U.S. patent application number 15/722283 was filed with the patent office on 2019-04-04 for bed system.
The applicant listed for this patent is Sauder Woodworking Co.. Invention is credited to Neal J. Fifer, Brian D. Fritch, Douglas B. Gerig, Ronald D. Roth, Barry J. Tuckerman.
Application Number | 20190099006 15/722283 |
Document ID | / |
Family ID | 65896452 |
Filed Date | 2019-04-04 |
United States Patent
Application |
20190099006 |
Kind Code |
A1 |
Gerig; Douglas B. ; et
al. |
April 4, 2019 |
BED SYSTEM
Abstract
A bed assembly includes first, second, third, and fourth side
rails, first and second slat supports, first and second rail
supports, and a slat. The side rails each include an end and a
side. The end of the second side rail is coupled to the end of the
first side rail. The end of the fourth side rail is coupled to the
end of the third side rail such that the sides of the first and
second side rails are facing the sides of the third and fourth side
rails. The first and second slat supports are configured to engage
the first and third side rails, respectively. The first and second
rail supports each include a continuous surface coupled to two of
the first, second, third, and fourth side rails and configured to
inhibit movement of the two of the first, second, third, and fourth
side rails.
Inventors: |
Gerig; Douglas B.;
(Archbold, OH) ; Roth; Ronald D.; (Wauseon,
OH) ; Tuckerman; Barry J.; (Wauseon, OH) ;
Fifer; Neal J.; (McClure, OH) ; Fritch; Brian D.;
(Stryker, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sauder Woodworking Co. |
Archbold |
OH |
US |
|
|
Family ID: |
65896452 |
Appl. No.: |
15/722283 |
Filed: |
October 2, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 19/005 20130101;
A47C 23/062 20130101; A47C 19/025 20130101; A47C 23/061 20130101;
A47C 23/06 20130101; A47C 17/86 20130101 |
International
Class: |
A47C 19/02 20060101
A47C019/02 |
Claims
1. A bed assembly comprising: a first side rail having an end and a
side extending from the end; a second side rail having an end and a
side extending from the end of the second side rail, wherein the
end of the second side rail is coupled to the end of the first side
rail; a third side rail having an end and a side extending from the
end of the third side rail; a fourth side rail having an end and a
side extending from the end of the fourth side rail, wherein the
end of the fourth side rail is coupled to the end of the third side
rail, and wherein the sides of the first and second side rails are
facing the sides of the third and fourth side rails; a first slat
support configured to engage the first side rail; a second slat
support configured to engage the third side rail; a slat coupled to
the first slat support and the second slat support; a first rail
support having a continuous surface coupled to the first side rail
and the second side rail and configured to inhibit movement of the
first side rail relative to the second side rail; and a second rail
support having a continuous surface coupled to the third side rail
and the fourth side rail and configured to inhibit movement of the
first side rail relative to the second side rail.
2. The bed assembly of claim 1, wherein the first rail support
includes a dowel having a first end and a second end, the first end
of the dowel configured to engage the end of the first side rail,
the second end of the dowel configured to engage the end of the
second side rail.
3. The bed assembly of claim 1, wherein the first rail support
includes a leg configured to engage the first side rail and the
second side rail.
4. The bed assembly of claim 1, wherein the first rail support
includes a bracket having a base configured to engage the side of
the first side rail and the side of the second side rail.
5. The bed assembly of claim 4, wherein the bracket includes an
upper flange extending from the base in a first direction and
configured to engage a bottom of the first side rail and a bottom
of the second side rail.
6. The bed assembly of claim 5, wherein the bracket includes a
lower flange extending from the base in a second direction opposite
the first direction.
7. The bed assembly of claim 1, wherein: the first slat support
includes a slat-support portion and a rail-support portion, the
rail-support portion including a body portion configured to engage
the side of the first side rail, the slat-support portion including
a leg portion and a slat-lock portion, the leg portion extending
from the body portion in a first direction, the slat-lock portion
extending from the leg portion in a second direction transverse to
the first direction and configured to engage the slat.
8. The bed assembly of claim 7, wherein the rail-support portion
includes an arm portion and a catch portion, the arm portion
extending from the body portion in a third direction, and the catch
portion extending from the arm portion in a fourth direction
transverse to the third direction.
9. The bed assembly of claim 8, wherein the body portion, the arm
portion, and the catch portion collectively define a channel
configured to receive the first side rail.
10. The bed assembly of claim 8, wherein the third direction is
parallel to the first direction.
11. The bed assembly of claim 7, wherein the slat-lock portion
includes a lip extending from the leg portion in second direction
transverse to the first direction, and wherein the slat includes a
groove configured to receive the lip.
12. The bed assembly of claim 11, wherein the body portion, the leg
portion, and the lip collectively define a channel configured to
receive the slat.
13. The bed assembly of claim 11, wherein the lip defines a notch,
a first height extending from the leg portion adjacent the notch,
and a second height extending from the leg portion at the notch,
the second height being less than the first height.
