The bassinet upper panel 28 is configured as a wrap-around panel that covers an upper portion of the legs 18 and the top rails 20 of the frame assembly 12, and also covers the upper corners 24 connected to the top of each of the legs 18. As such, the bassinet upper panel 28 covers the upper perimeter of the child support assembly 10 which serves to cover the upper corners 24 and top rails 20, making the final assembled appearance more aesthetically pleasing.

[0076] For additional stability of the child support assembly 10, each leg 18 is angled outwards from a center of the child support assembly 10. The legs 18 being angled outwards creates a pyramidal shape inside the assembly 10 (i.e. the width and length of the inside of the assembly 10 increases from the top in a direction towards the bottom). The shape change, if not alleviated, would prevent the user from using the same mattress 50 in the base or bottom surface of the soft goods assembly 14 and in the bassinet 26. To maintain the same width and length along the entire interior of the assembly 10, the soft goods assembly 14 includes an additional triangular-shaped fabric extension 68. The triangular-shaped fabric extension 68 is positioned at each corner of the soft goods assembly 14, between the respective corner and the leg 18 positioned at each corner, and extending a height of the leg 18. In some embodiments, the triangular-shaped fabric extension 68 can be formed from the soft goods sheath 32 of the soft goods assembly 14. The triangular-shaped fabric extension 68 allows the user to utilize the same mattress 50 for the bassinet and playard modes by creating a constant internal shape and size for the mattress 50 to rest.

[0077] FIGS. 13A-13C are perspective views illustrating attachment of the bassinet 26 to the frame assembly 12. FIGS. 14A-14C are magnified perspective views illustrating attachment of the bassinet 26 to the frame assembly 12 with a bassinet clip 70. FIGS. 15A-15B illustrate the bassinet 26 connected to the frame assembly 12 without and with the bassinet clip 70, respectively.

[0078] With the zipper connection 66 of the soft goods assembly 14 to the bassinet 26, there is some room for the soft goods of the bassinet 26 to shift downward towards the supporting surface with weight applied to the mattress 50 within the bassinet 26. This is generally not an issue from a structural perspective, but this can cause the bassinet upper panel 28 to shift upwards away from the supporting surface and away from the upper corners 24, as illustrated in FIG. 15A. The aforementioned leads to the final assembly 10 not having the desired aesthetics, and possibly leading to perceived issues of deficient strength.

[0079] To address the aforementioned issues, the bassinet 26 includes a bassinet clip 70 that is coupled to the bassinet upper panel 28 at each corner of the bassinet 26. When attaching the bassinet upper panel 28 to the frame assembly 12, a user pulls the bassinet upper panel 28 around the upper corners 24 (see FIG. 13A) and then downwards over the upper corners 24 such that the bassinet clip 70 is aligned with the leg 18 (see FIG. 13B). Then the user can snap-fit the bassinet clip 70 onto the leg 18 to secure the bassinet clip 70 and the bassinet upper panel 28 in place on the frame assembly 12 (see FIG. 13C).

[0080] More specifically, referring to FIGS. 14B-14C, the bassinet clip 70 includes an alignment spacer 70A and a retainer portion 70B which is axially offset from the alignment space 70A along an axis of the bassinet clip 70. The bassinet clip 70 can be coupled (e.g. sewn) to an inner surface of the corners of the bassinet upper panel 28 through a tab or other similar feature positioned adjacent the retainer portion 70B of the bassinet clip 70. Referring to FIG. 14C, when the bassinet clip 70 is coupled to the leg 18, the alignment spacer 70A contacts a base or underside of the upper corner 24 (represented by the dashed line) which prevents the bassinet upper panel 28 from shifting upwards with weight applied to the mattress 50 within the bassinet 26. Additionally, when the bassinet clip 70 is coupled to the leg 18, the retainer portion 70B snaps around and is coupled to at least a portion of the circumference of the legs 18. Referring to FIGS. 15A-15B, the bassinet clip 70 prevents the bassinet upper panel 28 from shifting upwards away from the legs 18 (see FIG. 15A), and keeps the bassinet upper panel 28 in the correct location in a tight and fixed configuration (see FIG. 15B).

[0081] FIG. 16 is a perspective view of an alternative embodiment of the soft goods assembly 14A. FIGS. 17A-17C illustrate details of the alternative embodiment of the soft goods assembly 14A in FIG. 16. FIGS. 16-17C will be discussed together. In the soft goods assembly 14, a triangular-shaped fabric extension 68 is included to maintain the correct dimensions and shape for the mattress 50 to fitwithin. In the soft goods assembly 14A, a parallel fabric extension 72 is included along with other features to maintain the correct dimensions and shape for the mattress 50 to fit within. The parallel fabric extension 72 is oriented generally parallel to the angle of the legs 18, and the parallel fabric extension 72 can be formed as part of the soft goods sheath 30.

[0082] Referring to FIGS. 17A-17C, the soft goods assembly 14A can further include a diagonal panel 74 that is coupled to an upper seam of a draft shield 76 (which is a surface or sidewall of the soft goods assembly 14A) at one end, and coupled to a bottom panel 78 of the soft goods assembly 14A at the other end. The diagonal panel 74 is configured to provide a side support surface for the mattress 50, and the diagonal panel 74 is configured to fill the extra space around the bottom internal perimeter of the soft goods assembly 14A, which is formed based on the angled orientation of the legs 18. The soft goods assembly 14A including the diagonal panel 74, the draft shield 76, and the bottom panel 78 provides an alternative approach that allows the user to utilize the same mattress 50 for the bassinet and playard modes by creating a constant internal shape and size for the mattress 50 to rest. It is to be understood that the diagonal panel 74, the draft shield 76, and the bottom panel 78 can be positioned at each corner of the soft goods assembly 14A of the child support assembly 10.

