U.S. patent application number 16/256168 was filed with the patent office on 2019-05-23 for mattress supporting system with hinged brackets for headboard support.
The applicant listed for this patent is Zinus Inc.. Invention is credited to Youn Jae Lee.
Application Number | 20190150625 16/256168 |
Document ID | / |
Family ID | 66533664 |
Filed Date | 2019-05-23 |
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United States Patent
Application |
20190150625 |
Kind Code |
A1 |
Lee; Youn Jae |
May 23, 2019 |
Mattress Supporting System with Hinged Brackets for Headboard
Support
Abstract
A bed frame assembly has hinged brackets that can be used to
attach a headboard to a bed frame. Each hinged bracket has two
metal plates that each have metal tongues that are rolled into
curved sections. A hinge is formed by sliding a pin through
staggered curved sections on opposite metal plates. The metal
plates pivotally rotate about the axis of the hinge such that the
hinged bracket consumed less volume in a packing box when folded
flat. Screws are inserted through slots in each metal plate to
secure the hinged bracket to the bed frame. Tongues on a headboard
are slid into slots in the metal plates of the hinged brackets in
order to attach the headboard to the bed frame.
Inventors: |
Lee; Youn Jae; (Pleasanton,
CA) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Zinus Inc. |
Tracy |
CA |
US |
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|
Family ID: |
66533664 |
Appl. No.: |
16/256168 |
Filed: |
January 24, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14711799 |
May 14, 2015 |
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16256168 |
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12655859 |
Jan 7, 2010 |
9107509 |
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14711799 |
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12378496 |
Feb 17, 2009 |
7721366 |
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12655859 |
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12287440 |
Oct 8, 2008 |
7600278 |
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12378496 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 19/12 20130101;
A47C 19/022 20130101; A47C 19/122 20130101; A47C 19/024 20130101;
A47C 19/005 20130101; A47C 19/02 20130101; A47C 19/025 20130101;
A47C 19/04 20130101 |
International
Class: |
A47C 19/12 20060101
A47C019/12; A47C 19/04 20060101 A47C019/04; A47C 19/02 20060101
A47C019/02 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 19, 2007 |
CN |
200720008515.1 |
Jan 6, 2015 |
CN |
20150005133.8 |
Claims
1-20. (canceled)
21. An apparatus comprising: a first planar metal plate portion
that has a first slot and a first portion of a hinge; a second
planar metal plate portion having a second portion of the hinge,
wherein the first portion of the hinge adjoins the second portion
of the hinge at a hinged edge, and wherein the first planar metal
portion is pivotally attached to the second planar metal portion at
the hinged edge; a first lip that meets the first planar metal
plate portion at an upper edge of the first planar metal plate
portion, wherein the upper edge of the first planar metal plate
portion is perpendicular to the first portion of the hinge, and
wherein a bottom half of the first planar metal plate portion is
opposite the upper edge of the first planar metal plate portion;
and a second lip that meets the second planar metal plate portion
at an upper edge of the second planar metal plate portion, wherein
the upper edge of the second planar metal plate portion is
perpendicular to the second portion of the hinge, wherein the first
planar metal plate portion has a first descending edge that is
opposite the first portion of the hinge but that is not parallel to
the first portion of the hinge, wherein the second planar metal
plate portion has a second descending edge that is opposite the
second portion of the hinge but is not parallel to the second
portion of the hinge, wherein the first slot is disposed in the
bottom half of the first planar metal plate portion and is oriented
parallel to the upper edge of the first planar metal plate portion,
and wherein the apparatus is adapted to be supported by a bed frame
assembly such that no part of the bed frame assembly contacts the
bottom half of the first planar metal plate portion.
22. The apparatus of claim 21, wherein the first portion of the
hinge includes a first curved section and a third curved section,
wherein the second portion of the hinge includes a second curved
section and a fourth curved section, and wherein the second curved
section is disposed between the first curved section and the third
curved section.
23. The apparatus of claim 22, wherein a pin passes through the
first, second, third and fourth curved sections.
24. The apparatus of claim 21, wherein the bed frame assembly
includes an upper side edge bar and an outer side edge bar, wherein
the first lip rests on the upper side edge bar, wherein the second
lip rests on the outer side edge bar, and wherein the first planar
metal plate portion hangs down from the upper side edge bar.
25. The apparatus of claim 21, wherein the bed frame assembly
includes an upper side edge bar and an outer side edge bar, wherein
the first planar metal plate portion is screwed into and hangs down
from the upper side edge bar, and wherein the second planar metal
plate portion is screwed into and hangs down from the outer side
edge bar.
26. The apparatus of claim 21, further comprising: a headboard of a
bed, wherein the headboard is attached to the first planar metal
plate portion.
27. The apparatus of claim 26, wherein the headboard includes a
tongue that slips into the first slot of the first planar metal
plate portion.
28. The apparatus of claim 21, wherein the first planar metal plate
portion includes a second slot, and wherein the second slot is
oriented parallel to the first slot.
29. The apparatus of claim 21, wherein the first descending edge is
straight and descends diagonally down from the upper edge of the
first planar metal plate portion.
30. The apparatus of claim 21, wherein the first planar metal plate
portion has a length along the hinged edge of less than fourteen
inches.
31. The apparatus of claim 21, wherein the first lip is a means for
hanging the apparatus from a side edge bar of a folding bed
frame.
32. An apparatus comprising: a first planar metal plate portion
that has a slot, a first rolled tongue and a second rolled tongue;
a second planar metal plate portion that has a third rolled tongue
and a fourth rolled tongue; a pin that passes through the first,
second, third and fourth rolled tongues at a hinge axis, wherein
the first planar metal plate portion is pivotally attached to the
second planar metal plate portion at the hinge axis; a first lip
that meets the first planar metal plate portion at an upper edge of
the first planar metal plate portion, wherein the upper edge of the
first planar metal plate portion is perpendicular to the first
portion of the hinge, and wherein a bottom half of the first planar
metal plate portion is opposite the upper edge of the first planar
metal plate portion; and a second lip that meets the second planar
metal plate portion at an upper edge of the second planar metal
plate portion, wherein the upper edge of the second planar metal
plate portion is perpendicular to the second portion of the hinge,
wherein the first planar metal plate portion has a first descending
edge that is opposite the first portion of the hinge but that is
not parallel to the first portion of the hinge, wherein the second
planar metal plate portion has a second descending edge that is
opposite the second portion of the hinge but is not parallel to the
second portion of the hinge, wherein the slot is disposed in the
bottom half of the first planar metal plate portion and is oriented
parallel to the upper edge of the first planar metal plate portion,
and wherein the apparatus is adapted to be supported by a bed frame
assembly such that no part of the bed frame assembly contacts the
bottom half of the first planar metal plate portion.
33. The apparatus of claim 32, wherein the first planar metal plate
portion is oriented perpendicular to the second planar metal plate
portion when the apparatus is supported by the bed frame
assembly.
34. The apparatus of claim 32, further comprising: a cardboard
packing box, wherein the first planar metal plate portion is folded
over the second planar metal plate portion in the cardboard packing
box such that the first planar metal plate portion and the second
planar metal plate portion are oriented parallel to each other.
35. The apparatus of claim 32, further comprising: a nut, wherein
the pin is threaded, and wherein the nut is screwed onto the
pin.
36. An apparatus comprising: a bed frame assembly with a first
hinge at its middle axis at which the bed frame assembly folds,
wherein the bed frame assembly has an upper side edge bar and an
outer side edge bar; and an edge attachment that attaches both to
the upper side edge bar and to the outer side edge bar, wherein the
edge attachment hangs down from the upper side edge bar and from
the outer side edge bar, wherein a first planar portion of the edge
attachment is pivotally attached to a second planar portion of the
edge attachment at a second hinge, and wherein the edge attachment
is adapted to hold a headboard.
37. The apparatus of claim 36, wherein the first planar portion is
oriented perpendicular to the second planar portion when the edge
attachment is attached to both the upper side edge bar and to the
outer side edge bar.
38. The apparatus of claim 36, wherein the edge attachment has a
slot, and wherein a tongue on the headboard fits into the slot in
the edge attachment.
39. The apparatus of claim 36, further comprising: the headboard,
wherein the headboard is attached to the edge attachment at a
location below the upper side edge bar.
40. The apparatus of claim 36, further comprising: the headboard,
wherein the headboard has a tongue that slips into a slot in the
first planar portion.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of, and claims
priority under 35 U.S.C. .sctn. 120 from, U.S. patent application
Ser. No. 14/711,799 entitled "Mattress Supporting System with
Locking Mechanism for Leg Supports," filed on May 14, 2015.
Application Ser. No. 14/711,799, in turn, is a continuation-in-part
of, and claims priority under 35 U.S.C. .sctn. 120 from, U.S.
patent application Ser. No. 12/655,859 entitled "Mattress
Supporting System with Headboard Attachment," filed on Jan. 7,
2010, now U.S. Pat. No. 9,107,509. Application Ser. No. 14/711,799
is also a continuation-in-part of, and claims priority under 35
U.S.C. .sctn. 119 from Chinese Patent Application No.
20150005133.8, filed on Jan. 6, 2015, in China. Application Ser.
No. 12/655,859, in turn, is a continuation-in-part of, and claims
priority under 35 U.S.C. .sctn. 120 from, U.S. patent application
Ser. No. 12/378,496 entitled "Mattress Supporting System," filed on
Feb. 17, 2009, now U.S. Pat. No. 7,721,366. Application Ser. No.