14. The bed assembly of claim 13, wherein the groove extends
through a first side and a second side of the slat, and wherein the
lip is configured to abut the first side of the slat.
15. The bed assembly of claim 14, wherein the notch is disposed
between the first and second sides of the slat.
16. A method of assembling a bed, the method comprising: coupling
an end of a first side rail to an end of a second side rail;
coupling an end of a third side rail to an end of a fourth side
rail; coupling a first slat support to the first side rail;
coupling a second slat support to the third side rail; coupling a
continuous surface of a first rail support to the first side rail
and the second side rail to inhibit movement of the first side rail
relative to the second side rail; coupling a continuous surface of
a second rail support to the third side rail and the fourth side
rail to inhibit movement of the third side rail relative to the
fourth side rail; and coupling a slat to the first slat support and
the second slat support.
17. The method of claim 16, wherein the first slat support includes
a lip and the slat includes a groove, and wherein coupling the slat
to the first slat support includes positioning the lip within the
groove.
18. The method of claim 17, wherein the first slat support defines
a channel, and wherein coupling the slat to the first slat support
includes positioning the slat in the channel.
19. The method of claim 18, wherein coupling the slat to the first
slat support includes abutting the lip with a side of the slat.
20. The method of claim 16, wherein coupling a continuous surface
of a first rail support to the first side rail and the second side
rail includes at least one of (i) positioning a first end of a
dowel in the end of the first side rail and positioning a second
end of the dowel in the end of the second side rail, (ii) coupling
a leg to the first side rail and the second side rail, or (iii)
coupling a bracket to the side of the first side rail and to the
side of the second side rail.
Description
FIELD
[0001] The present disclosure relates to a bed system, including
methods of assembling the bed system.
BACKGROUND
[0002] This section provides background information related to the
present disclosure and is not necessarily prior art.
[0003] Bed systems often include various components that must be
assembled prior to using the bed. For example, known bed systems
often include a pair of side rails, a head board, a footboard, and
a plurality of slats or support members. Prior to using the bed
system to support a mattress or a box spring, the bed system must
be assembled by coupling one end of each side rail to the headboard
and the opposite end of each side rail to the footboard, and by
engaging each slat with each of the pair of siderails. The
components of such a bed system are often very large and involve
numerous assembly steps. For example, the side rails are often
between six and seven feet long. Accordingly, such systems present
challenges during the packaging, shipping, handling, and assembly
processes.
[0004] While known bed systems and known methods of assembling bed
systems have proven useful for their intended purposes, a need for
continuous improvement in the pertinent art remains.
SUMMARY
[0005] This section provides a general summary of the disclosure,
and is not a comprehensive disclosure of its full scope or all of
its features.
[0006] One aspect of the disclosure provides a bed assembly. The
bed system may include first, second, third, and fourth side rails,
first and second slat supports, first and second rail supports, and
a slat. The first, second, third, and fourth side rails may each
include an end and a side extending from the end of the respective
side rail. The end of the second side rail may be coupled to the
end of the first side rail. The end of the fourth side rail may be
coupled to the end of the third side rail such that the sides of
the first and second side rails are facing the sides of the third
and fourth side rails. The first slat support may be configured to
engage the first side rail. The second slat support may be
configured to engage the third side rail. The slat may be coupled
to the first slat support and the second slat support. The first
rail support may include a continuous surface coupled to the first
side rail and the second side rail and configured to inhibit
movement of the first side rail relative to the second side rail.
The second rail support may include a continuous surface coupled to
the third side rail and the fourth side rail and configured to
inhibit movement of the first side rail relative to the second side
rail.
[0007] Implementations of the disclosure may include one or more of
the following optional features. In some implementations, the first
rail support includes a dowel having a first end and a second end.
The first end of the dowel may be configured to engage the end of
the first side rail. The second end of the dowel may be configured
to engage the end of the second side rail.
[0008] In some implementations, the first rail support includes a
leg configured to engage the first side rail and the second side
rail.
[0009] In some implementations, the first rail support includes a
bracket having a base configured to engage the side of the first
side rail and the side of the second side rail. The bracket may
include an upper flange extending from the base in a first
direction and configured to engage a bottom of the first side rail
and a bottom of the second side rail. The bracket may also include
a lower flange extending from the base in a second direction
opposite the first direction.
[0010] In some implementations, the first slat support includes a
slat-support portion and a rail-support portion. The rail-support
portion may include a body portion configured to engage the side of
the first side rail. The slat-support portion may include a leg
portion and a slat-lock portion. The leg portion may extend from
the body portion in a first direction. The slat-lock portion may
extend from the leg portion in a second direction transverse to the
first direction. The slat-lock portion may be configured to engage
the slat.
[0011] In some implementations, the rail-support portion includes
an arm portion and a catch portion. The arm portion may extend from
the body portion in a third direction. The catch portion may extend
from the arm portion in a fourth direction transverse to the third
direction. The body portion, the arm portion, and the catch portion
may collectively define a channel configured to receive the first
side rail. The third direction may be parallel to the first
direction.