[0083] FIGS. 18A-24C illustrate various manufacturing methods for cutting a groove in the (wooden) legs 18 of the child support assembly 10 by using a fixture to hold the legs 18 and various sawing / cutting techniques to achieve the desired channel 30. The disclosed methods simplify the process of cutting an undercut channel 30 in the legs 18 by: reducing machine time and number of operations; reducing complexity of operation and operator time; simplifying fixturing and removal of the legs 18 to / from the fixture for the cutting process; and protecting the operator with a fixture that keeps hands clear of the cutting tool.

[0084] FIGS. 18A-18G illustrate a method of cutting the channel 30 in the legs 18 of the child support assembly 10. In the embodiment illustrated in FIGS. 18A-18G, the channel 30 can be described as having a “lollipop” shape based on the cutting tool that is used. As illustrated in FIG. 18A, initially the leg 18 is a solid wood leg 18 from one distal end to the other distal end (lengthwise direction) of the leg 18. Then a straight cylinder cutter 80 connected to a spindle (see FIGS. 18D and 18F) can be used to cut a straight channel 30 in the leg 18 along an entire length of the leg 18 (see FIG. 18B). Then after the straight channel 30 has been cut, a ball cutter 82 is connected to the spindle (see FIGS. 18E and 18G) which is used to cut an undercut in the channel 30 along the entire length of the leg 18 to produce the “lollipop” shaped channel 30 (see FIG. 18C).

[0085] FIG. 19A is a perspective view of the leg 18 including the channel 30 as described thus far having the “lollipop” shape. FIG. 19B is a perspective end view of the leg 18 including a channel 30’ having a second shape, which can be described as a “dovetail” shaped channel 30’. The channel 30’ isan alternative to the channel 30, but either configuration can be used with the legs 18 of the child support assembly 10. FIGS. 19C-19D illustrate a fixture 84 that can be used to produce the channel 30’ having the “dovetail” shape, as illustrated in FIG. 19B. FIGS. 19A-19D will be discussed together.

[0086] The fixture 84 includes a fixture upper end 84A, a fixture lower end 84B, a set screw 86, and a spacer 88. To utilize the fixture 84, a user removes the spacer 88 from the lower end 84B and then inserts a first end of the leg 18 into a hole in the lower end 84B of the fixture 84 (see FIG. 19C). The user guides the leg 18 up to the upper end 84A of the fixture 84, and the first end of the leg 18 is secured in the upper end 84A of the fixture 84 through the set screw 86, which is tightened onto the first end of the leg 18 to prevent rotation of the leg 18 relative to the fixture 84. Then the user re-inserts and attaches the spacer 88 to the lower end 84B of the fixture 84 to fix and secure the leg 18 within the fixture 84 (see FIG. 19D). A user can then grasp any of the upper end 84A, the lower end 84B, or the side surfaces of the fixture 84 to pass the leg 18 and fixture 84 over a saw blade or other cutter, while keeping the user’s hands at a safe distance away from the saw blade or other cutter. Specifically, the user can pass the leg 18 and fixture 84 over a saw blade or other cutter to make a first cut with the upper end 84A initially contacting the cutter first, then the user rotates the coupled leg 18 and fixture 84 such that the lower end 84B contacts the cutter first during a second pass. In other words, in some embodiments, two cutting passes are required to cut the channel 30’, and the assembly is rotated 180 degrees between each cutting pass, discussed further below.

[0087] FIGS. 20A-20D illustrate a method of cutting the channel 30’ of FIG. 19B in the legs 18 of the child support assembly 10. In the embodiment illustrated in FIGS. 20A-20D, the channel 30’ can be described as having a “dovetail” shape based on the cutting tool that is used. As illustrated in FIG. 20B, initially the leg 18 is a solid wood leg 18 from one distal end to the other distal end (lengthwise direction) of the leg 18. Then a table saw (not shown) with a circular blade 90 is used to make the channel 30’. Specifically, with the leg 18 mounted to the fixture 84 (not shown), the channel 30’ is cut with that circular blade 90 set to the appropriate height (depth) and beveled to an angle of approximately 8°. The fixture 84 and leg 18 are passed through the table saw one time, such that the circular blade 90 makes a first cut (see FIG. 20C). Then the fixture 84 and leg 18 are rotated 180° and passed through the table saw again, such that the circular blade 90 makes a second cut to produce the channel 30’ with the “dovetail” shape (see FIG. 20D). It is to be understood that in other embodiments the beveled angle can be altered from approximately 8° to any desired beveled angle, depending on the desired shape of the channel 30’.

[0088] FIGS. 21 A-22C illustrate another method of cutting the channel 30’ of FIG. 19B in the legs 18 of the child support assembly 10. In the embodiment illustrated in FIGS. 21 A-22C, the channel 30’ can be described as having a “dovetail” shape based on the cutting tool that is used. As illustrated inFIG. 22A, initially the leg 18 is a solid wood leg 18 from one distal end to the other distal end (lengthwise direction) of the leg 18. Then a table saw (not shown) with a circular blade 90 and a ball cutter 82 are used to make the channel 30’. Specifically, with the leg 18 mounted to the fixture 84 (not shown), the channel 30’ is first cut with that circular blade 90 set to the appropriate height (depth) and oriented vertically. The fixture 84 and leg 18 are passed through the table saw one time, such that the circular blade 90 makes a first cut (see FIG. 22B). Then the fixture 84 and leg 18 are passed through a table router with dovetail or ball cutter 82 during a second pass, such that the ball cutter 82 makes a second cut to produce the channel 30’ with the “dovetail” shape (see FIG. 22C).

