Patent Publication Number: US-2018027977-A1

Title: Mattress foundation kit

Description:
FIELD OF INVENTION 
     The present disclosure generally relates to a mattress foundation. More specifically, the present disclosure relates to a knock down mattress foundation kit. 
     BACKGROUND OF THE INVENTION 
     Conventional bedding structures commonly have separate bedding components which together form a system having an upper mattress resting on top of a mattress foundation, which in turn rests over a floor surface. In some cases, the mattress foundation may be supported by legs extending from the mattress foundation towards the floor surface. Mattress foundations provide support and firmness to the mattress. Foundations are typically constructed of a frame, such as a rectangular frame including perimeter members and internal members. 
     With the rise of e-commerce, end users may order mattress foundations online. However, traditional mattress foundations are generally sold as single units. Therefore, they require freight or truck carriers to be delivered to an end user. This causes increased cost and delays in delivering the mattress foundation to end users. 
     Further, it is challenging to carry the mattress foundations in high rise buildings. The mattress foundations must traverse stairs or freight elevators in the high-rise buildings to arrive to the end user. 
     Accordingly, there is a need for improved mattress foundations that may be transported easily to end users. 
     SUMMARY OF THE INVENTION 
     Disclosed is a mattress foundation kit configured to be assembled by a user. The mattress foundation kit may include a plurality of rails. Further, each rail may be a longitudinal member. In an embodiment, each rail may be constructed of, for example, a structural foam core connected, for example by being permanently laminated, with at least one supporting material. Furthermore, the mattress foundation kit may include a plurality of interconnecting members corresponding to the plurality of rails. Moreover, the mattress foundation kit may include a plurality of retainer clips attached along a side of at least two rails of the plurality of rails. Yet further, the mattress foundation kit may include a plurality of slats corresponding to the plurality of retainer clips. In some embodiments, the plurality of slats may be configured to support a mattress such that each end of a slat may be configured to detachably engage with a corresponding retainer clip. 
     According to some aspects, a method of manufacturing a mattress foundation kit is disclosed. The method may include permanently laminating at least one supporting material onto each rail of a plurality of rails. Further, each rail may be a longitudinal member. In an embodiment, each rail may be constructed of, for example, a structural foam core. Furthermore, the method may include permanently laminating a plurality of interconnecting members onto the plurality of rails. Additionally, each interconnecting member may be connected, for example by being permanently laminated, to at least one part of a corresponding rail of the plurality of rails. Moreover, a first interconnecting member of a first rail of the plurality of rails may be configured to detachably engage with a second interconnecting member of a second rail of the plurality of rails. Finally, the method may include attaching a plurality of retainer clips along a side of at least two rails of the plurality of rails. Further, each retainer clip may be configured to detachably engage with a slat of a plurality of slats configured to support a mattress. 
     According to some aspects, a mattress foundation kit is disclosed. The kit may be configured to be assembled by a user. The mattress foundation kit may include a plurality of rails, a plurality of interconnecting members corresponding to the plurality of rails, a plurality of retainer clips attached along a side of at least two rails of the plurality of rails, a plurality of slats and a plurality of securing members. 
     According to some further aspects, the plurality of interconnecting members includes a plurality of male interconnecting members and a plurality of female interconnecting members. A male interconnecting member may be configured to detachably engage with a female interconnecting member. Further, the plurality of rails may be interconnected using the interconnecting members to form a rectangular-shaped or a square shaped frame. 
     According to some further aspects, the rectangular-shaped or the square shaped frame may also include one or more mid rails to provide support to the frame. 
     According to some aspects, the mattress foundation kit may include a plurality of rails, a plurality of interconnecting members corresponding to the plurality of rails, a plurality of retainer clips attached along a side of at least two rails of the plurality of rails, a plurality of slats, a plurality of securing members and a plurality of legs corresponding to the plurality of rails. The plurality of legs may be configured to support the mattress foundation on the ground such that at least one end portion of each leg is configured to be detachably attached to an interconnecting member on a corresponding rail of the plurality of rails. 
     According to some further aspects, at least one rail of the plurality of rails of the mattress foundation kit may include a drawer opening configured to receive a drawer configured to function as a storage compartment. 
