Apparatus and method of use for a PVC composite mattress frame

Abstract

A mattress frame that is lightweight, durable, and minimizes material use. The apparatus includes a pair of side rails connected to a pair of end rails via four end caps to form a generally rectangular shape. The side rails and the end rails can vary in length and each of the side rails and end rails has an identical cross-section shape made up of five sections surrounding a slot. The end caps each include two tabs for insertion into the slots of the side rails and end rails. The side rails and end rails further include a pair of strengthening steel ribs. An alternate embodiment includes slats which extend from side rail to side rail or from end rail to end rail. Each slat has a generally U-shaped cross section and further includes two galvanized steel ribs running their entire length. Another alternate embodiment includes feet.

1 . A mattress frame comprising:
 a first non-metallic side rail connected to a first non-metallic end rail by a first end cap;   the first non-metallic end rail connected to a second non-metallic side rail by a second end cap;   the second non-metallic side rail connected to a second non-metallic end rail by a third end cap;   the second non-metallic end rail connected to the first non-metallic side rail by a fourth end cap;   the first non-metallic side rail, second non-metallic side rail, first non-metallic end rail and second non-metallic end rail each having a cross-section;   wherein the cross section comprises:
 a first section, second section and third section integrally formed to define a rectangular channel; 
 a tab support, attached to the first section, adjacent to and extending into the rectangular channel; and 
 a slat support, attached to the third section and extending away from the rectangular channel. 
   
     
     
         2 . The mattress frame of  claim 1  further comprises:
 a first metallic strengthening rib, encapsulated in the first section; and 
 a second metallic strengthening rib, encapsulated in the third section. 
 
     
     
         3 . The mattress frame of  claim 2  wherein the first metallic strengthening rib encapsulated in the first section of the first side rail and the second metallic strengthening rib encapsulated in the third section of the first side rail are of greater height than the first metallic strengthening rib encapsulated in the first section of the first end rail and the second metallic strengthening rib encapsulated in the third section of the first end rail. 
     
     
         4 . The mattress frame of  claim 2  wherein the first metallic strengthening rib includes a knurled section encapsulated by the first section. 
     
     
         5 . The mattress frame of  claim 2  wherein the first metallic strengthening rib includes a plurality of holes encapsulated by the first section. 
     
     
         6 . The mattress frame of  claim 1  further comprising:
 a plurality of non-metallic slats, supported by the slat support of the first non-metallic side rail and the slat support of the second non-metallic side rail. 
 
     
     
         7 . The mattress frame of  claim 6  where each of the plurality of non-metallic slats further comprises:
 a first vertical stanchion; 
 a second vertical stanchion; 
 a horizontal base section, connected to the first vertical stanchion and the second vertical stanchion; 
 a third non-metallic strengthening rib encapsulated in the first vertical stanchion; and, 
 a fourth non-metallic strengthening rib encapsulated in the second vertical stanchion. 
 
     
     
         8 . The mattress frame of  claim 7  where:
 the third non-metallic strengthening rib includes a first knurled section and a first plurality of holes encapsulated in the first vertical stanchion; and 
 the fourth non-metallic strengthening rib includes a second knurled section and a second plurality of holes encapsulated in the second vertical stanchion. 
 
     
     
         9 . The mattress frame of  claim 1  where the first end cap further comprises:
 a non-metallic arcurate corner having an inside semi-cylindrical wall integrally and an outside semi-cylindrical wall; 
 the inside semi-cylindrical wall and the outside semi-cylindrical wall connected by a first radial vertical wall and a second radial vertical wall; 
 the first vertical wall and the second vertical wall forming a generally right angle; 
 a first tab extending generally perpendicularly from the first vertical wall; 
 a second tab extending generally perpendicularly from the second vertical wall; 
 wherein the first tab removably engages the first non-metallic side rail; and 
 the second tab removably engages the first non-metallic end rail. 
 
     
     
         10 . The mattress frame of  claim 9  further comprising a foot, removably secured to the non-metallic arcurate corner. 
     
     
         11 . The mattress frame of  claim 10  wherein the first tab further includes a first longitudinal strengthening channel and the second tab includes a second longitudinal strengthening channel. 
     