[0089] FIGS. 23A-23E illustrate a method of cutting the channel 30’ of FIG. 19B in the legs 18 of the child support assembly 10. In the embodiment illustrated in FIGS. 23A-23E, the channel 30’ can be described as having a “dovetail” shape based on the cutting tool that is used. As illustrated in FIG. 23C, initially the leg 18 is a solid wood leg 18 from one distal end to the other distal end (lengthwise direction) of the leg 18. Then a table router (not shown) with a straight cylinder cutter 80 is used to make the channel 30’. Specifically, with the leg 18 mounted to the fixture 84 (not shown), the channel 30’ is cut with the straight cylinder cutter 80 set to the appropriate height (depth) and beveled to an angle of approximately 8°. The fixture 84 and leg 18 are passed through the table router one time, such that the straight cylinder cutter 80 makes a first cut (see FIGS. 23A and 23D). Then the fixture 84 and leg 18 are rotated 180° and passed through the table router again, such that the straight cylinder cutter 80 makes a second cut to produce the channel 30’ with the “dovetail” shape (see FIGS. 23B and 23E). It is to be understood that in other embodiments the beveled angle can be altered from approximately 8° to any desired beveled angle, depending on the desired shape of the channel 30’.

[0090] FIGS. 24A-24C illustrate yet another method of cutting the channel 30’ of FIG. 19B in the legs 18 of the child support assembly 10. In the embodiment illustrated in FIGS. 24A-24C, the channel 30’ can be described as having a “dovetail” shape based on the cutting tool that is used. As illustrated in FIG. 24B, initially the leg 18 is a solid wood leg 18 from one distal end to the other distal end (lengthwise direction) of the leg 18. Then a table router (not shown) with a ball cutter 82 is used to make the channel 30’. Specifically, with the leg 18 mounted to the fixture 84 (not shown), the channel 30’ is cut with the ball cutter 82 using only a single pass to create the “dovetail” shape of the channel 30’ (see FIG. 24C).

[0091] FIGS. 25A-45B illustrate various embodiments of the legs 18, the lower feet 22, and / or the upper corners 24 of the frame assembly 12 of the child support assembly 10. The various embodiments are intended to simplify the construction, assembly, and part count for the legs 18, the lower feet 22, and / or the upper corners 24. More specifically, in an effort to save cost and simplify the assembly 10, various embodiments of the following elements were developed: Upper Corners 24 - size, shape, fastening hardware, and other features are disclosed; Legs 18 - economizing raw materials andoperations, simplifying foot and corner attachment methods are disclosed; and Lower Feet 22 - size, shape, fastening hardware, and other features are disclosed.

[0092] FIGS. 25A-25G illustrate various views of the base or original embodiment of the leg 18, lower feet 22, and upper corners 24 of the child support assembly 10, which are illustrated in FIGS. 1-6 of the present application. In the illustrated embodiment, the leg 18 includes an upper end 19A and a lower end 19B. The upper end 19A and a lower end 19B can both be formed as tenons that are configured to be inserted into other apertures or cavities. Specifically, the upper end 19A is configured to be inserted into an aperture or cavity with the upper corner 24. Further, fasteners (not shown) extend through fastener apertures within the upper corner 24, such that the fasteners thread into the apertures 92A positioned in the upper end 19Aof the leg 18 (see FIG. 25E). In some examples, the upper end 19A of the leg 18 can include two apertures 92A, and two fasteners can be used to couple the upper corner 24 to the leg 18. The lower end 19B is configured to be inserted into an aperture or cavity with the lower feet 22. Further, a fastener (not shown) extends through a fastener aperture within the lower feet 22, such that the fastener threads into the aperture 92B positioned within the channel 30 in the lower end 19B of the leg 18 (see FIG. 25F). Additionally, as previously disclosed, the stiffener 34 can be used to secure the soft goods assembly 14 to the legs 18.

[0093] FIGS. 26A-26I illustrate various views of another embodiment of the leg 18A, lower feet 22A, and upper corners 24A of the child support assembly 10. In the illustrated embodiment, the leg 18A includes an upper end 19A and a lower end 19B. The upper end 19A is formed as a tenon that is configured to be inserted into other apertures or cavities. The lower end 19B of leg 18A does not include a tenon, but rather includes a constantly tapering diameter to the distal end. The upper end 19A of the leg 18A is configured to be inserted into an aperture or cavity with the upper corner 24A. In this embodiment, a snap ring 94 is secured within the upper corner 24A and the snap ring 94 is configured to couple with a radial groove 96 cut into the tenon of the upper end 19A of the leg 18A. As such, when the upper corner 24A is inserted and pressed onto the upper end 19A of the leg 18A, the snap ring 94 engages and couples with the radial groove 96 to secure the upper corner 24A to the upper end 19A of the leg 18A. The lower end 19B is configured to be inserted into an aperture or cavity with the lower feet 22A. Further, a fastener (not shown) extends through a fastener aperture within the lower feet 22A, such that the fastener threads into the aperture 92B positioned within the channel 30 in the lower end 19B of the leg 18A (see FIG. 26F).