     According to some further aspects. a knock down mattress foundation kit is disclosed. The mattress foundation kit may be light weight, compact and can be easily assembled by an end user. The mattress foundation kit may be designed for internet sales to accompany internet sales of mattresses. Accordingly, the mattress foundation kit may be stored in a box of a certain volume, such that the mattress foundation kit may be shipped through courier services, such as, but not limited to, FedEx and UPS, without necessarily requiring transport through large vehicles such as trucks. For example, the mattress foundation kit may be capable of being stored within a volume represented by dimensions of 9″, 10″, and 80″. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is an illustration of a mattress foundation kit in accordance with some embodiments. 
         FIG. 1B  is an illustration of a plurality of slats comprised in the mattress foundation kit of  FIG. 1A . 
         FIG. 2  is a close-up view of a portion of the mattress foundation kit of  FIG. 1A  illustrating mating of a male interconnecting member and a female interconnecting member attached to the plurality of rails. 
         FIG. 3  is a close-up view of a portion of the mattress foundation kit of  FIG. 1A  illustrating engagement of a mid rail with an end rail. 
         FIG. 4  is a close-up view of a portion of the mattress foundation kit of  FIG. 1A  illustrating a plurality of retainer clips attached to a side of a rail. 
         FIG. 5  is a perspective view of a mattress foundation built using the mattress foundation kit of  FIG. 1A . 
         FIG. 6  is a top view of the mattress foundation of  FIG. 5 . 
         FIG. 7  illustrates multiple views of a corner male interconnecting member for a rail of the mattress foundation kit of  FIG. 1A . 
         FIG. 8  illustrates multiple views of a corner female interconnecting member for a rail of the mattress foundation kit of  FIG. 1A . 
         FIG. 9  illustrates multiple views of a mid rail male interconnecting member of the mattress foundation kit of  FIG. 1A . 
         FIG. 10  illustrates multiple views of a mid rail female interconnecting member of the mattress foundation kit of  FIG. 1A . 
         FIG. 11  illustrates multiple views of a securing member for interconnecting the rails of the mattress foundation kit of  FIG. 1A . 
         FIG. 12  is a flowchart depicting a method for manufacturing the mattress foundation kit of  FIG. 1A  in accordance with some embodiments. 
     
    
    
     DETAIL DESCRIPTIONS OF THE INVENTION 
     All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention. 
     This overview is provided to introduce a selection of concepts in a simplified form that are further described below. The overview is not intended to identify key features or essential features of the claimed subject matter. Further, the overview is not intended to be used to limit the claimed subject matter&#39;s scope. 
     The present disclosure relates generally to a knock down mattress foundation kit that may, in some embodiments, be light weight, compact and easily assembled by an end user. The mattress foundation kit may be designed for internet sales to accompany internet sales of mattresses. Accordingly, the mattress foundation kit may be stored in a box of a certain volume, such that the mattress foundation kit may be shipped using courier services, without necessarily requiring transport through large vehicles such as trucks. 
     Disclosed is a mattress foundation kit  100  configured to be assembled by a user.  FIG. 1A  illustrating a mattress foundation kit  100  in accordance with some embodiments. The mattress foundation kit  100  includes multiple rails  102 ,  104 ,  106 ,  108 , and  110 . The multiple rails  102 ,  104 ,  106 ,  108 , and  110  may be configured to form, for example, a rectangular frame of a mattress foundation. The multiple rails  102 ,  104 ,  106 ,  108 , and  110  may include a pair of side rails  102  and  106 , a pair of end rails  104  and  108  and a mid rail  110 . Each rail may be a longitudinal member constructed of, for example, but not limited to, a structural foam core connected, for example by being permanently laminated, with a supporting material. In general, the plurality of rails may be constructed of a strong and light weight material. The supporting material may be, but is not limited to, wood, plastic, metal, and composite material. Further, each of a top side and a bottom side of the structural foam core may be connected, for example by being permanently laminated, with the supporting material. 
     The pair of side rails  102  and  106  may form the longer sides of the rectangular frame of the mattress foundation. Likewise, the pair of end rails  104  and  108  may form the shorter sides of the rectangular frame. A first end portion  112  of the mid rail  110  may be configured to be detachably engaged with one rail (say, the end rail  104 ) of the pair of end rails  102  and  106 . A second end portion  114  of the mid rail  110  may be configured to be detachably engaged with the other rail (say, the end rail  108 ) of the pair of end rails  102  and  106 . 