12/378,496, in turn, is a continuation-in-part of, and claims
priority under 35 U.S.C. .sctn. 120 from, U.S. patent application
Ser. No. 12/287,440 entitled "Folding Bed Frame," filed on Oct. 8,
2008, now U.S. Pat. No. 7,600,278. Application Ser. No. 12/287,440,
in turn, is a continuation-in-part of, and claims the benefit under
35 U.S.C. .sctn. 119 from, Chinese Patent Application No.
200720008515.1, filed on Oct. 19, 2007, in China. The contents of
each of the aforementioned patent documents are incorporated herein
by reference.
TECHNICAL FIELD
[0002] The described embodiments relate to bedding products, and
more particularly to a folding bed frame and a mattress supporting
system.
BACKGROUND INFORMATION
[0003] Conventional folding bed frames are relatively heavy and
awkward. FIG. 1 (prior art) shows the structure of a conventional
folding bed frame including a mattress frame 1 and support legs 2.
Mattress frame 1 can be folded in half. The plurality of support
legs 2 are pivotally connected under the mattress frame 1. In use,
a mattress (not shown) is placed on the mattress frame 1. This
structure of the folding bed frame must possess a certain level of
bearing strength because the mattress frame 1 must support the
mattress. In order to provide bearing strength, mattress frame 1 is
made with relatively thick cross-bars and thinner longitudinal
bars. The thick cross-bars have relatively large intervals between
them, whereas the thinner longitudinal bars are spaced at
relatively small intervals. The thick cross-bars and the thinner
longitudinal bars are both welded to mattress frame 1. Although the
bed frame of FIG. 1 provides stable support for a mattress, the bed
frame is awkward and bulky. Because this type of bed frame is
typically made of metal, the crossed design of the thick cross-bars
and the longitudinal bars increases the weight of the bed frame
even further. Especially in the case of a double bed that supports
a queen or king size mattress, the bed frame is even more awkward
and difficult to carry and transport.
[0004] In addition, the bed frame of FIG. 1 is not adaptable to
different mattress sizes. Even a conventional bed frame that is
sized for either a single bed or a double bed does not accommodate
the various dimensions of the single and double mattresses, such as
single, twin, full, double, queen, king and California king. A
different bed frame size must be manufactured to accommodate each
different mattress dimension. Because the bed frame of FIG. 1
cannot be standardized to fit multiple mattress dimensions, the
manufacturing cost of the various sizes of the bed frame is
increased.
[0005] A bed frame is sought that is lighter and less awkward than
the conventional bed frame and that can accommodate multiple
mattress dimensions. In addition, a folding bed frame is sought
that can replace a conventional box spring.
SUMMARY
[0006] A folding bed frame includes standardized right and left bed
frame assemblies. The bed frame assemblies are connected by a
plurality of central connecting bars to form an adjustable bedboard
frame that can accommodate mattresses of differing widths. The
small, standardized bed frame assemblies can be manufactured at
less cost than can a conventional unitary bed frame. In addition,
the folding bed frame is easy to transport when disassembled into
the separate frame assemblies that are each less than half the
width of a conventional bed frame for a double bed. The bedboard
frame formed by the standardized frame assemblies and the central
connecting bars is lighter than the conventional unitary bed frame
and is therefore less expensive to transport and easier to
install.
[0007] Leg supports are pivotally connected to the bottom of the
bedboard frame under each bed frame assembly and support the
bedboard frame and mattress. Each central connecting bar has
U-shaped slots on its ends that clip over the inner side edges of
the right and left bed frame assemblies. Each frame assembly has a
hinge at its middle axis at which a lower half of the assembly
folds over onto an upper half of the assembly to allow the frame
assemblies to fit in a packing box. The leg supports fold in to fit
in the packing box.
[0008] Edge attachments are attached by screws to the upper left
corner of the left bed frame assembly and to the upper right corner
of right bed frame assembly. A headboard of the bed attaches to the
edge attachments of the folding bed frame. Tongues on the headboard
slip into slots in the edge attachments.
[0009] A method of packing the folding bed frame into a packing box
involves folding lower halves of the bedboard frames of bed frame
assemblies over onto upper halves of the bedboard frames. The leg
supports that are pivotally connected to the bedboard frames are
folded in. The folded bedboard frames are then inserted into a
packing box that is about half as long as the unfolded bedboard
frames. The packing box has a width of little more than the width
of one bed frame assembly. The packing box is about four times as
thick as the folded-in leg supports plus four times as thick as an
unfolded bedboard frame. Central connecting bars are inserted into
the packing box and fit between the folded-in leg supports.
[0010] In one embodiment, the folding bed frame includes no central
connecting bars. The folding bed frame includes right and left bed
frame assemblies. The right bed frame assembly has a left inner
side edge that faces the left bed frame assembly, and the left bed
frame assembly has a right inner side edge that faces the right bed
frame assembly. The left inner side edge is directly connected to
the right inner side edge and forms a bedboard frame for a single
bed.
[0011] An apparatus includes a packing box and a means for
assembling a bed frame that fits mattresses of differing widths.
The means is inserted into the packing box. The bed frame is
adaptable to fit a mattress having an area that is larger than four
times the length times the width of the packing box.
[0012] A folding bed frame comprises mutually connected left and
right bed frame assemblies, one on each side. Each bed frame
assembly includes a bedboard frame and a plurality of leg supports
that are pivotally connected under the bedboard frame. In one
aspect, a bedboard frame for a single bed is provided in which no
central connecting bars are used. In another aspect, a plurality of
central connecting bars span between the left and right bed frame
assemblies. Central connecting bars with different lengths are
selected to accommodate mattresses of different widths. Thus, a
bedboard frame for double beds with different widths can be
conveniently manufactured without the need to re-manufacture the
bed frame assemblies. The specifications of the bed frame
assemblies are standardized, which greatly reduces the
manufacturing cost of the folding bed frame.
[0013] In another embodiment, an apparatus includes a bed frame
assembly and an edge attachment. The bed frame assembly has a hinge
at which a first portion of the bed frame assembly is adapted to
fold over onto a second portion of the bed frame assembly. A leg
support is pivotally connected to the bed frame assembly. The edge
attachment clips over a head side edge and an outer side edge of
the bed frame assembly and is adapted to hold a bed skirt taut
around the bed frame assembly when the bed frame assembly is
resting on the extended leg support.
[0014] The edge attachment holds the bed skirt such that more than
half of the leg support is not visible behind the bed skirt when
the bed frame assembly is resting on the extended leg support. The
bed frame assembly also includes a second edge attachment that
holds the bed skirt and that clips over the middle of the outer
side edge of the bed frame assembly. A third edge attachment is
attached to the head side edge and the outer side edge of the bed
frame assembly and both holds the bed skirt taut around the bed
frame assembly and holds a headboard.
[0015] The edge attachments at the corners of the bed frame
assembly slant at an angle down and away from the bed frame
assembly when no bed skirt is being held so that a bed skirt is
held taut when the bed skirt is slipped on over the slanted edge
attachments. A storage container with a floor height of at least
twelve inches can slide past the bed skirt under the bed when the
taut bed skirt is stretched.
[0016] A method for setting up a mattress support system includes
the steps of: (i) removing a folded bed frame assembly and an edge
attachment from a packing box, (ii) unfolding a first portion of
the bed frame assembly from a second portion of the bed frame
assembly that is pivotally connected to the first portion at a
hinge, (iii) unfolding a leg support that is pivotally connected to
the bed frame assembly, (iv) standing the unfolded bed frame on the
unfolded leg support, (v) attaching the edge attachment at a corner
or the bed frame assembly, (vi) slipping a bed skirt down over the
edge attachment such that the bed skirt is held taut around the bed
frame assembly when the bed frame assembly is standing on the
unfolded leg support, and (vii) placing a mattress on top of the
assembled bed frame assembly. The method also includes the steps of
attaching a second edge attachment to the bed frame assembly at a
second corner and attaching a headboard to the second edge
attachment.
[0017] In yet another embodiment, an apparatus includes a bed frame
assembly and a means for holding a bed skirt taut around the bed
frame assembly when the bed frame assembly is standing on leg
supports. The means is also for holding a headboard of the bed
frame assembly. The bed frame assembly has a hinge at which a first
portion of the bed frame assembly folds over onto a second portion
of the bed frame assembly. The bed frame assembly has leg supports
that are pivotally connected to the bed frame assembly.
[0018] In yet another embodiment, a mattress supporting system
includes a bed frame, an edge attachment and a headboard
attachment. The headboard attachment is adapted to hold a
headboard. The bed frame assembly has a leg support that is
pivotally connected to the bed frame assembly. The edge attachment
is attached to a head side edge and to an outer side edge of the
bed frame assembly. The edge attachment is adapted to hold a bed
skirt taut around the bed frame assembly when the bed frame
assembly is resting on the extended leg support. The headboard
attachment is attached to the leg support and extends out from
under the bed skirt laterally past the head side edge. The
headboard attachment has an angle bracket that rests on a cross bar
of the leg support when the headboard attachment is attached to the
leg support.
[0019] A method of supporting a headboard includes unfolding a
first portion of a bed frame assembly from a second portion of the
bed frame assembly. A leg support is pivotally connected to the
first portion. The first and second portions are pivotally
connected at a hinge. When the bed frame assembly is unfolded, the
assembly has an outer side edge and a head side edge that meet at a
corner.
[0020] The leg support is unfolded, and the unfolded bed frame is
stood on the unfolded leg support. An edge attachment is attached
at the corner where the outer side edge and the head side edge
meet. A bed skirt is slipped down over the edge attachment such
that the bed skirt is held taut around the bed frame assembly. A
headboard attachment is attached to the leg support such that the
headboard attachment extends out from under the bed skirt laterally
past the head side edge. A headboard is then attached to the
headboard attachment.
