Collapsible, folding mattress support with adjustable elevating shoulder section

• US 8,769,740 B2
• Filed: 09/26/2012
• Issued: 07/08/2014
• Est. Priority Date: 09/19/2011
• Status: Active Grant

• Current Assignee: Zinus Incorporated
• Original Assignee: Zinus Incorporated
• Inventors: Oh, Suk Kan
• Primary Examiner(s): KELLEHER, WILLIAM J
• Application Number:
  US13/627,493
• Publication Number:
  US 20130067659A1
• Time in Patent Office: 650 Days
• Field of Search: 5249-252, 5174-180, 520/1, 520/2, 520/01, 540/0, 540/1, 531/0, 528/5
• US Class Current: 5/250
• CPC Class Codes: A47C 19/12 Folding bedsteads travelling or camp beds A47C17/64

Abstract

A foldable mattress support has an adjustable inner frame with a ratchet support for raising the head of a mattress. Legs are incorporated into the side and end bars of the mattress support. Upper and lower bars of the support are pivotally attached to the vertical plate of a hinge. Bolts oriented along axes of rotation pass through the bars and through the vertical plate. A first upper bar pivots about a first axis; a second upper bar pivots about a second axis; a first lower bar pivots about a third axis; and a second lower bar pivots about a fourth axis. Each of the axes is orthogonal to the vertical plate, and the third axis is spaced farther apart from the fourth axis than the first axis is spaced apart from the second axis. The distal ends of the upper and lower bars are pivotally attached to end bars.

Claims

1. A foldable mattress support comprising:

a first upper bar;

a first lower bar;

a second upper bar;

a second lower bar;

a vertical plate, wherein the first upper bar is pivotally attached to the vertical plate and pivots about a first axis, wherein the first upper bar has a first distal end away from the vertical plate, wherein the second upper bar is pivotally attached to the vertical plate and pivots about a second axis, wherein the first lower bar has a second distal end away from the vertical plate, wherein the first lower bar is pivotally attached to the vertical plate and pivots about a third axis, wherein the second lower bar is pivotally attached to the vertical plate and pivots about a fourth axis, wherein each of the first axis, the second axis, the third axis and the fourth axis is orthogonal to the vertical plate, and wherein the third axis is spaced farther apart from the fourth axis than the first axis is spaced apart from the second axis; and

an end bar, wherein the first distal end is pivotally attached to the end bar, and wherein the second distal end is pivotally attached to the end bar.

2. The foldable mattress support of claim 1, wherein the end bar has a leg, and wherein the foldable mattress support rests on the leg when the foldable mattress support is completely unfolded.

3. The foldable mattress support of claim 1, wherein the end bar extends above the first upper bar and below the first lower bar when the foldable mattress support is completely unfolded.

4. The foldable mattress support of claim 1, further comprising:

a third upper bar with an inner end and an outer end, wherein the third upper bar pivots at the inner end about a fifth axis, wherein the fifth axis passes through the first upper bar, and wherein the first distal end is farther from the fifth axis than the outer end is from the fifth axis.

5. The foldable mattress support of claim 4, further comprising:

a ratchet support pivotally attached to both the third upper bar and the first upper bar.

6. The foldable mattress support of claim 4, wherein the third upper bar is part of an adjustable inner frame that can be elevated at the outer end when the foldable mattress support is completely unfolded.

7. The foldable mattress support of claim 1, wherein the vertical plate is connected to a bottom flange with foot pads, and wherein the foldable mattress support rests on the foot pads.

8. The foldable mattress support of claim 7, wherein the foldable mattress support rests only on the foot pads when the foldable mattress support is completely folded.

9. The foldable mattress support of claim 1, further comprising:

a brace attached to the vertical plate, wherein the first lower bar is prevented by the brace from further pivoting about the third axis when the foldable mattress support is completely unfolded.

10. A foldable mattress support comprising:

a first upper bar;

a first lower bar;

a second upper bar;

a second lower bar; and

a hinge that includes a central plate, a first angled flange and a second angled flange, wherein the first upper bar is pivotally attached to the central plate and pivots about a first axis, wherein the second upper bar is pivotally attached to the central plate and pivots about a second axis, wherein the first lower bar is pivotally attached to the central plate and pivots about a third axis, wherein the second lower bar is pivotally attached to the central plate and pivots about a fourth axis, wherein each of the first axis, the second axis, the third axis and the fourth axis is orthogonal to the central plate, and wherein the third axis is spaced farther apart from the fourth axis than the first axis is spaced apart from the second axis.

11. The foldable mattress support of claim 10, wherein the first angled flange is perpendicular to the central plate, and wherein the first lower bar is prevented by a lower edge of the first angled flange from further pivoting about the third axis when the foldable mattress support is completely unfolded.

12. The foldable mattress support of claim 10, wherein the first angled flange is perpendicular to the central plate, and wherein the first upper bar is prevented by an upper edge of the first angled flange from further pivoting about the first axis when the foldable mattress support is completely unfolded.

13. The foldable mattress support of claim 10, wherein the first upper bar has a first distal end away from the central plate, and wherein the first lower bar has a second distal end away from the central plate, further comprising:

an end bar, wherein the first distal end is pivotally attached to the end bar, and wherein the second distal end is pivotally attached to the end bar.

14. The foldable mattress support of claim 10, wherein the end bar includes a hinge extension, wherein the first distal end is pivotally attached to the hinge extension, and wherein the hinge extension allows the end bar to be oriented parallel to the first lower bar when the first upper bar and the first lower bar are rotated so as to become adjacent to one another.

15. A method of manufacturing a foldable mattress support, comprising:

bending a sheet of metal to form a first angled flange, a second angled flange and a central plate, wherein the first angled flange is bent from the central plate at a first crease, wherein the second angled flange is bent from the central plate at a second crease, and wherein the first crease is parallel to the second crease;

pivotally attaching a first upper bar to the central plate such that the first upper bar pivots about a first axis;

pivotally attaching a second upper bar to the central plate such that the second upper bar pivots about a second axis;

pivotally attaching a first lower bar to the central plate such that the first lower bar pivots about a third axis; and

pivotally attaching a second lower bar to the central plate such that the second lower bar pivots about a fourth axis, wherein each of the first axis, the second axis, the third axis and the fourth axis is orthogonal to the central plate, and wherein the third axis is spaced farther apart from the fourth axis than the first axis is spaced apart from the second axis.

16. The method of claim 15, further comprising:

pivotally attaching a third upper bar to the first upper bar, wherein the third upper bar has an inner end and an outer end, wherein the third upper bar pivots at the inner end about a fifth axis, and wherein the fifth axis is parallel to the first axis.

17. The method of claim 16, further comprising:

attaching a ratchet support to both the third upper bar and the first upper bar.

18. The method of claim 15, wherein the first upper bar has a first distal end away from the central plate, and wherein the first lower bar has a second distal end away from the central plate, further comprising:

pivotally attaching an end bar to both the first distal end and the second distal end.

19. The method of claim 15, further comprising:

folding the first upper bar and the second upper bar such that the first upper bar is substantially parallel to the second upper bar; and

inserting the foldable mattress support into a packing box.

20. The method of claim 15, further comprising:

attaching a brace to the central plate that prevents the first lower bar from pivoting about the third axis past a horizontal orientation.