     The multiple rails  102 ,  104 ,  106 ,  108 , and  110  may further include multiple interconnecting members  116 ,  118 ,  120 ,  122 ,  124 ,  126 ,  128 ,  130 ,  132 ,  134 ,  136  and  138 . Each interconnecting member may be connected, for example by being permanently laminated, to at least one part of a corresponding rail of the multiple rails  102 ,  104 ,  106 ,  108  and  110 . Alternatively, in some embodiments, each interconnecting member may be detachably connectable to a corresponding rail. Additionally, in some embodiments, each of a rail and corresponding one or more interconnecting members may be integrally formed. For example, a rail with a pair of interconnecting members disposed on either ends of the rail may be formed using a single mold, using for instance, an injection molding process. Alternatively, each of the rail and the pair of interconnecting members may be separately formed and connected together thereafter. 
     Further, a first interconnecting member of a first rail of the multiple rails  102 ,  104 ,  106 ,  108  and  110  may be configured to detachably engage with a second interconnecting member of a second rail of the multiple rails  102 ,  104 ,  106 ,  108  and  110 . This is explained in further detail in conjunction with  FIGS. 2-4  below which show close-up views of regions  140 ,  142  and  144 . 
     The multiple interconnecting members  116 ,  118 ,  120 ,  122 ,  124 ,  126 ,  128 ,  130 ,  132 ,  134 ,  136  and  138  further include multiple corner male interconnecting members  116 ,  120 ,  124  and  128 , and multiple mid rail male interconnecting members  132  and  136 . The multiple interconnecting members  116 ,  118 ,  120 ,  122 ,  124 ,  126 ,  128 ,  130 ,  132 ,  134 ,  136  and  138  further include multiple corner female interconnecting members  118 ,  122 ,  126 , and  130 , and multiple mid rail female interconnecting members  134  and  138 . The multiple male interconnecting members  116 ,  120 ,  124 ,  128 ,  132  and  136  and the multiple corner female interconnecting members  118 ,  122 ,  126 ,  130  may be connected, for example by being permanently laminated, to an end portion of a corresponding rail. Further, the multiple mid rail female interconnecting members  134  and  138  may be connected, for example by being permanently laminated, to a side portion of the end rails  104  and  108  respectively. A male interconnecting member is configured to detachably engage with a female interconnecting member. Additionally, in some embodiments, the male interconnecting member may be engaged with the female interconnecting member through a locking mechanism in order to secure the engagement against, for example, weight of a mattress and/or a user on the mattress foundation. 
     The multiple corner male interconnecting members  116 ,  120 ,  124  and  128  are explained in detail in conjunction with  FIGS. 7A-H . The multiple corner female interconnecting members  118 ,  122 ,  126 , and  130  are explained in detail in conjunction with  FIGS. 8A-H . The multiple mid rail male interconnecting members  132  and  136  are explained in detail in conjunction with  FIGS. 9A-H . The multiple mid rail female interconnecting members  134  and  138  are explained in detail in conjunction with  FIGS. 10A-H . 
     The mattress foundation kit  100  may further include multiple slats  146  shown in  FIG. 1B . The multiple slats  146  may be configured to support a mattress. This is explained in further detail in conjunction with  FIG. 4  below. 
     Yet further, the mattress foundation kit  100  may include multiple securing members  148 ,  150 ,  152  and  154  corresponding to the multiple male interconnecting members  116 ,  120 ,  124 ,  128 ,  132  and  136 , and the multiple female interconnecting members  118 ,  122 ,  126 ,  130 ,  134  and  138 . 
     Referring to  FIG. 2 , a close-up view of a portion  140  of the mattress foundation kit  100  is shown. The corner male interconnecting member  120  is shown attached to the end rail  104 . The corner female interconnecting member  118  is shown attached to the side rail  102 . The corner male interconnecting member  120  may detachably engage with the corner female interconnecting member  118 . Thereafter, the securing member  148  may be used to detachably engage with each of the corner male interconnecting member  120  and the corner female interconnecting member  118 . Accordingly, the securing member  148  secures the engaged interconnecting members. The securing member  148  may be, but not limited to, a machine screw, a sheet metal screw, a wood screw, an eye bolt, a socket screw, an elevator bolt and a pin. For instance, some mechanisms used for the securing member  148  may be attached and detached without use of tools, while others may require use of a tool. Further, in some embodiments, the securing member  148  may be formed as a wedge. 
     Referring to  FIG. 3 , a close-up view of a portion  142  of the mattress foundation kit  100  is shown. The mid rail male interconnecting member  132  is shown attached at the end  112  of the mid rail  110 . The mid rail female interconnecting member  134  is shown attached to a side of the end rail  104 . The mid rail male interconnecting member  132  may be detachably engaged with the mid rail female interconnecting member  134  by inserting the mid rail male interconnecting member  132  within the mid rail female interconnecting member  134 . 