[0094] FIGS. 27A-27G illustrate various views of another embodiment of the leg 18B, lower feet 22B, and upper corners 24B of the child support assembly 10. In the illustrated embodiment, the leg 18B includes an upper end 19A and a lower end 19B. The upper end 19A is formed as a tenon that is configured to be inserted into other apertures or cavities. The lower end 19B of leg 18B does not includea tenon, but rather includes a constantly tapering diameter to the distal end. The upper end 19A of the leg 18B is configured to be inserted into an aperture or cavity with the upper corner 24B. In this embodiment, an aperture 24B’ extends axially through the upper corner 24B, such that a fastener (not shown) can be inserted into the aperture 24B’. Further, the tenon of the upper end 19A of the leg 18B includes an axially extending aperture 98A that extends into the leg 18B and is configured to receive the fastener to secure the upper corner 24B to the leg 18B. Likewise, in this embodiment, an aperture 22B’ extends axially through the lower feet 22B, such that a fastener (not shown) can be inserted into the aperture 22B’. Further, the lower end 19B of the leg 18B includes an axially extending aperture 98B that extends into the leg 18B and is configured to receive the fastener to secure the lower feet 22B to the leg 18B. In this embodiment, a cap 100 can also be provided that can be secured to the lower feet 22B to cover the fastener and the aperture 22B’.

[0095] FIGS. 28A-28B illustrate a method of producing the legs 18 of the child support assembly 10. Specifically, referring to FIG. 28A, two pieces of raw material 181 , 182 can be secured together and then the pieces can be turned on a lathe or other similar device to produce the generally cylindrical legs 18. More specifically, two rectangular pieces of wood 181 , 182 can be glued together along their long side surfaces. Then the glued together pieces can be turned on a lathe or other similar device to produce the generally cylindrical legs 18.

[0096] FIGS. 29A-29C illustrate another method of producing the legs 18 of the child support assembly 10. In this embodiment, the wooden leg 18 can be constructed from two shorter sections 183, 184 of wood with a hole 185 drilled in one end of each of the two shorter leg sections 183, 184. Further, a wooden dowel 186 can be inserted into the hole 185 in each of the two shorter leg sections 183, 184, and the two sections 183, 184 of wood can be combined and secured together. The joint and / or dowel 186 can also be glued for extra strength and to prevent separation of the components.

[0097] FIGS. 30A-30D illustrate another method of producing the legs of the child support assembly. In this embodiment, the wooden leg 18 can be constructed from two shorter sections 183, 184 of wood with a hole 185 drilled in one end of each of the two shorter leg sections 183, 184. Further, a threaded insert 187 can be inserted / threaded into the hole 185 in each of the two shorter leg sections 183, 184, and the two sections 183, 184 of wood can be combined and secured together. The joint and / or threaded insert 187 can also be glued for extra strength and to prevent separation of the components.

[0098] FIGS. 31A-31 B illustrate another method of producing the legs of the child support assembly. The embodiment of FIGS. 31A-31 B is substantially similar to the embodiment of 30A-30D, with the only difference being the inclusion of a disk 188 in the embodiment of FIGS. 31A-31 B. As such, the disclosure regarding the embodiment of 30A-30D is to be understood as equally applying to the embodiment of FIGS. 31A-31 B. In the embodiment of FIGS. 31A-31 B, the disk 188 is added andpositioned between the joint or connection location of the shorter sections 183, 184. The disk 188 includes a central aperture, such that the threaded insert 187 can extend through the disk 188. The disk 188 is added between the shorter sections 183, 184 to soften the visual impact of the joint that would otherwise highlight differing colors and grain between the two leg sections, to provide some margin of error in case of slight axial misalignment, and to provide an aesthetic look that is similar to other items within the “family” of products marketed under the same brand / collection.

[0099] FIGS. 32A-32E illustrate various views of another embodiment of coupling the upper corners 24C to the legs 18C of the child support assembly 10. In the illustrated embodiment, the legs 18C include a radial groove 96C in the upper end of the legs 18C. The upper corners 24C include a socket 102, a window 104 positioned is a radial sidewall of the socket 102 and the upper corners 24C, and a rib 106. The socket 102 is an aperture that is configured for receiving the upper end of the leg 18C. The window 104 is an opening positioned within and extending through a radial sidewall of the socket 102, the socket 102 can include at least one window 104. The leg 18C can have the radial groove 96C cut near the top of the leg 18C, and the C-clip 108 can be assembled and coupled to the radial groove 96C. The C-clip 108 spreads wider than the radial groove 96C diameter to allow radial flexing in and out of the C-clip 108 when squeezed.

[0100] The leg 18C is assembled to the upper corner 24C by squeezing the C-clip 108 and inserting the top end of the leg 18C into the socket 102 until the C-clip 108 expands into the window 104. Once assembled, the upper corner 24C cannot be removed unless a tool is inserted in the window 104 to press and release the C-clip 108 and thus remove the leg 18C. Additionally, the rib 106 is a protrusion positioned within an inner radial surface of the socket 102, and extending inwards towards a center of the socket 102. The rib 106 aligns with the channel 30, 30’ in the leg 18C to properly position the upper corner 24C relative to the leg 18C and to prevent relative rotation between the components.