[0012] In some implementations, the slat-lock portion includes a
lip extending from the leg portion in second direction transverse
to the first direction. The slat may include a groove configured to
receive the lip. The body portion, the leg portion, and the lip may
collectively define a channel configured to receive the slat. The
lip may define a notch, a first height extending from the leg
portion adjacent the notch, and a second height extending from the
leg portion at the notch. The second height may be less than the
first height. The groove may extend through a first side and a
second side of the slat. The lip may be configured to abut the
first side of the slat. The notch may be disposed between the first
and second sides of the slat.
[0013] Another aspect of the disclosure provides a method of
assembling a bed. The method may include coupling an end of a first
side rail to an end of a second side rail and coupling an end of a
third side rail to an end of a fourth side rail. The method may
also coupling a first slat support to the first side rail and
coupling a second slat support to the third side rail. The metho
may further include coupling a continuous surface of a first rail
support to the first side rail and the second side rail to inhibit
movement of the first side rail relative to the second side rail.
The method may also include coupling a continuous surface of a
second rail support to the third side rail and the fourth side rail
to inhibit movement of the third side rail relative to the fourth
side rail. The method may further include coupling a slat to the
first slat support and the second slat support.
[0014] Implementations of this aspect may include one or more of
the following optional features. In some implementations, the first
slat support includes a lip and the slat includes a groove.
Coupling the slat to the first slat support may include positioning
the lip within the groove. In some implementations, the first slat
support defines a channel. Coupling the slat to the first slat
support may include positioning the slat in the channel. In some
implementations, coupling the slat to the first slat support
includes abutting the lip with a side of the slat.
[0015] In some implementations, coupling a continuous surface of a
first rail support to the first side rail and the second side rail
includes at least one of (i) positioning a first end of a dowel in
the end of the first side rail and positioning a second end of the
dowel in the end of the second side rail, (ii) coupling a leg to
the first side rail and the second side rail, or (iii) coupling a
bracket to the side of the first side rail and to the side of the
second side rail.
[0016] The details of one or more implementations of the disclosure
are set forth in the accompanying drawings and the description
below. Other aspects, features, and advantages will be apparent
from the description and drawings, and from the claims.
DRAWINGS
[0017] The drawings described herein are for illustrative purposes
only of selected configurations and are not intended to limit the
scope of the present disclosure.
[0018] FIG. 1 is a perspective view of a bed system in accordance
with the principles of the present disclosure;
[0019] FIG. 2 is an exploded view of the bed system of FIG. 1;
[0020] FIG. 3 is a perspective view of a portion of the bed system
of FIG. 1;
[0021] FIG. 4 is cross-sectional view of the bed system of FIG. 1
taken along the line 4-4 of FIG. 1;
[0022] FIG. 5 is a perspective view of a rail support in accordance
with the principles of the present disclosure; and
[0023] FIG. 6 is a perspective view of another rail support in
accordance with the principles of the present disclosure.
[0024] Corresponding reference numerals indicate corresponding
parts throughout the drawings.
DETAILED DESCRIPTION
[0025] Example configurations will now be described more fully with
reference to the accompanying drawings. Example configurations are
provided so that this disclosure will be thorough, and will fully
convey the scope of the disclosure to those of ordinary skill in
the art. Specific details are set forth such as examples of
specific components, devices, and methods, to provide a thorough
understanding of configurations of the present disclosure. It will
be apparent to those of ordinary skill in the art that specific
details need not be employed, that example configurations may be
embodied in many different forms, and that the specific details and
the example configurations should not be construed to limit the
scope of the disclosure.
[0026] The terminology used herein is for the purpose of describing
particular exemplary configurations only and is not intended to be
limiting. As used herein, the singular articles "a," "an," and
"the" may be intended to include the plural forms as well, unless
the context clearly indicates otherwise. The terms "comprises,"
"comprising," "including," and "having," are inclusive and
therefore specify the presence of features, steps, operations,
elements, and/or components, but do not preclude the presence or
addition of one or more other features, steps, operations,
elements, components, and/or groups thereof. The method steps,
processes, and operations described herein are not to be construed
as necessarily requiring their performance in the particular order
discussed or illustrated, unless specifically identified as an
order of performance. Additional or alternative steps may be
employed.
[0027] When an element or layer is referred to as being "on,"
"engaged to," "connected to," "attached to," or "coupled to"
another element or layer, it may be directly on, engaged,
connected, attached, or coupled to the other element or layer, or
intervening elements or layers may be present. In contrast, when an
element is referred to as being "directly on," "directly engaged
to," "directly connected to," "directly attached to," or "directly
coupled to" another element or layer, there may be no intervening
elements or layers present. Other words used to describe the
relationship between elements should be interpreted in a like
fashion (e.g., "between" versus "directly between," "adjacent"
versus "directly adjacent," etc.). As used herein, the term
"and/or" includes any and all combinations of one or more of the
associated listed items.
[0028] The terms first, second, third, etc. may be used herein to
describe various elements, components, regions, layers and/or
sections. These elements, components, regions, layers and/or
sections should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms do not imply a
sequence or order unless clearly indicated by the context. Thus, a
first element, component, region, layer or section discussed below
could be termed a second element, component, region, layer or
section without departing from the teachings of the example
configurations.