     Referring to  FIG. 4 , a close-up view of a portion  144  of the mattress foundation kit  100  is shown. Each of the side rails  102  and  106  include multiple retainer clips  156  attached along the length of each side rail  102 ,  106 . The mattress foundation kit  100  includes the multiple slats  146  corresponding to the multiple retainer clips  156 . Each end of a slat is configured to detachably engage with a corresponding retainer clip. The multiple slats are configured to support a mattress. The multiple slats  156  may be constructed using one or more of wood, plastic, metal, and composite material. Further, in some embodiments, each slat of the multiple slats  156  may be shaped as a rod. 
     As mentioned before, the mattress foundation kit  100  of  FIG. 1A  may be configured to be assembled by a user. The user may first engage the multiple rails  102 ,  104 ,  106 ,  108 , and  110  to form, for example, a rectangular frame. For example, the user may engage the side rail  102  with the end rail  104 , the end rail  104  with the side rail  106 , the side rail  106  with the end rail  108  and the end rail  108  with the side rail  102  to form the rectangular frame of the mattress foundation  500 . However, in other embodiments, the mattress foundation kit  100  may enable the user to form a frame in the shape of a regular and/or an irregular polygon. Then, the user may engage the multiple slats  146  with the multiple retainer clips  156  to obtain the mattress foundation  500  shown in  FIG. 5 . A top view of the mattress foundation  500  is shown in  FIG. 6 . 
       FIGS. 7A-H  illustrate multiple views of the corner male interconnecting member  120  of the mattress foundation  100 . Specifically,  FIG. 7A  illustrates a front view,  7 B a back view,  7 C a right side view,  7 D a left side view,  7 E a top view,  7 F a bottom view,  7 G a first perspective view and  7 H a second perspective view. 
     The corner male interconnecting member  120  may include a clip  702  with a U-shaped cross-section (shown in  FIGS. 7E and 7F ). For example, the clip  702  may be made of sheet metal folded over in a U-shaped profile to provide parallel clip faces and one of the clip faces has at least one slit bordering a strip of the sheet metal which is bowed out. The height  704  of the clip  702  may be approximately same as the height of the end rail  104 . Further, the width  706  of the clip  702  may be slightly more than the width of the end rail  104 , such that the clip  702  can be secured to the end rail  104 . The back side of the clip  702  includes a cylindrical sleeve  708 . The height of the sleeve  708  may be roughly half the height of the clip  702 . The cylindrical sleeve  708  may be located at the center of back of the clip  702 . The cylindrical sleeve  708  may be hollow and include a cylindrical hole  710  along the length of the cylindrical sleeve  708  and inside the cylindrical sleeve  708 . 
       FIGS. 8A-H  illustrates multiple views of the corner female interconnecting member  118  of the mattress foundation kit  100 . Specifically,  FIG. 8A  illustrates a front view,  8 B a back view,  8 C a right side view,  8 D a left side view,  8 E a top view,  8 F a bottom view,  8 G a first perspective view and  8 H a second perspective view. 
     The corner female interconnecting member  118  may include a clip  802  with a U-shaped cross-section, similar to the clip  702 . The height  804  of the clip  802  may be approximately same as the height of the side rail  102 . Further, the width  806  of the clip  802  may be slightly more than the width of the side rail  102 , such that the clip  802  can be secured to the side rail  102 . The back side of the clip  802  includes two cylindrical sleeves  808  and  810 . The cylindrical sleeve  808  is hollow and includes a cylindrical hole  812  along the length of the cylindrical sleeve  808  and inside the cylindrical sleeve  808 . Similarly, the cylindrical sleeve  810  is hollow and includes a cylindrical hole  814  along the length of the cylindrical sleeve  810  and inside the cylindrical sleeve  810 . The combined total height of the two sleeves  808  and  810  may be roughly half the height of the clip  802 . The cylindrical sleeves  808  and  810  may be separated, which creates a receptacle  816  between them. The height of the receptacle  816  may be slightly more than the height of the sleeve  708 , such that the receptacle  816  may receive the cylindrical sleeve  708 . When the cylindrical sleeve  708  is placed in the receptacle  816 , the three cylindrical holes  710 ,  812  and  814  align, such that a securing member  148  (such as the pin  148 ) may pass through the three cylindrical holes  710 ,  812  and  814 . Accordingly, the pin may secure the side rail  102  and the end rail  104 . Similarly, the end rail  104  and the side rail  106  may be secured. Further, the side rail  106  and the end rail  108  may be secured. Finally, the end rail  108  and the side rail  102  may be secured to form, for example, a rectangular frame of the mattress foundation  500 . 