[0101] FIGS. 33A-33D illustrate various views of another embodiment of coupling the upper corners 24D to the legs 18D of the child support assembly 10. In the illustrated embodiment, the legs 18D include a radial groove 96D in the upper end of the legs 18D. The upper corners 24D include a socket 102D, a flex finger 110, and a rib 106D. The socket 102D is an aperture that is configured for receiving the upper end of the leg 18D. The flex finger 110 is positioned in and formed integral with a radial sidewall of the socket 102D and the upper corners 24D. The flex finger 110 is configured to flex radially inwardly and outwardly relative to the radial sidewall of the socket 102D. Additionally, the rib 106D is a protrusion positioned within an inner radial surface of the socket 102D, and extending inwards towards a center of the socket 102D. The rib 106D aligns with the channel 30, 30’ in the leg 18D to properly position the upper corner 24D relative to the leg 18D and to prevent relative rotation between the components.

[0102] The leg 18D can have the radial groove 96D cut near the top of the leg 18D, and the flex finger 100 can be assembled and coupled to the radial groove 96D. Specifically, the leg 18D with the radial groove 96D near the top is assembled to the upper corner 24D by inserting the top end of the leg 18D into the socket 102D. The flex finger 110 flexes out of the way during the insertion and then snaps into position and is held within the radial groove 96D. Once assembled, the upper corner 24D cannot be removed unless a tool is used to pry back the flex finger 110 and thus remove the leg 18D.

[0103] FIGS. 34A-34B illustrate various views of another embodiment of coupling the upper corners 24E to the legs 18E of the child support assembly 10. In the illustrated embodiment, the upper end of the leg 18E includes the channel 30’ and a shoulder screw 112 coupled to the upper end of the leg 18E within the channel 30’. The upper corners 24E include a socket 102E for receiving the upper end of the leg 18E and a pop rivet hole 114 for receiving a pop rivet 116. The leg 18E is assembled to the upper corner 24E by inserting the upper end of the leg 18E into the socket 102E and then the pop rivet 116 is fastened within the pop rivet hole 114. The engagement of the shoulder screw 112 and the pop rivet 116 prevents the leg 18E from pulling out of the socket 102E of the upper corner 24E.

[0104] FIGS. 35A-35D illustrate various views of another embodiment of coupling the upper corners 24F to the legs 18F of the child support assembly 10. In the illustrated embodiment, the axial end of the legs 18F include a hole (not shown) that is configured to receive and secure a metal post 118. As illustrated, the metal post 118 includes a groove 1 18A, which is a radial groove cut into the metal post 118 near an axial end of the metal post 118. The upper corner 24F includes a socket 102F that is configured to receive the metal post 118. The upper corner 24F also includes a window 104F extending through a radial sidewall of the upper corner 24F. To assemble, the leg 18F with the attached metal post 118 is inserted into the upper corner 24F, such that the metal post 118 is inserted into the socket 102F. With the metal post 118 positioned within the socket 102F and the upper corner 24F positioned adjacent the upper end of the leg 18F, a cotter pin 120A or a clip 120B is used to couple the upper corner 24F to the leg 18F. Specifically, the cotter pin 120A or the clip 120B is assembled through the window 104F in the side of the upper corner 24F, such that the cotter pin 120A or the clip 120B engages with the groove 118A in the metal post 118, preventing separation of the upper corner 24F and the leg 18F. An alignment rib 106F can also be provided within the upper corner 24F, which engages with the channel 30’ to prevent rotation.

[0105] FIG. 36 is a perspective view of another embodiment of coupling the upper corners 24G to the legs 18G of the child support assembly 10. In the illustrated embodiment, the leg 18G includes the channel 30’ and a channel cut 122 positioned at a distal end of the channel 30’ at the upper end of the leg 18G. The channel cut 122 can be circular in shape and can extend partially into the leg 18G, but not all the way through the leg 18G. The upper corner 24G includes a socket 102G for receiving the leg 18G,and a pop rivet hole 114G for receiving a pop rivet (not shown) or other fastener. The leg 18G is assembled to the upper corner 24G by inserting the upper end of the leg 18G into the socket 102G and then fastening the pop rivet to the pop rivet hole 114G to prevent the leg 18G from rotating and pulling out of the upper corner 24G.

[0106] FIGS. 37A-37B illustrate various views of another embodiment of coupling the upper corners 24H to the legs 18H of the child support assembly 10. In the illustrated embodiment, the leg 18H includes the channel 30’ and a radial groove 96H positioned near a distal end of the upper end of the leg 18H. The upper corner 24H includes a socket 102H for receiving the leg 18H, and two pop rivet holes 114H for receiving a pop rivet (not shown), push fastener, or screw, among other options not specifically listed. The leg 18H is assembled to the upper corner 24H by inserting the upper end of the leg 18H into the socket 102H and then fastening the pop rivets, push fasteners, screws, etc. to the pop rivet holes 114H to prevent the leg 18H from rotating and pulling out of the upper corner 24H. It is to be understood that the pop rivets, push fasteners, or screws may not necessarily penetrate the wooded leg 18H. Further, the upper corners 24H can include a rib 106H that aligns with the channel 30’ to prevent rotation between the leg 18H and the upper corner 24H.