[0021] The folding mattress support system replaces a conventional
bed frame with rails and the box spring. The mattress support
system is lighter, easier to transport, and provides more storage
space beneath the mattress. The mattress support system includes
bed frame assemblies, central connecting bars, edge attachments,
headboard attachments and a bed skirt. Leg supports fold out from
the bed frame assemblies, which themselves unfold in the middle.
Central connecting bars connect inner side edges of the bed frame
assemblies. Plastic edge attachments are attached at outer corners
of the bed frame assemblies and hold a bed skirt taut when the
frame assemblies are standing on extended leg supports. A mattress
is then placed on top of the assembled mattress support system.
Optionally, metal edge attachments at the head corners hold both
the bed skirt and a headboard. Alternatively, headboard attachments
protrude from under the bed skirt and support a headboard.
[0022] In yet another embodiment, the mattress support system is a
bed frame assembly with diagonal struts that lock leg supports into
place using novel locking mechanisms. The bed frame assembly has a
hinge at which a first portion of the bed frame assembly is adapted
to unfold from a second portion of the bed frame assembly. The bed
frame assembly has a first cross bar, a second cross bar,
longitudinal bars, leg supports, diagonal struts and the locking
mechanisms. Opposite ends of the cross bars are attached to the
longitudinal bars. A leg support is pivotally attached to the first
cross bar, and a slotted bracket with a rounded slot is attached to
the second cross bar. Attached to a first end of a diagonal strut
is a bolt with a conical washer on the bolt. The second end of the
diagonal strut is pivotally attached to the leg support, and the
first end of the diagonal strut is attached to the slotted bracket
by inserting the bolt into the rounded slot and by pressing the
conical washer down into the rounded slot using a wing nut. The
rounded slot has a round opening at the end of a channel whose
width is slightly larger than the diameter of the bolt. The
diameter of the round opening is larger than the width of the
channel and smaller than the largest diameter of a coned portion of
the conical washer.
[0023] In another embodiment, an apparatus includes a bed frame
assembly and hinged brackets. Each hinged bracket attaches to the
bed frame assembly to support a headboard. Each hinged bracket
includes a first planar metal plate portion and a second metal
plate portion that each have a set of rolled metal tongues. The
rolled metal tongues are shaped to form curved sections. The curved
sections of the first and second planar metal plate portions are
joined with pins and nuts to form a first hinge and a second hinge.
The first and second planar metal plate portions pivotally rotate
about the axis of the first and second hinges such that the hinged
bracket takes up less volume when placed in a packing box. The
first and second planar metal plate portions each include slots
into which the tongues on a headboard can be inserted. The hinged
brackets attach to the upper-left and upper-right sides of the
bedboard frame by screws that are inserted into slots in the first
and second planar metal plate portions.
[0024] A method for assembling the mattress support system includes
unfolding the bed frame assembly and the leg supports, and then
locking each leg support in place by inserting a bolt into a
rounded slot and pressing a conical washer into a round opening of
the rounded slot. A first portion of the bed frame assembly is
unfolded from a second portion of the bed frame assembly. The first
portion and the second portion are pivotally connected at a hinge.
A leg support is pivotally connected to the first portion. The leg
support has two legs disposed in a plane, and the two legs are
connected by a support bar. After the leg support is unfolded from
the first portion, a diagonal strut that is pivotally attached to
the support bar is rotated out of the plane of the leg support. A
bolt is fixedly attached to an end of the diagonal strut opposite
the support bar. A conical washer passes over the bolt and is held
on the bolt by a wing nut. The bolt is inserted into a round
opening of a rounded slot in a slotted bracket by rotating the
diagonal strut. The slotted bracket is attached to a cross bar of
the bed frame assembly. The wing nut is tightened so as to press
the conical washer down into the round opening, whose diameter is
smaller than the maximum diameter of the coned portion of the
conical washer. After the mattress support system is assembled, a
mattress is placed on top of the bed frame assembly.
[0025] Further details and embodiments are described in the
detailed description below. This summary does not purport to define
the invention. The invention is defined by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The accompanying drawings illustrate embodiments of the
invention.
[0027] FIG. 1 (prior art) is a schematic view of a conventional
folding bed frame.
[0028] FIG. 2 is a schematic view of a novel folding bed frame that
includes central connecting bars.
[0029] FIG. 3 is a more detailed view of one of the central
connecting bars of the folding bed frame of FIG. 2.
[0030] FIG. 4 is a schematic view of an edge attachment of the bed
frame of FIG. 2 to which a headboard can be attached.
[0031] FIG. 5 is a perspective, cut-away view of a king size
mattress placed on the folding bed frame of FIG. 2.
[0032] FIG. 6 is a schematic view of another embodiment of the
folding bed frame of FIG. 2.
[0033] FIG. 7 is a flowchart illustrating steps of a method of
packing the folding bed frame of FIG. 2 into a packing box.
[0034] FIG. 8 is a perspective view of another embodiment of
folding bed frames that form a mattress support system with edge
attachments that hold a bed skirt taut.
[0035] FIG. 9 shows an edge attachment of FIG. 8 in more
detail.
[0036] FIG. 10 is a cut-away view of a bed skirt that has been
slipped on over the edge attachment of FIG. 9.
[0037] FIG. 11 is a perspective view of the mattress support system
of FIG. 8 after a bed skirt has been slipped down over edge
attachments and is held taut.
[0038] FIG. 12 is a rear view of the edge attachment of FIG. 9.
[0039] FIG. 13 illustrates a large storage container being slid
past the bed skirt and inserted under the mattress support system
of FIG. 8.
[0040] FIG. 14 is a perspective view illustrating how storage
containers fit underneath the mattress support system of FIG.
8.
[0041] FIG. 15 is a flowchart illustrating steps of a method of
assembling the mattress support system of FIG. 8.
[0042] FIG. 16 is a perspective view of a mattress on top of the
assembled mattress support system of FIG. 8 after the method of
FIG. 15 has been performed.
[0043] FIG. 17 is a perspective view of another embodiment in which
solid plastic edge attachments cover the sides of the mattress
support system in place of the bed skirt.
[0044] FIG. 18 illustrates a mattress supporting system that
includes both edge attachments for holding a bed skirt as well as
headboard attachments for attaching a headboard.
[0045] FIG. 19 is a more detailed view of a headboard attachment of
FIG. 18.
[0046] FIG. 20 shows the headboard attachment of FIG. 19 from a
different angle.
[0047] FIG. 21 shows another embodiment of a headboard attachment
attached to a leg and cross bar of a mattress supporting
system.
[0048] FIG. 22 shows the headboard attachment of FIG. 21 attached
to a mattress supporting system over which a bed skirt has been
drawn.
[0049] FIG. 23 shows another embodiment of the mattress supporting
system that includes a locking mechanism for the leg supports.
[0050] FIG. 24 shows the upper portion of the bed frame assembly of
FIG. 23 in more detail from the underside.
[0051] FIG. 25 shows the locking mechanism of the bed frame
assembly of FIG. 24 in more detail.
[0052] FIG. 26 is a schematic diagram from above showing how a bolt
on a diagonal strut passes through a channel and into a round
opening of a rounded slot in a slotted bracket.
[0053] FIG. 27 is a cross-sectional schematic diagram of a bolt
centered in a round opening of the rounded slot of FIG. 26 before a
conical washer is lowered into the round opening.
[0054] FIG. 28 is a perspective schematic view of the locking
mechanism of FIG. 27 after the conical washer has been tightened by
the wing nut into the round opening of the rounded slot.
[0055] FIG. 29 is a perspective view of the locking mechanism of
FIG. 27 in which the wing nut has not yet tightened the conical
washer all the way down into the round opening of the rounded
slot.
[0056] FIG. 30 is a flowchart illustrating steps of a method of
assembling the mattress support system of FIG. 23.
[0057] FIG. 31 shows another embodiment of the mattress supporting
system that includes hinged brackets to which a headboard can be
attached.
[0058] FIG. 32 is a perspective view of the hinged bracket (left
side) of FIG. 31 after being attached to the upper-left portion of
the mattress supporting system.
[0059] FIG. 33 is a perspective schematic view of the hinged
bracket of FIG. 32 in which the first planar metal portion is
perpendicular to the second planar metal portion.
[0060] FIG. 34 is a perspective schematic view of the hinged
bracket of FIG. 33 in which the first planar metal portion is in
the same plane as the second planar metal portion.
[0061] FIG. 35 shows how the first and second planar metal plate
portions of the hinged bracket are joined and folded around a hinge
axis.
DETAILED DESCRIPTION
[0062] A less costly folding bed frame is disclosed that can
accommodate mattresses of various dimensions. A standardized bed
frame is provided that can be conveniently adjusted to various
mattress widths. The folding bed frame includes a left bed frame
assembly and a right bed frame assembly connected by a plurality of
central connecting bars. The assembled bed frame forms a bedboard
frame and a plurality of legs that are pivotally connected under
the bedboard frame. The central connecting bars form part of the
bedboard frame and connect the left bed frame assembly to the right
bed frame assembly. Each end of each central connecting bar has a
U-shaped slot opening downward. A U-shaped slot is clipped down
over the inner side edge of a bed frame assembly. In one
embodiment, the left and right bed frame assemblies are connected
to each other via the central connecting bars through riveting or
screwing.
[0063] In the description and claims, terms such as "upper",
"lower", "top", "bottom", "up", and "down" are used to describe
relative directions and orientations between different parts of the
mattress support system, and it is to be understood that the
overall structure being described can actually be oriented in any
way in three-dimensional space. For example, when a first object is
described as being pressed down into a second object, it is to be
understood that the first object may in fact be pressed up into the
second object. When a first object is referred to as being disposed
"over" or "on" a second object, it is to be understood that the
first object can be directly on the second object, or an
intervening object may be present between the first and second
objects.
