Mattress foundations, mattress foundation kits and related methods

Abstract

Mattress foundations, mattress foundation kits, and related methods are disclosed. In some embodiments, a mattress foundation kit may include four frames, corner members, at least one interior support member, and at least two deck panels. Each frame may include a first elongated member, a second elongated member, and a connective structure coupling the first elongated member to the second elongated member. Each corner member may be configured to couple a first end of an elongated member of a frame of the four frames to a second end of an elongated member of another frame. At least two frames may be configured to support an end of the at least one interior support member. Additionally, each deck panel may be sized and configured to extend at least partially over at least one frame of the four frames and the at least one interior support member.

1 . A mattress foundation kit, comprising:
 four frames, each frame comprising:
 a first elongated member having a first end and an opposing second end; 
 a second elongated member positioned substantially parallel to the first elongated member and having a first end and an opposing second end; and 
 a connective structure coupling the first elongated member to the second elongated member; 
   at least four corner members configured to couple a frame of the four frames to another frame of the four frames;   at least one interior support member;   at least two of the four frames configured to support an end of the at least one interior support member; and   at least two deck panels, each sized and configured to extend at least partially over at least one frame of the four frames and the at least one interior support member.   
   
   
       2 . The mattress foundation kit of  claim 1 , wherein corner members of the at least four corner members are integral to at least two of the four frames. 
   
   
       3 . The mattress foundation kit of  claim 1 , further comprising four corner assemblies, each of the four corner assemblies comprising two corner members of the at least four corner members coupled together. 
   
   
       4 . The mattress foundation kit of  claim 1 , wherein the at least four corner members configured to couple a frame of the four frames to another frame of the four frames comprise:
 four first corner members, each configured to couple a first end of a first elongated member of a frame of the four frames to a second end of a first elongated member of another frame of the four frames; and   four second corner members, each configured to couple a first end of a second elongated member of a frame of the four frames to a second end of a second elongated member of another frame of the four frames.   
   
   
       5 . The mattress foundation kit of  claim 1 , wherein the first elongated member and the second elongated member each comprise an elongated tube and the first end and opposing second end comprise openings of the elongated tube. 
   
   
       6 . The mattress foundation kit of  claim 5 , wherein each of the four first corner members and the four second corner members comprise a first end and a second end, each sized and configured for at least one of insertion into the openings of the elongated tubes of the four frames and positioning over the ends of the elongated tubes of the four frames. 
   
   
       7 . The mattress foundation kit of  claim 6 , wherein each of the four first corner members and the four second corner members comprises:
 an arcuate segment shaped generally as a circular arc subtending a right angle; and   at least substantially straight end segments.   
   
   
       8 . The mattress foundation kit of  claim 7 , wherein the at least substantially straight end segments include apertures formed therein sized and configured to receive spring buttons therein. 
   
   
       9 . The mattress foundation kit of  claim 8 , wherein each of the first elongated members and second elongated members of the four frames include apertures sized and configured to receive spring buttons therein. 
   
   
       10 . The mattress foundation kit of  claim 1 , wherein the at least two of the four frames configured to support an end of the at least one interior support member further comprise at least one discrete coupling feature for coupling to an end of the at least one interior support member. 
   
   
       11 . The mattress foundation kit of  claim 10 , wherein the at least one discrete coupling feature of the at least two of the four frames for coupling to an end of the at least one interior support member comprises a bracket having a U-shaped cross-section. 
   
   
       12 . The mattress foundation kit of  claim 11 , wherein the at least two deck panels are each further sized and configured to extend over the bracket having a U-shaped cross-section to maintain the at least one interior support member within the bracket having a U-shaped cross-section. 
   
   
       13 . The mattress foundation kit of  claim 1 , wherein the connective structure comprises a plurality of struts. 
   
   
       14 . The mattress foundation kit of  claim 13 , wherein each of the first elongated member, the second elongated member and the plurality of struts of the four frame members comprises metal tubing having substantially the same cross-sectional shape and size. 
   
   
       15 . The mattress foundation kit of  claim 14 , wherein each of the plurality of struts is positioned substantially perpendicular to the first elongated member and the second elongated member. 
   