[0107] FIGS. 38A-38B illustrate various views of another embodiment of coupling the upper corners 24I to the legs 181 of the child support assembly 10. In the illustrated embodiment, the leg 181 includes the channel 30’ and an aperture 981 extending into a distal end of the upper end of the leg 181. The aperture 981 is axially offset from a central axis of the leg 181, and the aperture 981 is parallel to the central axis of the leg 181. The upper corners 241 include a metal post 1181 that is pressed into an aperture (not shown) within the upper corners 241, such that the metal post 1181 is secured to the upper corners 241. The leg 181 is assembled to the upper corner 241 by inserting the metal post 1181 coupled to the upper corners 241 into the aperture 981 of the leg 181. The offset axes of the metal post 1181 and the leg 181 prevents the leg 181 from rotating relative to the upper corner 241.

[0108] FIGS. 39A-39C illustrate various views of another embodiment of coupling the lower feet 22C to the legs 18C of the child support assembly 10. In the illustrated embodiment, the lower feet 22C include a socket 124 for receiving the lower end of the wooden legs 18C. The wooden leg 18C has the channel 30’ cut into it, and the lower feet 22C have a vertical post 126 protruding from the center of the socket 124 in an upward direction. The vertical post 126 has an alignment rib 128 and a hole 130 for a screw assembly. The lower feet 22C are assembled to the lower end of the legs 18C with the vertical post 126 and the alignment rib 128 aligned and positioned within the channel 30’. A screw 132 (or other fastener) is inserted into the hole 130 in the vertical post 126 to secure the lowerfeet 22C to the leg 18C, to prevent the leg 18C from pulling off the lower feet 22C. The screw 132 and vertical post 126 are hidden behind the soft goods assembly, which are assembled in subsequent steps.

[0109] FIGS. 40A-40E illustrate various views of another embodiment of coupling the lower feet 22D to the legs 18D of the child support assembly 10. In the illustrated embodiment, the lower feet 22D include a metal bracket 134 with two interlocking tabs 136 with screw holes 136A in the tabs 136. The metal bracket 134 is wrapped around the lower end of the leg 18D until the interlocking tabs 136 overlap, allowing a screw 132 to be assembled through the tabs 136 and into the lower end of the leg 18D. A plastic, scratch resistant foot (i.e. the lower feet 22D) is pressed onto the metal bracket 134 and end of the leg 18D until the rivet holes 138 of the lower feet 22D and the metal bracket 134 are in alignment. The plastic foot is held on and prevented from pulling off by a rivet (not shown).

[0110] FIGS. 41A-41D illustrate various views of another embodiment of coupling the lower feet 22E to the legs 18E of the child support assembly 10. The lower feet 22E include has a socket 124E for receiving the lower end of a wooden leg 18E. The wooden leg 18E has a channel 30’ cut into it from the top down, but the channel 30’ stops prior to interfering with the lower end of the leg 18E. The lower end of the leg 18E also has a radial groove 138 and a flat section 140 cut into the lower end of the leg 18E. A flat metal ring 142 with resilient fingers is imbedded in the lower feet 22E by pressing it past the undercuts 144 on the standoff ribs. The lower feet 22E and the flat metal ring 142 are pressed onto the lower end of the leg 18E until the resilient fingers of the flat metal ring 142 snap into the radial groove 138. The flat section 140 provides an anti-rotation feature to prevent the lower feet 22E from twisting relative to the leg 18E. In a second embodiment (FIG. 41 D), mold-in undercut tabs 146 within the socket 124E of the lower feet 22E can engage directly with the radial groove 138.

[0111] FIGS. 42A-42C illustrate various views of another embodiment of coupling the lower feet 22F to the legs 18F of the child support assembly 10. The lower feet 22F include a socket 124F for receiving the lower end of a wooden leg 18F. The wooden leg 18F has a channel 30’ cut into it from the top down, but the channel 30’ stops prior to interfering with the lower end of the leg 18F. The lower end of the leg 18F has a hole 130F drilled in the center of it for a threaded fastener 148. The threaded fastener 148 is assembled to the lower end of the leg 18F. The lower feet 22F is then assembled to the threaded fastener 148 by spinning / rotating / threading the socket 124F onto the other end of threaded fastener 148. Threads on the threaded fastener 148 engage with the inner wall of the socket 148 to hold the lower feet 22F in place on the leg 18F.

[0112] FIGS. 43A-43D illustrate various views of another embodiment of coupling the lower feet 22G to the legs 18G of the child support assembly 10. In the illustrated embodiment, the lower feet 22G include a socket 124G for receiving the lower end of a wooden leg 18G. The wooden leg 18G has a channel 30’ cut into it from the top down, the channel 30’ terminates prior to passing through the lower end of the leg 18G, but does not pass all the way through. A flexible snap button 150 is assembled to and positioned within the channel 30’. The flexible snap button 150 is configured to snap into and engagewith an undercut 152 in the lower feet 22G. The undercut 152 can be an aperture extending through the radial sidewalls of the lower feet 22G.

[0113] FIGS. 44A-44C illustrate various views of another embodiment of coupling the lower feet to the legs of the child support assembly. FIGS. 45A-45B illustrate cross-section views of the lower feet of FIGS. 44A-44B. Further, the lower feet illustrated in FIGS. 44A-45B are the same as the lower feet 22B illustrated in FIGS. 27A-27G. As discussed, the lower feet 22B include an aperture 22 B’ that extends axially through the lower feet 22B, such that a fastener 132B can be inserted into the aperture 22B’. Further, the lower end 19B of the leg 18B includes an axially extending aperture 98B that extends into the leg 18B and is configured to receive the fastener 132B to secure the lower feet 22B to the leg 18B. In this embodiment, a cap 100 can also be provided that can be secured to the lower feet 22B to cover the fastener 132B and the aperture 22B’. As illustrated, in some embodiments, the lower feet 22B can also include an alignment rib 128B that is configured to engage with the channel 30’ to properly orientate the lower feet 22B on the leg 18B, as well as to prevent rotation between the components.