[0064] The combined width of the pair of bed frame assemblies is
narrower than the width of a traditional folding bed frame for a
double bed. By connecting the left and right bed frame assemblies
directly to each other through bolts, riveting or screwing without
using the central connecting bars, a frame for a single bed is
provided. A frame for a double bed is provided by spanning the
plurality of central connecting bars between the left and right bed
frame assemblies. Thus, the standardized left and right bed frame
assemblies are adaptable to form frames for mattresses of various
dimensions. In addition, the standardized left and right bed frame
assemblies reduce the cost of manufacturing bed frames that
accommodate different sized mattresses.
[0065] Because the central connecting bars are independent of the
standardized left and right bed frame assemblies, the lengths of
the bars can be easily varied. Bed frames that can accommodate
different widths of mattresses can be manufactured simply by
producing central connecting bars with different lengths. Central
connecting bars having a specified length can be selected to match
the width requirement of each bed without the need to
re-manufacture a bedboard frame. Thus, the novel bed frame has a
greatly reduced manufacturing cost.
[0066] Especially when configured as a frame for a double bed, the
novel folding bed frame is much lighter than conventional folding
bed frames with cross and longitudinal bars. The weight of the
central connecting bars is less than that of the welded cross and
longitudinal bars.
[0067] The novel folding bed frame is also easier to transport than
a conventional folding bed frame.
[0068] Conventional frames have a single mattress frame whose size
hampers the ease of transport. The novel bed frame is divided into
two bed frame assemblies connected by central connecting bars. The
novel bed frame can be disassembled into the two separate bed frame
assemblies that are easier to carry and transport.
[0069] FIG. 2 shows a novel folding bed frame 10 that can
accommodate mattresses of differing dimensions. Bed frame 10
includes a left bed frame assembly 11, a right bed frame assembly
12, and a plurality of central connecting bars 13. Each of frame
assemblies 11 and 12 resembles a very narrow folding bed frame.
Each of frame assemblies 11 and 12 includes a bedboard frame 14 and
a plurality of leg supports 15 pivotally connected under the
bedboard frame 11. The bed frame assemblies 11 and 12 stand upon
the leg supports 15 when the leg supports are folded out and
locked. A bedboard frame is formed by longitudinal bars 16 welded
to cross bars 17. In one embodiment, the longitudinal bars 16 are
metal rods. Each leg support 15 includes two legs. Three exemplary
leg supports 15 are labeled in FIG. 2. Left bed frame assembly 11
differs from a conventional folding bed frame in that assembly 11
is narrower, normally less than half the width of a frame for a
double bed.
[0070] FIG. 3 shows an exemplary central connecting bar 13 in more
detail. Each central connecting bar is disposed between left bed
frame assembly 11 and right bed frame assembly 12. Both ends of
each central connecting bar 13 have a U-shaped slot 18 opening
downward. The U-shaped slot 18 is clipped down over an inner side
edge 19 of one of frame assemblies 11 or 12.
[0071] In another embodiment, the connection between the end of a
central connecting bar 13 and an inner side edge 19 is made by
inserting a narrow tip of the connecting bar through a hole in the
side edge 19. Alternatively, the end of a central connecting bar 13
is bolted to the side edge 19. Other connection means can also be
used to connect the central connecting bars to the inner side
edges.
[0072] Folding bed frame 10 is shipped from the manufacturer to
retail stores in a disassembled condition. Typically, a customer
also purchases folding bed frame 10 in a disassembled condition and
assembles the bed frame at home in the bedroom where the bed frame
will be used. All of the disassembled pieces of folding bed frame
10 fit in a packing box having a length that is about half the
length of each bed frame assembly. In the packing box, each bed
frame assembly is folded at its middle axis 20, which is hinged.
For example, the lower half of each bed frame assembly is folded
over onto the upper half of the frame assembly in order to fit in
the packing box. The packing box has a width of little more than
the width of one bed frame assembly. The thickness of the box is
about four times the thickness of the bedboard frame plus four
times the thickness occupied by a folded leg support 15. The
central connecting bars fit in the packing box between the
folded-in leg supports. Thus, the area defined by the length and
width of the packing box is less than a quarter of the area of the
mattress that fits on the bedboard frame formed by the bed frame
assemblies and the central connecting bars.
[0073] To assemble bed frame 10, bed frame assemblies 11 and 12 are
first deployed. The bedboard frame 14 of each bed frame assembly is
unfolded, and the three leg supports 15 of each frame assembly are
folded out and locked. Right bed frame assembly 12 is placed to the
right of left bed frame assembly 11. Next, the plurality of central
connecting bars 13 are fixedly clipped onto the inner edges 19 of
left and right bed frame assemblies 11 and 12 such that the bars
transversely span between the left and right bed frame assemblies
11 and 12. The U-shaped slots 18 are clipped down over the metal
bars that form the inner edges 19. Next, edge attachments 21 (not
shown in FIG. 2) are attached by screws to the upper left corner of
left bed frame assembly 11 and to the upper right corner of right
bed frame assembly 12.
[0074] FIG. 4 shows the edge attachment 21 attached to the right
head corner of right bed frame assembly 12. In this embodiment,
edge attachment 21 clips over a head side edge as well as over an
outer side edge of right bed frame assembly 12. Then edge
attachment 21 is screwed in and hangs down from the side edge of
right bed frame assembly 12. A headboard is attached to the edge
attachments. Tongues on the headboard slip into slots 22 in edge
attachment 21.
[0075] FIG. 5 shows a king size mattress 23 placed on 14 bedboard
frame 14 of folding bed frame 10. A headboard 24 is attached to
edge attachments 21. FIG. 5 illustrates that the area of bedboard
frame 14 formed by the longitudinal bars 16 and cross bars 17 is
limited to the sides where the bed frame assemblies are located.
The central area of bedboard frame 14 is formed by the central
connecting bars 13. Because the weight of the central connecting
bars 13 is less than that of the longitudinal bars 16 and cross
bars 17, folding bed frame 10 is lighter and less awkward. Folding
bed frame 10 is also less awkward than conventional bed frames
because the size of the disassembled, folded bed frame inside the
packing box is smaller and can be more easily fit inside the trunk
of a car or through a doorway.
[0076] Left and right bed frame assemblies 11 and 12 provide
support on the side edges of mattresses of every width. Edge
support is beneficial, as consumers tend to sit on the side of a
mattress before getting in and out of bed. In one embodiment, some
unsupported length remains at the foot of the mattress because the
length of left and right bed frame assemblies 11 and 12 fits the
length of a single mattress, and a headboard is attached to the
head of the bed frame assemblies. In another embodiment, a central
connecting bar connects the foot side edges of left and right bed
frame assemblies 11 and 12 and provides support for mattress 23 at
the foot of the bed.
[0077] In addition, the manufacturing cost of folding bed frame 10
is reduced because bed frame assemblies 11 and 12 are standardized,
and the length of the central connecting bars 13 can be adjusted.
In one embodiment, central connecting bars 13 having a length that
is appropriate for the width of a certain mattress are included in
the packing box. For example, shorter connecting bars are included
in the packing box of a bed frame for a queen size mattress than
are included in the box for a king size mattress. In another
embodiment, the central connecting bars are conveniently adjustable
by allowing one side of each connecting bar to telescope into the
other side of the connecting bar. A screw from the outer bar then
tightens into the inner bar to fix the length of the connecting
bar. Alternatively, a connecting bar is made adjustable by sliding
a smaller U-shaped bar inside a larger, outer U-shaped bar.
[0078] FIG. 6 shows another embodiment of folding bed frame 10 in
which no central connecting bars are used. Left and right bed frame
assemblies 11 and 12 are placed directly adjacent to each other.
The inner side edges 19 of the bed frame assemblies 11 and 12 are
attached to each other by bolts 25 and nuts. Alternatively, the bed
frame assemblies 11 and 12 can be connected by screws or rivets.
The bed frame of FIG. 6 has a width that is appropriate for a
narrow mattress, such as an extra-long college twin mattress that
measures 38 inches by 84 inches. Thus, the same standardized bed
frame assemblies 11 and 12 form a bedboard frame 14 that supports
mattresses of different dimensions. Not only is the manufacturing
cost reduced, but the disassembled folding bed frame can be more
conveniently packaged and transported.
[0079] FIG. 7 is a flowchart illustrating steps 26-31 of a method
of packing folding bed frame 10 into a packing box that is
conveniently sized for transporting. In a first step 26, a lower
half of the bedboard frame 14 of right bed frame assembly 12 is
folded over onto an upper half of the bedboard frame. Bedboard
frame 14 is folded over at a hinge at middle axis 20.
[0080] In step 27, a first leg support 15 that is pivotally
connected to the bedboard frame 14 of right bed frame assembly 12
is folded in. In step 28, a lower half of the bedboard frame 14 of
left bed frame assembly 11 is folded over onto an upper half of the
bedboard frame. In step 29, a second leg support 15 that is
pivotally connected to the bedboard frame 14 of left bed frame
assembly 11 is folded in. In step 30, the folded bedboard frame of
right bed frame assembly 12 and the folded bedboard frame of left
bed frame assembly 11 are inserted into a packing box. The packing
box is about half as long as the unfolded bedboard frame of right
bed frame assembly 12. The packing box has a width of little more
than the width of right bed frame assembly 12. The packing box is
about four times as thick as the folded first leg support plus four
times as thick as the unfolded bedboard frame of right bed frame
assembly 12. In step 31, a central connecting bar 13 is inserted
into the packing box. The central connecting bar 13 is adapted to
connect the bedboard frame of left bed frame assembly 11 to the
bedboard frame of right bed frame assembly 12.
