Knock down bed foundation

Abstract

A bed foundation capable of being assembled by the end user or a retailer. The bed foundation utilizes support members having I-beam construction, thereby reducing noise and greatly increasing the strength of the foundation. The foundation is also constructed to provide a flush, uniform top surface onto which top panels are attached. The flush uniform top surface also contributes to noise reduction and increased strength. The foundation, when unassembled, can be packed into a single, relatively small container, thereby significantly reducing shipping costs.

1 . A bed foundation comprising: 
 a plurality of longitudinal members each having an upper surface defining a plurality of grooves;    a pair of transverse members operably attached to opposite ends of the longitudinal members;    a plurality of cross members operably disposed in the grooves of the longitudinal members, each of the cross members having upper surfaces; and,    at least one top panel operably disposed on the upper surfaces of the longitudinal members;    wherein the upper surfaces of the cross members are substantially flush with the upper surfaces of the longitudinal members, thereby crating a substantially planar support grid onto which the top panel is operably disposed;    wherein all of the members and the at least one top panel are constructed and arranged to be shipped in an unassembled state in a package and assembled by a recipient; and    wherein the package has a length less than or equal to 108 inches and a length and girth combined of less than or equal to 165 inches.    
   
   
       2 . The bed foundation of  claim 1  wherein the longitudinal members comprise wood.  
   
   
       3 . The bed foundation of  claim 1  wherein the longitudinal member members comprise I-beams.  
   
   
       4 . The bed foundation of  claim 3  wherein the longitudinal members comprise wood.  
   
   
       5 . The bed foundation of  claim 1  wherein the at least one top panel comprises plywood.  
   
   
       6 . The bed foundation of  claim 1  further comprising a joist member operably disposed between the longitudinal members and parallel thereto.  
   
   
       7 . The bed foundation of  claim 6  wherein the joist member defines a plurality of grooves sized and arranged to accept the cross members therein.  
   
   
       8 . (canceled)  
   
   
       9 . (canceled)  
   
   
       10 . A bed foundation comprising: 
 a plurality of parallel longitudinal members each including: 
 an upper portion;  
 a middle portion; and,  
 a lower portion;  
 wherein the upper and lower portions are thicker than the middle portion, thereby forming an I-beam construction;  
   a pair of parallel transverse member, operably connected to opposite ends of the longitudinal members, each including: 
 an upper portion;  
 a middle portion; and,  
 a lower portion;  
 wherein the upper and lower portions are thicker than the middle portion, thereby forming an I-beam construction;  
   a plurality of cross members transversely spanning, and operably attached to, the longitudinal members;    at least one top panel operably disposed on top of the cross members.    
   
   
       11 . The bed foundation of  claim 10  wherein the upper portions of the longitudinal members comprise top surfaces that define a plurality of grooves therein, the grooves constructed and arranged for accepting the cross members such that when the cross members are placed in the grooves, top surfaces of the cross members are substantially flush with the top surfaces of the upper portions of the longitudinal members.  
   
   
       12 . The bed foundation of  claim 10  further comprising at least one joist member having two opposite ends, each of the ends attached to one of the parallel transverse members, the joist member having a substantially rectangular cross-section.  
   
   
       13 . The bed foundation of  claim 11  further comprising at least one joist member having two opposite ends, each of the ends attached to one of the parallel transverse members, the joist member having a substantially rectangular cross-section and defining a plurality of grooves therein that match the grooves of the longitudinal members; the grooves constructed and arranged for accepting the cross members such that when the cross members are placed in the grooves, top surfaces of the cross members are substantially flush with top surfaces of the joist members.  
   
   
       14 . The bed foundation of  claim 10  wherein the longitudinal members comprise wood.  
   
   
       15 . The bed foundation of  claim 10  wherein the longitudinal members comprise plastic.  
   
   
       16 . The bed foundation of  claim 10  wherein the at least one top panel comprises plywood.  
   
   
       17 . The bed foundation of  claim 10  wherein the at least one top panel comprises plastic.  
   
   
       18 . The bed foundation of  claim 10  wherein the longitudinal members comprise one-piece unitary construction.  
   
   
       19 . The bed foundation of  claim 10  wherein the longitudinal members comprise panel construction.  
   
   
       20 . The bed foundation of  claim 10  wherein the transverse members comprise one-piece unitary construction.  
   
   
       21 . The bed foundation of  claim 10  wherein the transverse members comprise panel construction.  
   
   
       22 . The bed foundation of  claim 10  wherein all of the members and the at least one top panel are constructed and arranged to be shipped in an unassembled state in a package and assembled by a recipient.  
   
   
       23 . The bed foundation of  claim 22  wherein the package has a length less than or equal to 108 inches and a length and girth combined of less than or equal to 165 inches.  
   
   
       24 . A bed foundation comprising: 
 a pair of juxtaposed subfoundations, each subfoundation including: 
 a plurality of parallel longitudinal members each having: 
 an upper portion;  
 a middle portion; and,  
 a lower portion;  
 wherein the upper and lower portions are thicker than the middle portion, thereby forming an I-beam construction;  
 
 a pair of parallel transverse members, operably connected to opposite ends of the longitudinal members, each including: 
 an upper portion;  
 a middle portion; and,  
 a lower portion;  
 wherein the upper and lower portions are thicker than the middle portion, thereby forming an I-beam construction;  
 
 a plurality of cross members transversely spanning, and operably attached to, the longitudinal members;  
   at least one top panel operably disposed on top of the cross members of at least one of the subfoundations.    
   
   
       25 . The bed foundation of  claim 24  wherein the upper portions of the longitudinal members comprise top surfaces that define a plurality of grooves therein, the grooves constructed and arranged for accepting the cross members such that when the cross members are placed in the grooves, top surfaces of the cross members are substantially flush with the top surfaces of the upper portions of the longitudinal members.  
   
   
       26 . The bed foundation of  claim 24 , further comprising at least one joist member having two opposite ends, each of the ends attached to one of the parallel transverse members of at least one of the subfoundations, the joist member having a substantially rectangular cross-section.  
   
   
       27 . The bed foundation of  claim 25  further comprising at least one joist member having two opposite ends, each of the ends attached to one of the parallel transverse members of at least one of the subfoundations, the joist member having a substantially rectangular cross-section and defining a plurality of grooves therein that match the grooves of the longitudinal members; the grooves constructed and arranged for accepting the cross members such that when the cross members are placed in the grooves, top surfaces of the cross members are substantially flush with top surfaces of the joist members.  
   
   
       28 . The bed foundation of  claim 24  wherein the longitudinal members comprise wood.  
   
   
       29 . The bed foundation of  claim 24  wherein the longitudinal members comprise plastic.  
   
   
       30 . The bed foundation of  claim 24  wherein the at least one top panel comprises plywood.  
   
   
       31 . The bed foundation of  claim 24  wherein the at least one top panel comprises plastic.  
   
   
       32 . The bed foundation of  claim 24  wherein the longitudinal members comprise one-piece unitary construction.  
   
   
       33 . The bed foundation of  claim 24  wherein the longitudinal members comprise panel construction.  
   
   
       34 . The bed foundation of  claim 24  wherein the transverse members comprise one-piece unitary construction.  
   
   
       35 . The bed foundation of  claim 24  wherein the transverse members comprise panel construction.  
   
   
       36 . The bed foundation of  claim 24  wherein all of the members and the at least one top panel of both of the subfoundations are constructed and arranged to be shipped in an unassembled state in a package and assembled by a recipient.  
   
   
       37 . The bed foundation of  claim 36  wherein the package has a length less than or equal to 108 inches and a length and girth combined of less than or equal to 165 inches.