[0114] While a particular series of modes and configurations has been described for a child support assembly, one of ordinary skill in the art would understand that additional modes are possible.

[0115] Having thus described the illustrated embodiments in detail, it is to be appreciated and will be apparent to those skilled in the art that many physical changes, only a few of which are exemplified in the detailed description of the disclosure, could be made without altering the inventive concepts and principles embodied therein. It is also to be appreciated that numerous embodiments incorporating only part of the illustrated embodiment are possible which do not alter, with respect to those parts, the inventive concepts and principles embodied therein.

[0116] The present embodiment and optional configurations are therefore to be considered in all respects as exemplary and / or illustrative and not restrictive, the scope of the disclosure being indicated by the appended claims rather than by the foregoing description, and all alternate embodiments and changes to this embodiment which come within the meaning and range of equivalency of said claims are therefore to be embraced therein.

Claims

CLAIMSWhat is claimed is:1 . A playard for a child, the playard comprising: a frame assembly and a soft goods assembly connected to the frame assembly; the frame assembly comprising: a plurality of legs each extending from a supporting surface to a plurality of top rails of the frame assembly, wherein each of the plurality of legs are formed from a wooden material; and a bottom X-frame disposed adjacent the supporting surface below the soft goods assembly and the bottom X-frame being connectable to the plurality of legs, the bottom X-frame comprising: a hub positioned at a central location below the soft goods assembly; a plurality of tubes rotationally coupled to the hub; and a release mechanism including a hub lock coupled to the hub; wherein the hub lock is configured to transition between a locked state and an unlocked state to secure and release for rotation, respectively, the plurality of tubes.

2. The playard of claim 1 , wherein each of the plurality of legs include a channel.

3. The playard of claim 2, wherein the channel of each of the plurality of legs is configured to receive a portion of the soft goods assembly.

4. The playard of claim 3, wherein a plurality of stiffeners are inserted into a plurality of soft goods sheaths of the soft goods assembly, which soft goods sheaths are configured to be positioned within the channel of each of the plurality of legs, such that the stiffeners secure the soft goods assembly to each of the plurality of legs.

5. The playard of claim 1 , wherein transitioning of the hub lock between the locked state and the unlocked state comprises the hub lock rotating about a central axis of the hub lock.

6. The playard of claim 5, wherein the central axis of the hub lock is axially aligned with a central axis of the hub.

7. A child support assembly comprising: a frame assembly and a soft goods assembly connected to the frame assembly, the frame assembly comprising a plurality of wooden legs; a bassinet removably connected to at least one of the frame assembly and the soft goods assembly, the bassinet including a mattress configured to fit within the bassinet, wherein the mattress is removeable from the bassinet; and a toy bar that is configured to selectively attach to either a top rail of the frame assembly or the mattress, wherein the toy bar is attachable to the mattress when the mattress is removed from the bassinet.

8. The child support assembly of claim 7, wherein the toy bar includes at least one clip that is configured to couple to the top rail of the frame assembly to secure the toy bar to the frame assembly.

9. The child support assembly of claim 8, wherein the at least one clip comprises a clip disposed at each end of the toy bar.

10. The child support assembly of claim 7, wherein the toy bar includes at least one clip that is configured to couple to the mattress to secure the toy bar to the mattress.11 . The child support assembly of claim 10, wherein the at least one clip is pivotable relative to a toy bar stalk of the toy bar.

12. The child support assembly of claim 10, wherein the at least one clip comprises a clip disposed at each end of the toy bar.

13. A child support assembly comprising: a frame assembly and a soft goods assembly connected to the frame assembly, the frame assembly comprising a plurality of legs; a bassinet removably connected to at least one of the frame assembly and the soft goods assembly, the bassinet including: a bassinet upper panel extending about an upper perimeter of the bassinet; anda bassinet clip coupled to the bassinet upper panel at each corner of the bassinet, the bassinet clip comprising a retainer portion that is sized to receive and detachably lock onto one leg of the plurality of legs to couple to the bassinet upper panel to the plurality of legs.

14. The child support assembly of claim 13, wherein the bassinet clip further comprises an alignment spacer that is axially offset from the retainer portion along an axis of the bassinet clip.

15. The child support assembly of claim 14, wherein the alignment spacer is configured to contact a base or underside of an upper corner of each of the plurality of legs.

16. The child support assembly of claim 13, wherein the bassinet clip is coupled to an inner surface of the bassinet upper panel at each corner of the bassinet.

17. The child support assembly of claim 16, wherein the bassinet clip is sewn into the inner surface of the bassinet upper panel.

18. The child support assembly of claim 13, wherein the bassinet clip being coupled to a leg of the plurality of legs causes the bassinet upper panel to extend over an upper exterior surface of the frame assembly.

19. A playard for a child, the playard comprising: a frame assembly and a soft goods assembly connected to the frame assembly, the soft goods assembly defining an interior space, and the frame assembly comprising: a plurality of legs each extending from a supporting surface to a plurality of top rails of the frame assembly, wherein: each of the plurality of legs are formed from a wooden material;each of the plurality of legs are angled outwards extending from the plurality of top rails to the supporting surface, at an angle away from a center of the frame assembly; and a cross-sectional area of the interior space is constant from the plurality of top rails to a base of the soft goods assembly.