[0081] FIG. 8 illustrates another embodiment of a folding bed frame
that includes edge attachments for holding a bed skirt. The folding
bed frame of FIG. 8 provides a mattress supporting system 32 that
performs the functions of both a conventional box spring and a
conventional metal bed frame with wood rails. Thus, mattress
supporting system 32 can replace conventional bed frames and box
springs. Mattress supporting system 32 includes left bed frame
assembly 11, right bed frame assembly 12, and central connecting
bars 13. Each of the bed frame assemblies 11 and 12 includes a
bedboard frame 14. The bed frame assemblies 11 and 12 stand upon
leg supports 15 when the leg supports are folded out and locked.
Each bed frame assembly has a hinge at its middle axis 20 at which
a lower portion of the assembly unfolds from an upper portion.
[0082] Mattress supporting system 32 includes an edge attachment 33
attached to the right foot corner 34 (the lower right corner) of
right bed frame assembly. (For simplicity, the remaining edge
attachments are not shown in FIG. 8, but are illustrated in
subsequent figures.) Edge attachment 33 clips over a foot side edge
35 and an outer side edge 36 of right bed frame assembly 12. Edge
attachment 33 is adapted to hold a bed skirt taut around both bed
frame assemblies of mattress supporting system 32 when the bed
frame assemblies are resting on the extended leg supports 15.
[0083] In one embodiment of mattress supporting system 32, edge
attachment 33 and the other edge attachments (not shown) slant at
an angle 37 down and away from the bed frame assemblies when no bed
skirt is being held such that a bed skirt that is slipped on over
the slanted edge attachments is held taut. Edge attachment 33
slants down at an angle 37 that is about five to ten degrees from
vertical. The bottom edge of the bed skirt is held taut as the bed
skirt pulls the bottoms of the edge attachments inward. Thus, the
long side of edge attachment 33 is oriented vertically when the bed
skirt is slipped over mattress supporting system 32.
[0084] FIG. 9 shows edge attachment 33 in more detail. In one
embodiment, edge attachment 33 is made of hard molded plastic. Edge
attachments at the foot of a bed are preferably made of plastic
instead of metal to avoid injury to the shins, feet and children as
consumers walk around the foot of mattress support system 32.
Plastic edge attachments are also less expensive to manufacture
than metal edge attachments. In addition, plastic edge attachments
are lighter weight than metal edge attachments and are therefore
less expensive to transport. Where stronger edge attachments are
required to hold both a bed skirt and a headboard, metal is used.
Clips 38 on edge attachment 33 clip down over foot side edge 35 and
outer side edge 36 such that no screws, bolts or nuts are required
to attach edge attachment 33 to the side edges.
[0085] FIG. 10 is a cut-away view of a bed skirt 39 that has been
slipped on over slanted edge attachment 33. Bed skirt 39 has a
skirt portion 40 and center fabric 41. Skirt portion 40 has an
upper edge 42 and a lower edge 43. While bed skirt 39 is slipped
over the slanted edge attachments on the four corners of mattress
support system 32, the edge attachments hold lower edge 43 of skirt
portion 40 taut. Skirt portion 40 gives the appearance of a
covering of a solid box spring. In one embodiment, center fabric 41
is made of a non-skid fabric such that a mattress placed on
mattress support system 32 does not slip.
[0086] FIG. 11 shows bed skirt 39 after being slipped down over
edge attachment 33 and the other edge attachments such that bed
skirt 39 is held taut around bed frame assemblies 11 and 12 when
the bed frame assemblies are standing on the unfolded leg supports
15. The edge attachments hold bed skirt 39 such that more than half
of each leg support 15 is not visible behind bed skirt 39 when the
bed frame assemblies are resting on the extended leg supports 15.
Thus, mattress support system 32 appears to be a solid box spring
sitting on short legs.
[0087] Although mattress support system 32 has an appearance
similar to a conventional box spring, mattress support system 32
has several advantages over a conventional box spring that is
supported by the metal rails of a conventional bed frame. First,
mattress support system 32 is easier to move than a conventional
box spring. Whereas a conventional box spring is constructed with a
unitary wood frame that cannot be bent or disassembled into pieces,
mattress support system 32 can be delivered in a relatively small
packing box. Consequently, mattress support system 32 can be
transported in an elevator and moved around the bend in a
staircase, whereas a queen or king size box spring may be too large
or awkward. Mattress support system 32 fits in a packing box that
is about half as long as the unfolded bed frame assemblies and
about as wide as the width of one bed frame assembly.
[0088] Second, mattress support system 32 is lighter than a
conventional bed frame and box spring, and thus is both less
expensive and easier to transport. The wood frame of a conventional
box spring has solid sides, which weigh more than the edge
attachments of mattress support system 32 over which the fabric of
the bed skirt is stretched. Wood beams of a conventional box spring
form both a top surface and a bottom surface, whereas the bottom of
mattress support system 32 remains open. The leg supports of
mattress support system 32 are lighter than a conventional metal
bed frame with wooden rails upon which the conventional box spring
sits.
[0089] Third, mattress support system 32 is quieter than a
conventional box spring sitting on wooden rails of a bed frame. As
a person moves on a mattress, the joints in the wood of the box
spring squeak. In addition, movement of the box spring over the
wooden rails also makes noise. The metal construction of mattress
support system 32 is less likely to make noise as a person moves on
a mattress supported by the support system.
[0090] Fourth, mattress support system 32 provides a significant
amount of storage space beneath the supported mattress. Because the
wood frame of a conventional box spring has solid sides and beams
forming top and bottom surfaces, the volume inside a conventional
box spring cannot be accessed for storage. On the other hand,
mattress support system 32 is open at the bottom and permits that
space between the leg supports 15 to be used for storage.
[0091] FIG. 12 is a rear view of edge attachment 33 of FIG. 9. In
the view of FIG. 12, foot side edge 35 and outer side edge 36 have
been cut away. FIG. 12 illustrates how a clip 38 clips down over
and locks to outer side edge 36. Clip 38 holds edge attachment 33
firmly to the side edges without using separate attachment pieces,
such as screws, bolts or nuts.
[0092] FIG. 13 illustrates the significant storage area available
beneath a mattress supported by mattress support system 32. A large
storage container 44 can be slid past bed skirt 39 and inserted
under mattress support system 32. Storage container 44 has a floor
height of more than twelve inches and would not fit under the rail
of a conventional bed frame that stands only a few inches off the
floor. A bed frame assembly and an edge attachment 45 are adapted
to allow storage container 44 to slide under the bed frame assembly
when the taut bed skirt 39 is stretched at the middle of a side
between edge attachments. In FIG. 13, skirt portion 40 of bed skirt
39 has been detached from left foot edge attachment 45 to allow
storage container 44 to be slid under mattress support system 32
past the skirt portion 40. In the embodiment of FIG. 13, storage
container 44 has a floor height of fourteen inches and slides below
outer side edge 46.
[0093] FIG. 14 is a picture of mattress support system 32
illustrating how twelve storage containers fit underneath bed frame
assemblies 11 and 12 and central connecting bars 13. For purposes
of illustration, mattress support system 32 is shown in FIG. 14
without bed skirt 39. In addition to large storage container 44,
which fits under left bed frame assembly 11, there is an even
bigger storage container 47 that fits under right bed frame
assembly 12 and central connecting bars 13. A smaller storage
container 48 slides under the side edges and under the diagonal
support bars 49 near the foot of the mattress support system
32.
[0094] In the embodiment of FIG. 14, mattress support system 32 has
six edge attachments: four at the corners and two at the middle of
the sides. In addition to left foot edge attachment 45 and edge
attachment 33 at the bottom right corner of mattress support system
32, FIG. 14 also shows a side edge attachment 50. Side edge
attachment 50 stabilizes skirt portion 40 of bed skirt 39 at the
middle of outer side edge 46 while skirt portion 40 is being held
taut by left foot edge attachment 45 and a left head edge
attachment 51. In one embodiment, the bottom of side edge
attachment 50 holds lower edge 43 of skirt portion 40 down such
that lower edge 43 forms a straight line from the bottom of left
foot edge attachment 45 to the bottom of left head edge attachment
51.
[0095] FIG. 15 is a flowchart illustrating steps 54-61 of a method
of setting up mattress support system 32. In a first step 54, the
contents are removed from a packing box containing mattress support
system 32. In the embodiment of FIG. 8, the packing box includes
left bed frame assembly 11, right bed frame assembly 12, seven
central connecting bars 13, six edge attachments 33, 45, 50-53 and
bed skirt 39. Leg supports 15 are part of bed frame assemblies 11
and 12. Thus, right bed frame assembly 12 and edge attachment 33
are removed from the packing box.
[0096] In a step 55, the upper portion of each bed frame assembly
is unfolded from the lower portion at hinges located along middle
axis 20. In the folded condition in the packing box, the leg
supports are folded into the outer sides of each folded bed frame
assembly. In step 55, the upper portion of right bed frame assembly
12 is unfolded from the lower portion of bed frame assembly 12.
[0097] In a step 56, the leg supports 15 are unfolded. For example,
a leg support 62 that is pivotally connected to the upper portion
of right bed frame assembly 12 is unfolded and locked into
place.
[0098] In a step 57, the unfolded bed frame assemblies 11 and 12
are stood on the unfolded leg supports 15. For example, the
unfolded right bed frame assembly 12 is stood on unfolded leg
supports 15, including unfolded and locked leg support 62.