       FIGS. 9A-H  illustrates multiple views of the mid rail male interconnecting member  132  of the mattress foundation kit  100 . Specifically,  FIG. 9A  illustrates a right side view,  9 B a left side view,  9 C a front view,  9 D a back view,  9 E a top view,  9 F a bottom view,  9 G a first perspective view and  9 H a second perspective view. 
     The mid rail male interconnecting member  132  includes a clip  902  with a U-shaped cross-section, similar to the clip  702 . The height  904  of the clip  902  may be approximately same as the height of the mid rail  110 . Further, the width  906  of the clip  902  may be slightly more than the width of the mid rail  110 , such that the clip  902  may be secured to the mid rail  110 . The back side of the clip  902  may include a rectangular projection  908 . 
       FIGS. 10A-H  illustrates multiple views of the mid rail female interconnecting member  134  of the mattress foundation kit  100 . Specifically,  FIG. 10A  illustrates a front view,  10 B a back view,  10 C a left side view,  10 D a right side view,  10 E a top view, 1° F. a bottom view,  10 G a first perspective view and  10 H a second perspective view. 
     The mid rail female interconnecting member  134  may generally have a rectangular shape with a rectangular depression  1002  in the middle of the mid rail female interconnecting member  134 . The rectangular depression  1002  is closed from five sides. However, it is an opening  1004 . Further, the size of the rectangular depression  1002  may be slightly bigger than the rectangular projection  908  such that at least a portion of the rectangular projection  908  fits inside the rectangular depression  1002 . 
     The rectangular depression  1002  may also have two holes  1006 ,  1008  on two opposite sides of the rectangular depression  1002 . Further, the rectangular projection  908  may have a hole (not shown) across its breadth. When the rectangular projection  908  is placed inside the rectangular depression  1002 , the hole on the rectangular projection  908  and the two holes  1006 , and  1008  may align such that a pin may secure the mid rail male interconnecting member  132  and the mid rail female interconnecting member  134  together. 
       FIGS. 11A-E  illustrates multiple views of the securing member  148  for interconnecting the rails of the mattress foundation kit  100 . Specifically,  FIG. 11A  illustrates a side view,  11 B a top view,  11 C a bottom view,  11 D a first perspective view and  11 E a second perspective view. 
     The securing member  148  may have sufficient length to be able to pass through the holes in the respective interconnecting members (for example, the holes  710 ,  812 ,  814 ) and secure the same. In some embodiments, the securing member  148  may have a threaded portion that may engage with a nut. Alternatively, the holes in the respective interconnecting members (for example, the holes  710 ,  812 ,  814 ) may be threaded from inside to engage with the threads on the securing member  148 . Further, securing member  148  may be hollow along the length of the securing member  148 , such that in includes a hole  1102 . 
       FIG. 12  is a flowchart depicting a method  1200  for manufacturing the mattress foundation kit of  FIG. 1A  in accordance with some embodiments. At step  1202 , the method  1200  includes permanently laminating at least one supporting material onto each rail of the multiple rails (for example the multiple rails  102 ,  104 ,  106 ,  108  and  110 ). Each rail is a longitudinal member constructed of, for example, but not limited to, a structural foam core. 
     Next, at step  1204 , the method  1200  includes permanently laminating multiple interconnecting members (for example, the multiple interconnecting members  116 ,  118 ,  120 ,  122 ,  124 ,  126 ,  128 ,  130 ,  132 ,  134 ,  136  and  138 ) onto the multiple rails. Each interconnecting member is connected, for example by being permanently laminated, to at least one part of a corresponding rail of the multiple rails. Further, a first interconnecting member of a first rail of the plurality of rails is configured to detachably engage with a second interconnecting member of a second rail of the multiple rails. 
     Finally, at step  1206 , the method  1200  includes attaching multiple retainer clips along a side of at least two rails of the multiple rails. Each retainer clip is configured to detachably engage with a slat of multiple slats configured to support a mattress. 
     Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention. Obvious changes, modifications, and substitutions may be made by those skilled in the art to achieve the same purpose the invention. The exemplary embodiments are merely examples and are not intended to limit the scope of the invention. It is intended that the present invention cover all other embodiments that are within the scope of the descriptions and their equivalents.