20. The playard of claim 19, wherein the soft goods assembly further comprises a triangular-shaped fabric extension positioned at each corner of the soft goods assembly.21 . The playard of claim 20, wherein the triangular-shaped fabric extension produces the constant cross-sectional area within the interior space of the soft goods assembly.

22. The playard of claim 19, wherein the soft goods assembly further comprises a diagonal panel extending between a sidewall of the soft goods assembly and a bottom panel of the soft goods assembly, the diagonal panel being positioned along an entire inner bottom perimeter of the soft goods assembly.

23. The playard of claim 22, wherein the diagonal panel produces the constant cross-sectional area within the interior space of the soft goods assembly.

24. A method of manufacturing a playard with a wooden leg for supporting a soft goods assembly, the method comprising: providing a soft goods assembly having a narrow portion and a wide portion extending from the narrow portion; making a first lengthwise cut along the wooden leg with a cutting tool using a cutting implement, the first lengthwise cut forming a groove in the wooden leg; making a second lengthwise cut along the wooden leg with the cutting tool using the cutting implement, the second lengthwise cut widening an inner portion of the groove; and attaching the soft goods assembly to the wooden leg by sliding the wide portion of the soft goods assembly into the inner portion of the groove.

25. The method of claim 24, wherein the inner portion of the groove is positioned radially inward of a radially outer circumference of the wooden leg.

26. The method of claim 24, wherein after the first lengthwise cut, the wooden leg is reoriented by rotating the wooden leg 180 degrees.

27. The method of claim 24, wherein during the first lengthwise cut, the cutting implement is a saw blade that is angled obliquely to a long axis of the wooden leg.

28. The method of claim 27, wherein after the first lengthwise cut, the wooden leg is reoriented by rotating the wooden leg 180 degrees.

29. The method of claim 27, wherein the saw blade is angled between 5 - 15 degrees from vertical.

30. The method of claim 24, wherein the cutting implement is a ball cutter.31 . A playard for a child, the playard comprising: a frame assembly and a soft goods assembly connected to the frame assembly, the frame assembly comprising: a plurality of legs each extending from a supporting surface to a plurality of top rails of the frame assembly, wherein at least one of the plurality of legs are formed from a wooden material; a bottom X-frame disposed adjacent the supporting surface below the soft goods assembly; an upper corner coupled to each of the plurality of legs at an upper distal end of each of the plurality of legs, each of the upper corners being configured to couple to two top rails of the plurality of top rails; and a lower foot coupled to each of the plurality of legs at a lower distal end of each of the plurality of legs, each of the lower feet being configured to couple to at least a portion of the bottom X-frame.

32. The playard of claim 31 , wherein each of the plurality of legs are formed from a wooden material.

33. The playard of claim 31 , wherein each of the upper corners are coupled to a leg of the plurality of legs through a c-clip engaging in a radial groove of the leg and engaging in a window within the upper corners.

34. The playard of claim 31 , wherein each of the upper corners are coupled to a leg of the plurality of legs through a flex finger of the upper corners engaging with a radial groove of the legs.

35. The playard of claim 31 , wherein each of the upper corners are coupled to a leg of the plurality of legs through engagement between a shoulder screw coupled to the leg within a channel of the leg and a pop rivet that extends through a pop rivet hole within the upper corners.

36. The playard of claim 31 , wherein each of the upper corners are coupled to a leg of the plurality of legs through a metal post coupled within an aperture in the distal end of the leg engaging with a socket within the upper corners.

37. The playard of claim 36, wherein a pin or clip engage with a groove in the metal post to prevent the metal post from being removed from the socket.

38. The playard of claim 31 , wherein each of the upper corners are coupled to a leg of the plurality of legs through at least one pop rivet extending through at least one pop rivet hole in the upper corners, which at least one pop rivet engages a radial groove of the leg.

39. The playard of claim 31 , wherein each of the lower feet are coupled to a leg of the plurality of legs through a fastener extending through an aperture within a vertical post extending from the lower feet in a direction upwards towards the leg.

40. The playard of claim 39, wherein the vertical post is positioned within a channel of the leg.41 . The playard of claim 31 , wherein each of the lower feet are coupled to a leg of the plurality of legs through a metal bracket that is wrapped around a lower end of each of the plurality of legs, and wherein a fastener extends through tabs within the metal bracket into a channel of the leg when secured to the leg.

42. The playard of claim 31 , wherein each of the lower feet are coupled to a leg of the plurality of legs through a metal ring positioned within the lower feet, the metal ring being configured to engage a radial groove within a lower end of each of the plurality of legs.

43. The playard of claim 31 , wherein each of the lower feet are coupled to a leg of the plurality of legs through a threaded fastener that threads into an aperture within an axial end of the leg, and the threaded fastener threads into a socket within the lower feet.

44. The playard of claim 31 , wherein each of the lower feet are coupled to a leg of the plurality of legs through a snap button that is positioned within a channel of the legs, the snap button being configured to engage an undercut within the lower feet.

45. The playard of claim 31 , wherein each of the lower feet are coupled to a leg of the plurality of legs through a fastener that extends axially through the lower feet and is coupled to the lower leg axially aligned with a central axis of the legs.

46. The playard of claim 45, wherein a cap is coupled to the lower feet to cover the fastener, the cap being axially aligned with the fastener.

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