[0029] With reference to FIGS. 1 and 2, a bed assembly or system 10
is provided. While the bed system 10 is generally shown herein as
being an assembly, or being in an assembled state, it will be
appreciated that, as described in more detail below, the bed system
10 may be provided to a user in an unassembled state within the
scope of the present disclosure. For example, the bed system 10 may
be packaged, shipped, and provided to the user (e.g., a retail
store, a home, a place of lodging, etc.) in an unassembled state
with instructions for assembly. In this regard, the bed system 10
may be packaged, shipped, and provided to the user as a kit of
components with instructions for transforming the bed system 10
from the unassembled state to the assembled state. Accordingly,
references herein to a "bed kit 10" will be understood to be
references to the bed system 10 in an unassembled state.
[0030] The bed system 10 may include a plurality of side rails 12,
a headboard 14, a footboard 16, a plurality of rail supports 18, a
plurality of slat supports 20, and a plurality of slats 22. As
illustrated in FIG. 2, in some implementations, the bed system 10
includes four side rails 12. For example, the bed system may
include a first side rail 12-1, a second side rail 12-2, a third
side rail 12-3, and a fourth side rail 12-4. It will be
appreciated, however, that the bed system 10 may include more or
less than four siderails 12 within the scope of the present
disclosure.
[0031] The first side rail 12-1 may be substantially similar to the
second, third, and fourth side rails 12-2, 12-3, 12-4, apart from
any exceptions described below or shown in the Figures.
Accordingly, references herein to the side rail 12 will be
understood to apply equally to the first, second, third, and fourth
side rails 12-1, 12-2, 12-3, 12-4, except as otherwise provided
herein.
[0032] With reference to FIG. 2, the side rail 12 may include a top
26, a bottom 28, an outer side 30, an inner side 32, a proximal end
34, and a distal end 36. The bottom 28 may be disposed opposite the
top 26. The outer side 30 may extend between the top 26 and the
bottom 28. For example, in some implementations, the outer side 30
extends from the top 26 to the bottom 28. The inner side 32 may be
disposed opposite the outer side 30 and may extend between the top
26 and the bottom 28. For example, in some implementations, the
inner side 32 extends from the top 26 to the bottom 28. In this
regard, the inner side 32 may be parallel to the outer side 30. The
proximal end 34 may extend between the top 26, the bottom 28, the
outer side 30, and the inner side 32. For example, in some
implementations, the proximal end 34 extends from the top 26 to the
bottom 28 and from the outer side 30 to the inner side 32. The
distal end 36 may be disposed opposite the proximal end 34 and may
extend between the top 26, the bottom 28, the outer side 30, and
the inner side 32. For example, in some implementations, the distal
end 36 extends from the top 26 to the bottom 28 and from the outer
side 30 to the inner side 32. In this regard, the proximal end 34
may be parallel to the distal end 36.
[0033] As illustrated in FIGS. 3 and 4, at least one of the
proximal or distal ends 34, 36 may include one or more apertures
40. For example, in some implementations, the proximal end 34 of
the first and third side rails 12-1, 12-3 includes first and second
apertures 40-1, 40-2, and the distal end 36 of the second and
fourth side rails 12-2, 12-4 includes third and fourth apertures
40-3, 40-4. It will be appreciated, however, that the proximal or
distal ends 34, 36 may each include more or less than two apertures
40 within the scope of the present disclosure.
[0034] As will be explained in more detail below, in an assembled
configuration (e.g., FIG. 1), the apertures 40 of the first and
third side rails 12-1, 12-3 may be aligned with the apertures 40 of
the second and fourth side rails 12-2, 12-4, respectively, to
couple the proximal ends 34 of the first and third side rails 12-1,
12-3 to the distal ends 36 of the second and fourth side rails
12-2, 12-4, respectively. In this regard, the proximal ends 34 of
the first and third side rails 12-1, 12-3 may engage the distal
ends 36 of the second and fourth side rails 12-2, 12-4,
respectively, in the assembled configuration.
[0035] With reference to FIG. 2, in some implementations, the bed
system 10 includes a plurality of rail supports 18. For example,
the bed system may include a first rail support 18-1, a second rail
support 18-2, a third rail support 18-3, a fourth rail support
18-4, a fifth rail support 18-5, a sixth rail support 18-6, a
seventh rail support 18-7, and an eighth rail support 18-8. It will
be appreciated, however, that the bed system 10 may include more or
less than eight rail supports 18 within the scope of the present
disclosure. In this regard, the bed system 10 may be formed without
one or more of the first, second, third, fourth, fifth, sixth,
seventh, or eighth rail supports 18-1, 18-2, 18-3, 18-4, 18-5,
18-6, 18-7, 18-8 within the scope of the present disclosure. For
example, in one embodiment, the bed system 10 may include the
first, second, third, fourth, fifth, and sixth rail supports 18-1,
18-2, 18-3, 18-4, 18-5, 18-6, while in another embodiment, the bed
system 10 may include the first, second, third, fourth, seventh,
and eighth rail supports 18-1, 18-2, 18-3, 18-4, 18-7, 18-8.