[0099] In a step 58, central connecting bars 13 are fixedly clipped
onto the inner side edges of bed frame assemblies 11 and 12 such
that the bars transversely span between the bed frame
assemblies.
[0100] In a step 59, the edge attachments are attached to the outer
corners and to the middle of the outer sides of bed frame
assemblies 11 and 12. For example, edge attachment 33 is clipped
down over the side edges at the right foot corner of mattress
support system 32. Edge attachment 50 is clipped down over outer
side edge 46 halfway between left foot edge attachment 45 and left
head edge attachment 51.
[0101] In a step 60, a bed skirt is slipped down over bed frame
assemblies 11 and 12 and over the edge attachments. The four edge
attachments 33, 45, 51, 52 at the corners of mattress support
system 32 hold the bed skirt taut around the bed frame assemblies
when the bed frame assemblies are standing on the unfolded leg
supports. For example, bed skirt 39 is slipped down over edge
attachment 33 such that skirt portion 40 of bed skirt 39 is held
taut around right bed frame assembly 12. When skirt portion 40 is
pulled down over the edge attachments, center fabric 41 is also
pulled taut over the bedboard frames of bed frame assemblies 11 and
12.
[0102] In a step 61, a mattress 63 is placed on center fabric 41
over the assembled mattress support system 32.
[0103] FIG. 16 shows the assembled mattress support system 32 after
the method of FIG. 15 has been performed. Mattress support system
32 has been set up with mattress 63 resting on top of center fabric
41.
[0104] In another embodiment, another type of edge attachment is
attached to the left head corner and to the right head corner of
mattress support system 32. In this embodiment, the edge
attachments on the head corners of mattress support system 32 are
made of metal and resemble edge attachment 21 of FIG. 4. The metal
edge attachments either screw into or are clipped down over the
side edges. Then bed skirt 39 is slipped down over the two plastic
edge attachments at the foot corners and over the two metal edge
attachments at the head corners of mattress support system 32.
Slits are made in the head side of skirt portion 40 to allow
tongues on a headboard to slip into slots in the metal edge
attachments. Thus, the metal edge attachments are used both to hold
skirt portion 40 taut around mattress support system 32, as well as
to hold a headboard. As shown in FIG. 4, the metal edge attachment
is adapted to hold a headboard that attaches to the edge attachment
only at locations below the head side edge of the bed frame
assembly.
[0105] FIG. 17 shows yet another embodiment in which the edge
attachments cover the sides of mattress support system 32 in place
of bed skirt 39. The embodiment of FIG. 17 has solid plastic edge
attachments 64 that snap down with clips 65 over the side edges.
Edge attachments 64 do not attach to the side edges at the corners,
as do edge attachments 33, 45, 51, 52, but rather attach along a
large section of each side edge and meet at the corners. In the
embodiment of FIG. 17, there are two edge attachments per side
edge. The hard plastic of edge attachments 64 may be made in
different colors so as to provide beds in a variety of colors. When
the sides of mattress support system 32 are covered by edge
attachments 33, 45, 51, 52, mattress support system 32 has the
appearance of a platform bed.
[0106] FIG. 18 illustrates another embodiment of a mattress
supporting system 66 that includes both edge attachments for
holding a bed skirt and separate headboard attachments for
attaching a headboard. Mattress supporting system 66 includes six
solid plastic edge attachments that clip over the side edges,
including left foot edge attachment 45, right feet edge attachment
33, left head edge attachment 51, right head edge attachment 52,
left side edge attachment 50 and right side edge attachment 53. The
plastic edge attachments 51-52 are not strong enough to hold the
weight of most headboards, so dual purpose metal edge attachment of
the type shown in FIG. 4 would be required both to hold a bed skirt
taut and to support a headboard. A headboard is attached to dual
purpose edge attachment 21 of FIG. 4 by slipping tongues on the
headboard into the slots 22 in edge attachment 21. Alternatively,
bolts on the headboard pass through the slots 22 and are fastened
by nuts or wing nuts on the opposite side of edge attachment
21.
[0107] Where edge attachment 21 holds a bed skirt, however,
attaching a headboard onto edge attachment 21 requires slitting the
bed skirt and passing the tongues or bolts through the slits.
Cutting or puncturing the bed skirt may be considered undesirable
and inconvenient. Moreover, the headboard must be removed in order
to remove and replace the bed skirt. Mattress supporting system 66
includes a metal headboard attachment 67 that is separate from the
plastic edge attachments 33, 45 and 50-53 that hold the bed skirt.
Headboard attachment 67 permits a bed skirt to be replaced without
removing the headboard. In addition, the bed skirt need not be
punctured or slit in order to allow bolts or tongues to pass from
the headboard through the bed skirt to the edge attachments.
[0108] Mattress supporting system 66 includes left bed frame
assembly 11, right bed frame assembly 12, and central connecting
bars 13. The bed frame assemblies 11 and 12 stand upon leg supports
15 when the leg supports are folded out and locked. Each leg
support 15 includes two legs and a cross bar. For example, the
upper left leg support 15 includes an outer leg 68 and a cross bar
69. Headboard attachment 67 attaches to leg 68 and extends under
the bed skirt laterally past head side edge 70. Mattress supporting
system 66 also includes a second metal headboard attachment (not
shown in FIG. 18) that is a mirror image of headboard attachment 67
and that attaches to the outer leg of the upper right leg support.
The headboard attaches to headboard attachment 67 only at locations
below head side edge 70 of left bed frame assembly 11. The
headboard also attaches to the second headboard attachment at
locations below the head side edge of right bed frame assembly
12.
[0109] FIG. 19 shows headboard attachment 67 of FIG. 18 in more
detail. Headboard attachment 67 has a main face 71 with slots 72
and a side surface 73. Side surface 73 prevents a person from
cutting her shin on the edge of main face 71 while walking around
the upper left corner of mattress supporting system 66 when a
headboard is not attached to headboard attachment 67. Tongues on a
headboard slip into the slots 72 in headboard attachment 67.
Alternatively, bolts attached to the headboard pass through the
slots 72 and are tightened by nuts or wing nuts. Headboard
attachment 67 also includes a separate fastening portion 74 and an
angle bracket 75 that protrudes from a flange 76. Fastening portion
74 is used to clamp headboard attachment 67 to leg 68 by tightening
wing nuts 77. When headboard attachment 67 is tightened around leg
68, angle bracket 75 rests on cross bar 69 of the leg support and
prevents a heavy headboard from causing headboard attachment 67 to
slip down leg 68.
[0110] FIG. 20 is a view of headboard attachment 67 from a
different angle. FIG. 20 shows fastening portion 74 loosened from
the main body of headboard attachment 67. Leg 68 is clamped between
flange 76 and fastening portion 74 using bolts and wing nuts.
[0111] FIG. 21 shows another embodiment of headboard attachment 67
attached to leg 68 and cross bar 69. The embodiment of FIG. 21 does
not include a side surface 73. The view of FIG. 21 is shown without
left head edge attachment 51.
[0112] FIG. 22 shows the embodiment of FIG. 21 attached to a
mattress supporting system over which a bed skirt 78 has been
drawn. Bed skirt 78 has skirt portion 40 and center fabric 41. FIG.
22 shows upper edge 42 and lower edge 43 of skirt portion 40.
Slanted edge attachment 51 holds lower edge 43 of skirt portion 40
taut. Skirt portion 40 gives the appearance of a covering of a
solid box spring. FIG. 22 also shows a dashed outline of a
headboard 79 that is attached to headboard attachment 67 and to the
second headboard attachment located at the right head corner of the
mattress supporting system.
[0113] FIG. 23 illustrates one of the bed frame assemblies of
another embodiment of the mattress supporting system 66 that
includes locking mechanisms for the upper and lower leg supports.
In the embodiment of FIG. 18, a separate headboard attachment 67 is
attached to upper leg support 15 and must support the heavy
headboard 79. Thus, the leg support 15 must support the combined
weight of the mattress, the occupant of the bed and the headboard.
The bed frame assembly 80 of FIG. 23 includes sturdy diagonal
struts 81-84 with locking mechanisms 85-88, respectively, that
prevent the upper and lower leg supports 89-90 from angling away
from vertical under the combined weight.
[0114] Bed frame assembly 80 includes a plurality of leg supports
89-91 pivotally connected to a bedboard frame 92. Assembly 80
stands upon the leg supports 89-91 when the leg supports are folded
out and locked. Bedboard frame 92 is formed by longitudinal bars
93-96 welded to cross bars 97-104. Each leg support 89-91 includes
two legs and a support bar. For example, upper left leg support 89
includes two legs 105-106 and support bar 107. Bed frame assembly
80 has a hinge at its middle axis at which the lower portion of
bedboard frame 92 unfolds from the upper portion. In the embodiment
of FIG. 23, the middle axis lies along a middle plane formed by the
two legs 108-109 of the middle leg support 91. Hinges on either
side of the middle plane pivotally attach the longitudinal bars
93-96 of the upper and lower portions of the bedboard frame 92 to
the middle leg support 91. The hinges are fixedly attached to the
middle leg support 91. The upper and lower leg supports 89-90 are
pivotally attached to cross bars 97 and 104, respectively.
[0115] After the upper portion of assembly 80 is unfolded from the
lower portion, the upper and lower leg supports 89-90 can be
unfolded. For example, upper leg support 89 that is pivotally
connected to the upper portion of bedboard frame 92 is unfolded and
locked into place by diagonal struts 81-82 and locking mechanisms
85-86. Before upper leg support 89 is unfolded, the plane of legs
105-106 is parallel to the plane of the upper portion of bedboard
frame 92. In addition, the diagonal struts 81-82 are not yet
attached to cross bar 98, but are instead parallel to the plane of
legs 105-106. Thus, the diagonal struts 81-82 are pivotally
attached to support bar 107 and are rotated out of the plane of
legs 105-106 after upper leg support 89 is unfolded.