   
       16 . The mattress foundation kit of  claim 1 , further comprising a textile cover. 
   
   
       17 . The mattress foundation kit of  claim 16 , wherein the textile cover comprises at least one of a zipper, hook and loop fasteners, buttons, snaps, elastic webbing and clips, for securing the textile cover over the four frames. 
   
   
       18 . The mattress foundation kit of  claim 1 , wherein the four frames are sized and configured for supporting at least one of a California king-sized mattress, a king-sized mattress, a queen-sized mattress, a full-XL-sized mattress, a twin-XL-sized mattress, a full-sized mattress, and a twin-sized mattress, when the four frames are assembled together. 
   
   
       19 . The mattress foundation kit of  claim 18 , wherein the four frames are sized and configured for mounting on at least one of a California king-sized bed frame, a king-sized bed frame, a queen-sized bed frame, a full-XL-sized bed frame, a twin-XL-sized bed frame, a full-sized bed frame, and a twin-sized bed frame, when the four frames are assembled together. 
   
   
       20 . The mattress foundation kit of  claim 19 , wherein the four frames, at least four corner members, at least one interior support member and at least two deck panels are sized and configured to be entirely disposed within a shipping box having a combined length and cross-sectional circumference of about 130 inches or less, when the four frames are disassembled. 
   
   
       21 . The mattress foundation kit of  claim 1 , wherein the four frames, at least four corner members, at least one interior support member and at least two deck panels are sized and configured to be entirely disposed within a shipping box having a combined length and cross-sectional circumference of about 130 inches or less, when the four frames are disassembled. 
   
   
       22 . The mattress foundation kit of  claim 1 , wherein the at least two deck panels are comprised of at least one of plywood, corrugated plastic, and expanded sheet metal. 
   
   
       23 . The mattress foundation kit of  claim 1 , wherein each of the first elongated member, and the second elongated member of the four frames, the four first corner members, the four second corner members, and the interior support member comprises a metal tube. 
   
   
       24 . The mattress foundation kit of  claim 23 , wherein the metal tube is a metal tube having a generally rectangular cross-section. 
   
   
       25 . The mattress foundation kit of  claim 1 , wherein the mattress foundation kit weighs about 100 pounds or less. 
   
   
       26 . The mattress foundation kit of  claim 1 , further comprising four corner plates configured to be positioned over and generally conform in shape to two of the at least four corner members when the mattress foundation kit is assembled to form a mattress foundation. 
   
   
       27 . The mattress foundation kit of  claim 1 , wherein the at least two deck panels, are further sized and configured such that substantially the entire peripheral edge of each of the at least two deck panels overlies and is supported by an upper support surface of one or more of the four frames and the at least one interior support member when the mattress foundation kit is assembled to form a mattress foundation. 
   
   
       28 . A mattress foundation, comprising:
 four frames, each frame comprising:
 a first elongated member having a first end and an opposing second end; 
 a second elongated member positioned substantially parallel to the first elongated member and having a first end and an opposing second end; and 
 a connective structure coupling the first elongated member to the second elongated member; 
   at least four corner members coupling the ends of each of the elongated members of the four frames to another of the elongated members of the four frames;   at least one interior support member extending between and supported by at least two frames of the four frames; and   at least two deck panels, each of the at least two deck panels extending at least partially over and supported by at least two of the four frames and the at least one interior support member.   
   
   
       29 . A method of transporting a mattress foundation comprising:
 positioning four frames, each frame comprising two parallel tubes coupled by a plurality of struts, within a shipping box having a combined width and girth less than about 130 inches;   positioning eight corner members, each corner member having end portions configured to couple with a tube of the four frames, within the shipping box;   positioning at least one interior support member, the interior support member having a first end configured to couple with a frame of the four frames and a second end configured to couple with another frame of the plurality of frames, within the shipping box;   positioning at least two deck panels configured to couple to the four frames and at least one interior support member within the shipping box; and   transporting the shipping box containing the four frames, the eight corner members, the at least one interior support member and the at least two deck panels to a point-of-use location.   
   
   
       30 . The method of  claim 29 , wherein transporting the shipping box further comprises transporting the shipping box by a courier service.