[0036] Apart from any exceptions described below or shown in the
Figures, (i) the first rail support 18-1 may be substantially
similar to the second rail support 18-2, (ii) the third rail
support 18-3 may be substantially similar to the fourth rail
support 18-4, (iii) the fifth rail support 18-5 may be
substantially similar to the sixth rail support 18-6, and (iv) the
seventh rail support 18-7 may substantially similar to the eighth
rail support 18-8. Accordingly, references herein to the first,
third, fifth, and seventh rail supports 18-1, 18-3, 18-5, 18-7 will
be understood to apply equally to the second, fourth, sixth, and
eighth rail supports 18-2, 18-4, 18-6, 18-8, respectively, except
as otherwise provided herein.
[0037] With reference to FIGS. 2-4, the first rail support 18-1 may
include, or otherwise define, a dowel. In this regard, the first
and second rails supports 18-1, 18-2 may be referred to herein as
dowels 18-1, 18-2. The dowels 18-1, 18-2 may each include a
continuous outer surface 44. As illustrated, in some
implementations, at least a portion of the continuous outer surface
44 defines a circular cylindrical shape. It will be appreciated,
however, that the continuous outer surface 44 may define other
shapes within the scope of the present disclosure. As will be
explained in more detail below, in the assembled configuration, the
first dowel 18-1 may be coupled to the first and second side rails
12-1, 12-2, and the second dowel 18-2 may be coupled to the third
and fourth side rails 12-3, 12-4. For example, the first dowel 18-1
may be disposed within the first aperture 40-1 of the first side
rail 12-1 and the third aperture 40-3 of the second side rail 12-2,
such that the continuous outer surface 44 of the dowel 18-1 engages
and connects the first and second side rails 12-1, 12-2. Similarly,
the second dowel 18-2 may be disposed within the first aperture
40-1 of the third side rail 12-3 and the third aperture 40-3 of the
fourth side rail 12-4, such that the continuous outer surface 44
engages and connects the third and fourth side rails 12-3,
12-4.
[0038] With reference to FIGS. 2 and 3, the third rail support 18-3
may include a plurality of cams 48 and a dowel 50. The dowel 50 may
include a continuous outer surface 52. As illustrated, in some
implementations, at least a portion of the continuous outer surface
52 defines a circular cylindrical shape. It will be appreciated,
however, that the continuous outer surface 52 may define other
shapes within the scope of the present disclosure.
[0039] As will be explained in more detail below, in the assembled
configuration, the dowel 50 of the third rail support 18-3 may be
coupled to the first and second side rails 12-1, 12-2, and the
dowel 50 of the fourth rail support 18-4 may be coupled to the
third and fourth side rails 12-3, 12-4. For example, the dowel 50
of the third rail support 18-3 may be disposed within the second
aperture 40-2 of the first side rail 12-1 and the fourth aperture
40-4 of the second side rail 12-2, such that the continuous outer
surface 52 of the dowel 50 of the third rail support 18-3 engages
the first and second side rails 12-1, 12-2. Similarly, the dowel 50
of the fourth rail support 18-4 may be disposed within the second
aperture 40-2 of the third side rail 12-3 and the fourth aperture
40-4 of the fourth side rail 12-4, such that the continuous outer
surface 52 of the dowel 50 of the fourth rail support 18-4 engages
the third and fourth side rails 12-3, 12-4. The cam 48 may be
disposed within one of the first, second, third or fourth side
rails 12-1, 12-2, 12-3, 12-4. During assembly, the user may rotate
the cam 48 to lock the cam 48 to the dowel 50 and thereby secure a
location of the first side rail 12-1 relative to the second side
rail 12-2, or secure a location of the third side rail 12-3
relative to the fourth side rail 12-4. In some implementations,
four cams 48 are used. For example, one cam 48 may be used in each
of the first, second, third, and fourth side rails 12-1, 12-2,
12-3, 12-4.
[0040] With reference to FIGS. 3 and 4, the fifth rail support 18-5
may include, or otherwise define, a bracket. In this regard, the
fifth rail support 18-5 may be referred to herein as the bracket
18-5. The bracket 18-5 may include a base 56, an upper flange 58,
and a lower flange 60. The base 56 may include a proximal end 62, a
distal end 64, an upper end 66, a lower end 68, a continuous inner
surface 70, and a continuous outer surface 72 opposite the
continuous inner surface 70. The continuous inner and outer
surfaces 70, 72 may extend between the proximal and distal ends 62,
64 and between the upper and lower ends 66, 68. For example, the
continuous inner and outer surfaces 70, 72 may extend from the
proximal end 62 to the distal end 64 and from the upper end 66 to
the lower end 68.