[0116] FIG. 24 shows the upper portion of bed frame assembly 80 in
more detail from the underside of bedboard frame 92 after upper leg
support 89 has been unfolded and after the diagonal struts 81-82
have been rotated out of the plane of legs 105-106. Struts 81-82
are rotated in opposite directions to reach slotted brackets
110-111 attached to cross bar 98. For example, diagonal strut 82 is
rotated clockwise in the perspective of FIG. 24 to reach a slotted
bracket 110 that is welded to cross bar 98. The locking mechanism
86 is formed between slotted bracket 110 and the end of diagonal
strut 82.
[0117] FIG. 25 shows the locking mechanism 86 in more detail from
the underside of bedboard frame 92 before diagonal strut 82 has
completely reached slotted bracket 110. A bolt 112 is fixedly
attached to the end of diagonal strut 82. A conical washer 113
slides along bolt 112 and is held on the bolt by a wing nut 114.
FIG. 25 also shows a conical washer and wing nut on a bolt at the
end of the other diagonal strut 81. Diagonal strut 81 is still in
the plane of upper support leg 89 and has not yet been rotated so
that the end of the strut reaches the slotted bracket 111. Diagonal
strut 82 is being rotated such that bolt 112 will pass into a
rounded slot 115 in slotted bracket 110. Rounded slot 115 has a
channel 116 that is only slightly wider than the diameter of bolt
112. A round opening 117 at the end of the channel 116 has a
diameter larger than the width of the channel.
[0118] FIG. 26 is a schematic diagram from above showing how bolt
112 passes through channel 116 and into the round opening 117 of
rounded slot 115 as diagonal strut 82 is rotated. Wing nut 114 is
not shown in FIG. 26. Conical washer 113 is raised above slotted
bracket 110 as bolt 112 passes through channel 116. Then the coned
portion of conical washer 113 fits into the round opening 117 once
bolt 112 is centered in the round opening. From the upside-down
perspective of FIG. 25, the coned portion fits down into the round
opening 117.
[0119] FIG. 27 is a cross-sectional schematic diagram of bolt 112
centered in the round opening 117 of rounded slot 115 before
conical washer 113 is lowered into the round opening 117. In the
right-side-up orientation of FIG. 23, conical washer 113 rises up
into the round opening 117 as wing nut 114 is tightened. In one
embodiment, conical washer 113 has a coned portion and a
cylindrical portion. The diameter of the cylindrical portion of
conical washer 113 is larger than the diameter of the round opening
117. In another embodiment, conical washer 113 has only the coned
portion, and the maximum diameter of the coned portion is larger
than the diameter of the round opening 117. After conical washer
113 is lowered into round opening 117 and wing nut 114 is tightened
to prevent conical washer 113 from rising up, the sides of the
coned portion of conical washer 113 prevent bolt 112 from passing
out of the narrower channel 116.
[0120] FIG. 28 is a perspective schematic view of locking mechanism
86 after conical washer 113 has been tightened by wing nut 114 into
the round opening 117 of rounded slot 115. The sides of the lower
coned portion of conical washer 113 press against the sides of the
round opening 117. FIG. 28 shows that the largest diameter of the
coned portion is larger than the diameter of the round opening
117.
[0121] FIG. 29 is a perspective view of locking mechanism 86 in
which bolt 112 has been rotated into rounded slot 115 but conical
washer 113 has not yet been tightened by wing nut 114 all the way
down into the round opening 117.
[0122] FIG. 30 is a flowchart illustrating steps 118-12X of a
method of setting up mattress support system 66 of FIG. 23. In a
first step 118, the contents are removed from a packing box
containing mattress support system 66. In the embodiment of FIG.
23, the packing box includes only the components of bed frame
assembly 80. Bed frame assembly 80 includes the upper and lower
portions of bedboard frame 92, leg supports 89-91, diagonal struts
81-84 and locking mechanisms 85-88.
[0123] In a step 119, the upper portion of bed frame assembly 80 is
unfolded along a middle axis from the lower portion. The upper
portion and the lower portion are pivotally connected at a hinge.
In the folded condition in the packing box, the leg supports 89-90
are folded into the bottom sides of the upper and lower portions of
the bed frame assembly. Each leg support has two legs disposed in a
plane, and the two legs are connected by a support bar.
[0124] In a step 120, the leg supports 89-90 are unfolded. For
example, upper leg support 89 that is pivotally connected to the
upper portion of bedboard frame 92 is unfolded to an orientation
perpendicular to the upper portion. Middle leg support 91 need not
be separately unfolded because the middle support is left standing
when the upper and lower portions of bedboard frame 92 are unfolded
from one another. After the upper and lower leg supports 89-90 are
unfolded, the diagonal struts 81-84 can be conveniently locked into
place using the locking mechanisms 85-88.
[0125] In a step 121, the diagonal struts 81-82 are rotated out of
the planes of the leg supports 89-90. For example, diagonal strut
81 that is pivotally attached to support bar 107 of upper leg
support 89 is rotated out of the plane of the leg support, and
diagonal strut 82 that is pivotally attached to support bar 107 is
also rotated out of the plane of upper leg support 89. Bolt 112 is
fixedly attached to an end of diagonal strut 82 opposite support
bar 107, and conical washer 113 passes over bolt 112 and is held on
bolt 112 by wing nut 114.
[0126] In a step 122, the bolts at the ends of the diagonal struts
are rotated into rounded slots in slotted brackets that are
attached to cross bars. For example, bolt 112 is inserted through
channel 116 and into round opening 117 of rounded slot 115 in
slotted bracket 110 by rotating diagonal strut 82. Slotted bracket
110 is attached to cross bar 98 of bedboard frame 92.
[0127] In a step 123, the wing nuts are tightened so as to press
the coned portions of the conical washers into the round openings
in the slotted brackets, which prevents the bolts from slipping out
of the rounded slots and thereby locks the unfolded leg supports in
place. For example, wing nut 114 is tightened so as to press
conical washer 113 down into round opening 117 such that the sides
of the lower coned portion of conical washer 113 press against the
sides of the round opening 117.
[0128] In a step 124, the unfolded bed frame assembly 80 is stood
on the unfolded and locked leg supports 89-91. For example, the
unfolded bed frame assembly 80 is stood on the leg supports 89-91,
including the unfolded and locked leg support 89.
[0129] In a step 125, a headboard attachment is attached to upper
leg support 89. Because leg support 89 is locked into place by
diagonal struts 81-82 and locking mechanisms 85-86, the leg support
is stable enough to hold the headboard attachment and the
headboard.
[0130] In a step 126, a mattress is placed on top of the assembled
bed frame assembly 80.
[0131] FIG. 31 is a perspective view of two hinged brackets for
headboard support of the bed frame assembly 80 of FIG. 23. The view
of FIG. 31 is from the upper side of the bed frame assembly 80. The
upper side of the bedboard frame 92 includes an upper side edge bar
128 and the two longitudinal bars 93 and 94. The longitudinal bars
93 and 94 are also referred to as outer side edge bars. A hinged
bracket (right side) 129 is secured to the longitudinal bar 94 and
the upper side edge bar 128. A hinged bracket (left side) 130 is
secured to the longitudinal bar 93 and the upper side edge bar 128.
Both hinged brackets 129 and 130 have the same design and are
manufactured in the same way. In the embodiment shown in FIG. 31,
the hinged brackets 129 and 130 are secured to the bedframe
assembly 80 using screws.
[0132] FIG. 32 shows the upper-left portion of bed frame assembly
80 in more detail after the hinged bracket (left side) 130 has been
unfolded and secured to the bedboard frame 92. The hinged bracket
130 includes a first planar metal plate portion 131, a second
planar metal plate portion 142, a first hinge 153 and a second
hinge 157. The first planar metal plate portion 131 includes a
first lip 134, a first slot 135, a second slot 136, and a third
slot 137. The first lip 134 rests on top of the upper side edge bar
128. The first planar metal plate portion is screwed into an outer
edge of upper side edge bar 128 through the third slot 137. The
first planar metal plate portion 131 hangs down from the upper side
edge bar 128. In one embodiment, the headboard of the bed frame
assembly 80 is attached to the hinged bracket 130 below the upper
side edge bar 128.
[0133] The second planar metal plate portion 142 includes a second
lip 145, a fourth slot 146, a fifth slot 147, and a sixth slot 148.
The second lip 145 rests on top of the longitudinal bar 93. The
second planar metal plate portion 142 is screwed into an outer edge
of the longitudinal bar 93 through the sixth slot 148. The first
planar metal plate portion 131 is pivotally attached to the second
planar metal plate portion 142 at the second hinge 157.
[0134] Similarly, the hinged bracket (right side) 129 mirrors the
components of the hinged bracket (left side) 130. For example, the
hinged bracket 129 has a first metal plate portion that includes a
first lip, a first slot, a second slot, and a third slot. In this
example, the first lip rests on top of the longitudinal bar 94, and
the first planar metal portion is screwed into an outer edge of the
longitudinal bar 94. Furthermore, in this example, the hinged
bracket 129 has a second metal plate portion that includes a second
lip, a fourth slot, a fifth slot, and a sixth slot, wherein the
second lip rests on top of the upper side edge bar 128 and the
second planar metal portion is screwed into an outer edge of the
upper side edge bar 128 (see FIG. 31). In the embodiment shown in
FIG. 32, the first planar metal plate portion 131 is oriented
perpendicular to the second planar metal plate portion 142, and the
hinged bracket 130 is supported by the bed frame assembly 80. The
hinged bracket 129 is also supported by the bed frame assembly 80
in a similar fashion to that of the hinged bracket 130.