[0041] The upper flange 58 may extend from and along the upper end
66 of the base 56 in a first direction and may include a continuous
upper flange surface 76. The lower flange 60 may extend from and
along the lower end 68 of the base 56 in a second direction and may
include a continuous lower flange surface 78. The second direction
may be opposite the first direction. In some implementations, the
continuous upper and lower flange surfaces 76, 78 extend from the
continuous inner and outer surfaces 70, 72, respectively, of the
base 56, such that the continuous upper flange surface 76 is
substantially parallel to the continuous lower flange surface
78.
[0042] As will be explained in more detail below, in the assembled
configuration, the fifth rail support 18-5 may be coupled to the
first and second side rails 12-1, 12-2, and the sixth rail support
18-6 may be coupled to the third and fourth side rails 12-3, 12-4.
For example, the fifth rail support 18-5 may be coupled to the
first and second side rails 12-1, 12-2 such that the continuous
inner surface 70 or the continuous lower flange surface 78 engage
the inner side 32 or the bottom 28, respectively, of the first and
second side rails 12-1, 12-2, and the sixth rail support 18-6 may
be coupled to the third and fourth side rails 12-3, 12-4 such that
the continuous outer surface 72 or the continuous upper flange
surface 76 engage the inner side 32 or the bottom 28, respectively,
of the third and fourth side rails 12-3, 12-4. In this regard, it
will be appreciated that the fifth and sixth rail supports 18-5,
18-6 may be reversible, or otherwise interchangeable, relative to
assembly to and with (i) the first and second side rails 12-1, 12-2
and (ii) the third and fourth side rails 12-3, 12-4.
[0043] With reference to FIGS. 1 and 2, the seventh rail support
18-7 may include a leg. In this regard, the seventh rail support
18-7 may be referred to herein as the leg 18-7. In the assembled
configuration, the seventh rail support 18-7 may be coupled to the
first and second side rails 12-1, 12-2, and the eighth rail support
18-8 may be coupled to the third and fourth side rails 12-3, 12-4.
In this regard, the seventh and eighth rail supports 18-7, 18-8 may
extend away from the first and second side rails 12-1, 12-2 and the
third and fourth side rails 12-3, 12-4, respectively, to support
the side rails 12 relative to a floor or ground surface.
[0044] In the assembled configuration, the first, second, third,
fourth, fifth, sixth, seventh, or eighth rail supports 18-1, 18-2,
18-3, 18-4, 18-5, 18-6, 18-7, 18-8 may inhibit movement of the
first and third side rails 12-1, 12-3 relative to the second and
fourth side rails 12-2, 12-4. In particular, the rail supports 18
help to prevent the proximal ends 34 of the first and third side
rails 12-1, 12-3 from moving relative to the distal ends 36 of the
second and fourth side rails 12-2, 12-4.
[0045] With reference to FIGS. 1 and 2, in some implementations,
the bed system 10 includes six slat supports 20. For example, the
bed system may include a first slat support 20-1, a second slat
support 20-2, a third slat support 20-3, a fourth slat support
20-4, a fifth slat support 20-5 and a sixth slat support 20-6. It
will be appreciated, however, that the bed system 10 may include
more or less than six slat supports 20 within the scope of the
present disclosure.
[0046] The first slat support 20-1 may be substantially similar to
the second, third, fourth, fifth, and sixth slat supports 20-2,
20-3, 20-4, 20-5, 20-6, apart from any exceptions described below
or shown in the Figures. Accordingly, references herein to the slat
support 20 will be understood to apply equally to the first,
second, third, fourth, fifth, and sixth slat supports 20-1, 20-2,
20-3, 20-4, 20-5, 20-6, except as otherwise provided herein.
[0047] With reference to FIGS. 4 and 5, the slat support 20 may
include a rail-support portion 80 and a slat-support portion 82. In
some implementations, the rail-support portion 80 is integrally
formed with the slat-support portion 82 such that the rail-support
portion and slat-support portion 80, 82 define a monolithic or
unitary construct. As will be explained in more detail below, in
the assembled configuration, the rail- and slat-support portions
80, 82 may be coupled to one or more of the first, second, third,
or fourth side rails 12-1, 12-2, 12-3, 12-4 to secure the location
of the slats 20 relative to the first, second, third, or fourth
side rails 12-1, 12-2, 12-3, 12-4.
[0048] The rail-support portion 80 may include a body portion 88,
an arm portion 90, and a catch portion 92. The arm portion 90 may
extend between the body portion 88 and the catch portion 92. In
particular, the arm portion 90 may extend in a first lateral
direction from the body portion 88 to the catch portion 92. In some
implementations, the arm portion 90 extends in a direction
substantially perpendicular to the body portion 88, and the catch
portion 92 extends in a direction substantially parallel to the
body portion 88. As illustrated, the body portion 88, the arm
portion 90, and the catch portion 92 may define a substantially
J-shaped construct, such that the body portion 88, the arm portion
90, and the catch portion 92 collectively define a channel 94. The
size and shape of the body portion 88, the arm portion 90, and the
catch portion 92 may be such that the size and shape of the channel
94 is substantially the same as, or equal to, the size and shape
defined by the top 26, the outer side 30, and the inner side 32 of
the side rails 12. Accordingly, as illustrated in FIG. 4, the
channel 94 may receive the side rails 12 in the assembled
configuration. In this regard, in the assembled configuration, the
body portion 88 may engage the inner side 32 of the side rails 12,
the arm portion 90 may engage the top 26 of the side rails 12, and
the catch portion 92 may engage the outer side 30 of the side rails
12.
[0049] The slat-support portion 82 may include a leg portion 98 and
a slat-lock portion 100. As will be explained in more detail below,
in the assembled configuration, the slat-lock portion 100 may
engage, and secure the position of, the slats 22. In this regard,
the leg portion 98 may extend between the slat-lock portion 100 of
the rail-support portion 80 and the body portion 88 of the
rail-support portion 80. The slat-lock portion 100 may include a
lip 102 extending from the leg portion 98. In some implementations,
the leg portion 98 may extend in a second lateral direction from
the body portion 88 to the lip 102. In particular, the leg portion
98 slat-support portion 82 may extend in a direction substantially
perpendicular to the body portion 88, and the lip 102 slat-support
portion 82 may extend in a direction substantially parallel to the
body portion 88. In this regard, the leg portion 98 may extend in a
direction substantially opposite, and parallel to, the arm portion
90 of the rail-support portion 80, and the lip 102 may extend in a
direction substantially opposite, and parallel to, the catch
portion 92 of the rail-support portion 80. As illustrated, the body
portion 88, the leg portion 98, and the lip 102 may define a
substantially J-shaped construct, such that the body portion 88,
the leg portion 98, and the lip 102 collectively define a channel
104.
[0050] With reference to FIG. 5, the lip 102 may define a plurality
of notches 106. In this regard, as illustrated in FIGS. 4 and 5,
the lip 102 may define (i) a first height H1 extending from the leg
portion 98 adjacent to, and in a location extending between, each
of the notches 106, and (ii) a second height H2, less than the
first height H1, extending from the leg portion 98 at each notch
106. Accordingly, the notches 106 may each be defined in part by
opposing sidewalls 107, 109 of the lip 102.
[0051] With reference to FIGS. 2 and 4, the slats 22 may extend
from a proximal end 108 to a distal end 110 opposite the proximal
end 108, from a first side 112 to a second side 114 opposite the
first side 112, and from a top 116 to a bottom 118 opposite the top
116. The first and second sides 112, 114 and the top and bottom
116, 118 may each extend from the proximal end 108 to the distal
end 110. As illustrated in FIG. 2, the slats 22 may define a first
groove 120 and a second groove 122. In particular, the bottom 118
may define the first and second grooves 120, 122. As illustrated,
in some implementations, the first groove 120 is disposed proximate
the proximal end 108 and extends across the bottom 118 and through
a portion of the first and second sides 112, 114, and the second
groove 122 is disposed proximate the distal end 110 and extends
across the bottom 118 and through a portion of the first and second
sides 112, 114.
[0052] As previously described, in the assembled configuration, the
slats 22 may be coupled to the slat-lock portion 100 of the slat
support 20. In particular, the lip 102 of the first, second, or
third slat support 20-1, 20-2, 20-3 may be disposed within the
first groove 120 of the slats 22, and the lip 102 of the fourth,
fifth, or sixth slat support 20-4, 20-5, 20-6 may be disposed
within the second groove 122 of the slats 22. In this regard, the
lip 102 of the first slat support 20-1 may be disposed within the
first groove 120 such that (i) the notch 106 is aligned with the
first groove 120 and (ii) the lip 102 abuts the first or second
sides 112, 114 of the slat 22 at the second height H2. For example,
the side 107 of the lip 102 of the first slat support 20-1 or the
side 109 of the lip 102 of the first slat support 20-1 may abut, or
otherwise face, the first or second sides 112, 114, respectively,
of the slat 22. Similarly, the lip 102 of the fourth slat support
20-4 may be disposed within the second groove 122 such that (i) the
notch 106 is aligned with the second groove 122 and (ii) the lip
102 abuts the first or second sides 112, 114 of the slat 22 at the
second height H2. For example, the side 107 of the lip 102 of the
fourth slat support 20-4 or the side 109 of the lip 102 of the
fourth slat support 20-4 may abut, or otherwise face, the first or
second sides 112, 114, respectively, of the slat 22. In this way,
the slat-lock portion 100 is able to secure the location of each
slat 22 relative to the other slats 22 in a spaced-apart (e.g.,
equally spaced) configuration and to evenly support a mattress or
box spring.
[0053] In some implementations, the bed kit 10, including the
plurality of side rails 12, the headboard 14, the footboard 16, the
plurality of rail supports 18, the plurality of slat supports 20,
and the plurality of slats 22, may be disposed within a package
(e.g., a box, carton, container, etc.) having a length between
three feet and five feet, a width between one half foot and two
feet, and a depth between one half foot and one foot. In this
regard, the bed kit 10 may be disposed within a package that can be
lifted and otherwise handled by a single person.