[0135] Furthermore, the hinged brackets 129 and 130 are adapted to
hold a headboard of a bed. For example, the hinged bracket 130,
shown in FIG. 32, includes the first slot 135 and the second slot
136, wherein each slot is capable of receiving a tongue of the
headboard. In another example, the tongue of the headboard slides
into the fourth slot or the fifth slot of the hinged bracket
129.
[0136] FIG. 33 is a perspective schematic view of the hinged
bracket (left side) 130. The view of FIG. 33 is the reverse view of
FIG. 32 without the bedframe assembly 80. The hinged bracket 130
includes the first planar metal plate portion 131, the second
planar metal plate portion 142, the first hinge 153, and the second
hinge 157.
[0137] The first planar metal plate portion 131 includes a first
upper edge 132, a first descending edge 133, the first lip 134, the
first slot 135, the second slot 136, the third slot 137, a seventh
slot 158, an eighth slot 159, and a first opening 162. The first
planar metal plate portion 131 also includes a first curved section
140 and a third curved section 141, as shown in FIG. 34. Each
curved section is made from a rolled tongue that extends from the
first planar metal plate portion 131 opposite the first descending
edge 133. The first curved section 140 and the third curved section
141 together form a first portion of the first hinge 139, as shown
in FIG. 33.
[0138] The second planar metal plate portion 142 includes a second
upper edge 143, a second descending edge 144, the second lip 145,
the fourth slot 146, the fifth slot 147, the sixth slot 148, a
ninth slot 160, a tenth slot 161, a second opening 163. The second
planar metal plate portion 142 also includes a second curved
section 151 and a fourth curved section 152 (see FIG. 34). The
second curved section 151 and the fourth curved section 152
together form a second portion of the first hinge 150 as shown in
FIG. 33.
[0139] The first hinge 153 includes the first portion 139 of the
first hinge, the second portion 150 of the first hinge, a pin 154,
and a nut 155. The pin 154 slides through the first curved section
140, the second curved section 151, the third curved section 141,
and the fourth curved section 152. The lower end of the pin 154 is
secured using the nut 155. The first portion 139 of the hinge
adjoins the second portion 150 of the hinge at a hinged edge of the
hinged bracket 130. The first planar metal plate portion 131 and
the second planar metal plate portion 142 are adjoined at a hinge
axis 156. The first planar metal plate portion 131 and second
planar metal plate portion 132 rotate axially around the hinge axis
156. The first planar metal plate portion 131 has a length along
its hinged edge of less than fourteen inches.
[0140] The second hinge 157 comprises a first portion of the second
hinge 164, a second portion of the second hinge 165, a pin 179 and
a nut 180. The first portion of the second hinge 164 includes a
fifth curved section 166 and a seventh curved section 167, which
are part of the first planar metal plate portion 131 (see FIG. 34).
The second portion of the second hinge 165 includes a sixth curved
section 168 and an eighth curved section 169, which are part of the
second planar metal plate portion 142 (see FIG. 34). The pin 179
slides through both the first portion 164 and the second portion
165 of the second hinge 157 and is secured using the nut 180. The
first hinge 153 and the second hinge 157 are disposed along the
hinged axis 156.
[0141] In one embodiment, the first planar metal plate portion 131
has a top half and a bottom half. The top half of the first planar
metal plate portion 131 includes the first upper edge 132, the
first lip 134, the third slot 137, the first portion of the first
hinge 139, and the first opening 162. The bottom half of the first
planar metal plate portion 131 includes the first slot 135, the
eighth slot 159, and the first portion of the second hinge 164. The
first lip 134 aligns the first upper edge 132 of the first planar
metal plate portion 131 with the upper side edge bar 128 (see FIG.
32). The first upper edge 132 of the first planar metal plate
portion 131 is perpendicular to the first portion of the first
hinge 139. The bottom half of the first planar metal plate portion
131 is opposite the first upper edge 132 of the first planar metal
plate portion 131. The first descending edge 133 is opposite the
first portion of the first hinge 139 but is not parallel to the
first portion of the first hinge 139. The hinged bracket 130 is
designed such that no part of the bed frame assembly 80 contacts
the bottom half of the first planar metal plate portion 131 (see
FIG. 32).
[0142] Furthermore, in this embodiment, the second planar metal
plate portion 142 has a top half and a bottom half. The top half of
the second planar metal plate portion 142 includes the second upper
edge 143, the second lip 145, the sixth slot 148, the second
portion of the first hinge 150, and the second opening 163. The
bottom half of the second planar metal plate portion 142 includes
the fourth slot 146, the tenth slot 161, and the second portion 165
of the second hinge 157. The second lip 145 aligns the second upper
edge 143 of the second planar metal plate portion 142 with the
longitudinal bar 93 (see FIG. 32). The second upper edge 143 of the
second planar metal plate portion 142 is perpendicular to the
second portion of the first hinge 150. The bottom half of the
second planar metal plate portion 142 is opposite the second upper
edge 143 of the second planar metal plate portion 142. The second
descending edge 144 is opposite the second portion of the first
hinge 150 but is not parallel to the second portion of the first
hinge 150. The hinged bracket 130 is designed such that no part of
the bed frame assembly 80 contacts the bottom half of the second
planar metal plate portion 142 (see FIG. 32).
[0143] FIG. 34 is a perspective schematic view of the hinged
bracket (left side) 130 of FIG. 33 in a flat open orientation in
which the first planar metal portion 131 is on the same plane as
the second planar metal portion 142. FIG. 34 shows that the first
planar metal plate portion 131 includes the first curved section
140, the third curved section 141, the fifth curved section 166,
and the seventh curved section 167. The second planar metal portion
142 includes the second curved section 151, the fourth curved
section 152, the sixth curved section 168, and the eight curved
section 169.
[0144] The second curved section 151 of the second planar metal
portion 142 is adjacent to both the first curved section 140 and
the third curved section 141 of the first planar metal portion 131.
The sixth curved section 168 of the second planar metal portion 142
is adjacent to both the fifth curved section 166 and the seventh
curved section 167 of the first planar metal portion 141.
[0145] FIG. 35 shows how the first and second planar metal plate
portion of the hinged bracket 130 are pivotally adjoined around a
hinge axis 156. The first planar metal plate portion 131 includes a
first metal tongue 171, a third metal tongue 172, a fifth metal
tongue 175, and a seventh metal tongue 176 that are opposite the
first descending edge 133. The second planar metal plate portion
142 includes a second metal tongue 173, a fourth metal tongue 174,
a sixth metal tongue 177, and an eighth metal tongue 178 that are
opposite the second descending edge 144.
[0146] In a next manufacturing step, the first metal tongue 171,
the third metal tongue 172, the fifth metal tongue 175, and the
seventh metal tongue 176 are shaped (rolled) to form the first
curved section 140, the third curved section 141, the fifth curved
section 166, and the seventh curved section 167, respectively. The
second metal tongue 173, the fourth metal tongue 174, the sixth
metal tongue 177, and the eighth metal tongue 178 are rolled to
form the second curved section 151, the fourth curved section 152,
the sixth curved section 168, and the eighth curved section 169,
respectively.
[0147] The first portion 139 of the first hinge 153 includes the
first curved section 140 and the third curved section 141 (see
FIGS. 33-34). The second portion 150 of the first hinge 153
includes the second curved section 151 and the fourth curved
section 152 (see FIGS. 33-34). The first portion 164 of the second
hinge 157 includes the fifth curved section 166 and the seventh
curved section 167 (see FIGS. 33-34). The second portion 165 of the
second hinge 157 includes the sixth curved section 168 and the
eighth curved section 169 (see FIGS. 33-34).
[0148] In a next manufacturing step, the pin 154 is slid through
the first and second portions of the first hinge and is secured by
the nut 155, creating the first hinge 153. The pin 179 is inserted
through the first and second portions of the second hinge and is
secured by the nut 180, creating the second hinge 157. The first
hinge 153 and second hinge 157 are aligned with the hinge axis 156.
The first planar metal plate portion 131 and the second planar
metal plate portion 142 rotate pivotally about the hinge axis 156.
In a packaging step, the first planar metal plate portion 131 and
the second planar metal plate portion 142 are rotated open such
that they are oriented in the same plane. Alternatively, the first
planar metal plate portion 131 is folded over the second planar
metal plate portion 142 such that the planes of both plates are
parallel to each other. Either packaging step reduces the width of
the bracket 130 in the packing box compared to a bracket whose
planar plates are fixed at a right angle to one another. Thus, by
folding the hinged bracket 130 closed or completely open, the
volume occupied by the bracket in the packing box is reduced. FIG.
35 shows the first planar metal plate portion 131 folded over the
second planar metal plate portion 142 as the hinged bracket 130
would be shipped in a packing box.
[0149] The hinged bracket (right side) 129 is designed in the same
way as the hinged bracket (left side) 130. The only difference
between bracket 129 and bracket 130 is how each bracket is attached
to the bedboard frame 92 (see FIG. 31).
[0150] Although certain specific embodiments are described above
for instructional purposes, the teachings of this patent document
have general applicability and are not limited to the specific
embodiments described above. For example, in another embodiment,
the hinged brackets 129 and 130 each have more or less than two
hinges. In yet another embodiment, the first planar metal portion
131 and the second planar metal portion 142 each have more or less
than five slots. Accordingly, various modifications, adaptations,
and combinations of various features of the described embodiments
can be practiced without departing from the scope of the invention
as set forth in the claims.
* * * * *