[0054] With reference to FIG. 6, an alternate slat support 20a for
use with the bed system 10 is shown. The structure and function of
the slat support 20a may be substantially similar to that of the
slat support 20, apart from any exceptions described below and/or
shown in the Figures. Accordingly, the structure and/or function of
similar features will not be described again in detail. In
addition, like reference numerals are used hereinafter and in the
drawings to identify like features, while like reference numerals
containing letter extensions (i.e., "a") are used to identify those
features that have been modified.
[0055] The slat support 20a may include the body portion 88 of the
rail-support portion 80 and the leg portion 98 and the slat-lock
portion 100 of the slat-support portion 82. In this regard, the
slat support 20a may be formed without the arm portion 90 and the
catch portion 92 of the rail-support portion 80. Accordingly, the
slat support 20a (e.g., the body portion 88) may be coupled to the
side rails 12 (e.g., the inner side 32) using a mechanical fastener
126 (e.g., a screw, a bolt, a nail, a pin, etc.), an adhesive, or
another suitable fastening technique.
[0056] A method of assembling the bed system 10 may include
removing (i) the plurality of side rails 12, (ii) the headboard 14,
(iii) the footboard 16, (iv) the plurality of rail supports 18, (v)
the plurality of slat supports 20, 20a and (vi) the plurality of
slats 22 from the package.
[0057] The method of assembling the bed system 10 may include
coupling the distal end 36 of the first and third side rails 12-1,
12-3 to the headboard 14 and coupling the proximal end 34 of the
first and third side rails 12-1, 12-3 to the distal end 36 of the
second and fourth side rails 12-2, 12-4, respectively. The method
may also including coupling the proximal end 34 of the second and
fourth side rails 12-2, 12-4 to the footboard 16.
[0058] The method of assembling the bed system 10 may also include
coupling one or more of the rail supports 18 to (i) the first and
second side rails 12-1, 12-2 and (ii) the third and fourth side
rails 12-3, 12-4. For example, the method may include coupling the
rail supports 18-1, 18-2, 18-3, 18-4, 18-5, 18-6, 18-7, 18-8 to (i)
the first and second side rails 12-1, 12-2 or (ii) the third and
fourth side rails 12-3, 12-4.
[0059] The method of assembling the bed system 10 may further
include coupling one or more of the slat supports 20, 20a to one or
more of the side rails 12. For example, the method may include
coupling the slat supports 20-1, 20-2, 20-3, 20-4, or 20a to one or
more of the side rails 12-1, 12-2, 12-3, or 12-4. In particular,
the method may include positioning one or more of the side rails 12
within the channel 94 of the rail-support portion 80 of the slat
support 20, or otherwise fastening the slat support 20a to one or
more of the side rails 12 using a mechanical fastener or other
fastening technique, as previously described.
[0060] The method of assembling the bed system 10 may also include
coupling a slat 22 to a plurality of the slat supports 20, 20a. For
example, the method may include positioning the lip 102 of a slat
support 20, 20a within a first groove 120 of the slat 22 such that
(i) the notch 106 is aligned with the first groove 120 and (ii) the
lip 102 abuts the first and second sides 112, 114 of the slat 22.
For example, the slat 22 may be positioned within the notch 106 of
a first of the slat supports 20, 20a such that the sides 107, 109
of the lip 102 abut, or otherwise face, the first or second sides
112, 114, respectively, of the slat 22. Similarly, the method may
include positioning the lip 102 of another slat support 20, 20a
within the second groove 122 such that (i) the notch 106 is aligned
with the second groove 122 and (ii) the lip 102 abuts the first and
second sides 112, 114 of the slat 22. For example, the slat 22 may
be positioned within the notch 106 of a second of the slat supports
20, 20a such that the sides 107, 109 of the lip 102 abut, or
otherwise face, the first or second sides 112, 114, respectively,
of the slat 22. The first and second of the slat supports 20, 20a
may be positioned on opposite sides of the bed system 10 (e.g., on
bed side rails 12-1, 12-3) such that a slat 22 extends between and
connects side rails 12-1 and 12-2. Multiple slats 22 may be
positioned between slat supports 20-1, 20-2, 20-3 on bed rails
12-1, 12-2 and slat supports 20-4, 20-5, 20-6 on bed rails 12-3,
12-4, in the same manner.
[0061] The configuration of, and related methods of assembling, the
bed system 10 described herein, including, for example, the method
of securing the proximal end 34 of a side rail 12 to a distal end
36 of another side rail 12, and the method of securing the rail
supports 18, slat supports 20, 20a, and slats 22 to the side rails
12, can allow a user to easily and efficiently assemble a bed
system having superior strength and durability.
[0062] The foregoing description has been provided for purposes of
illustration and description. It is not intended to be exhaustive
or to limit the disclosure. Individual elements or features of a
particular configuration are generally not limited to that
particular configuration, but, where applicable, are
interchangeable and can be used in a selected configuration, even
if not specifically shown or described. The same may also be varied
in many ways. Such variations are not to be regarded as a departure
from the disclosure, and all such modifications are intended to be
included within the scope of the disclosure.
* * * * *