     
         12 . The mattress frame of  claim 2  further comprising:
 a first plurality of non-metallic slats, extending from the slat support of the first non-metallic end rail to the slat support of the second non-metallic end rail; 
 a second plurality of non-metallic slats, supported by the second section of the first non-metallic side rail and the second section of the second non-metallic side rail and adjacent to and intersecting generally perpendicularly with the first plurality of non-metallic slats; 
 wherein the first plurality of non-metallic slats and the second plurality of non-metallic slats each comprise:
 a first vertical stanchion; 
 a second vertical stanchion; 
 a horizontal base section, connected to the first vertical stanchion and the second vertical stanchion; 
 a third metallic strengthening rib encapsulated in the first vertical stanchion; and, 
 a fourth metallic strengthening rib encapsulated in the second vertical stanchion. 
 
 
     
     
         13 . A mattress support comprising:
 a first non-metallic rail, having a first longitudinal slot, a first tab support adjacent the first longitudinal slot and a first slat support parallel to the first tab support;   a second non-metallic rail, having a second longitudinal slot, a second tab support adjacent the second longitudinal slot and a second slat support parallel to the second tab support;   a third non-metallic rail, having a third longitudinal slot, a third tab support adjacent the third longitudinal slot and a third slat support parallel to the third tab support;   a fourth non-metallic rail, having a fourth longitudinal slot, a fourth tab support adjacent the fourth longitudinal slot and a fourth slat support parallel to the fourth tab support;   a first corner piece, having a first tab perpendicularly opposed to a second tab;   a second corner piece, having a third tab perpendicularly opposed to a fourth tab;   a third corner piece, having a fifth tab perpendicularly opposed to a sixth tab;   a fourth corner piece, having a seventh tab perpendicularly opposed to an eighth tab;   the first tab contacting the first tab support and removably joining the first longitudinal slot;   the second tab contacting the second tab support and removably joining the second longitudinal slot;   the third tab contacting the second tab support and removably joining the second longitudinal slot;   the fourth tab contacting the third tab support and removably joining the third longitudinal slot;   the fifth tab contacting the third tab support and removably joining the third longitudinal slot;   the sixth tab contacting the fourth tab support and removably joining the fourth longitudinal slot;   the seventh tab contacting the fourth tab support and removably joining the fourth longitudinal slot; and   the eighth tab contacting the first tab support and removably joining the first longitudinal slot.   
     
     
         14 . The mattress support of  claim 13  wherein:
 the first non-metallic rail encapsulates a first pair of vertical strengthening ribs; 
 the second non-metallic rail encapsulates a second pair of vertical strengthening ribs; 
 the third non-metallic rail encapsulates a third pair of vertical strengthening ribs; and 
 the fourth non-metallic rail encapsulates a fourth pair of vertical strengthening ribs. 
 
     
     
         15 . The mattress support of  claim 14  wherein:
 the first pair of vertical strengthening ribs includes a first plurality of roughened surfaces and a first plurality of holes; 
 the second pair of vertical strengthening ribs includes a second plurality of roughened surfaces and a second plurality of holes; 
 the third pair of vertical strengthening ribs includes a third plurality of roughened surfaces and a third plurality of holes; and 
 the fourth pair of vertical strengthening ribs includes a fourth plurality of roughened surfaces and a fourth plurality of holes. 
 
     
     
         16 . The mattress support of  claim 14  wherein the:
 first pair of vertical strengthening ribs is formed of one of the group of steel, aluminum, fiberglass and Kevlar® fibers. 
 
     
     
         17 . The mattress support of  claim 16  wherein:
 each slat of the plurality of non-metallic slats encapsulates a pair of vertical strengthening ribs. 
 
     
     
         18 . The mattress support of  claim 17  wherein:
 each of the pair of vertical strengthening ribs includes a set of roughened areas and a set of holes. 
 
     
     
         19 . The mattress support of  claim 18  further comprises:
 a first foot removably attached to the first corner piece adjacent the first tab and the second tab; 
 a second foot removably attached to the second corner piece adjacent the third tab and the fourth tab; 
 a third foot removably attached to the third corner piece adjacent the fifth tab and the sixth tab; and 
 a fourth foot removably attached to the fourth corner piece adjacent the seventh tab and the eighth tab 
 
     
     
         20 . The mattress support of  claim 14  further comprising:
 a first plurality of non-metallic slats, extending from the first slat support of the first non-metallic rail to the third slat support of the third non-metallic rail; 
 a second plurality of non-metallic slats, supported by the second non-metallic rail and the fourth non-metallic rail and adjacent to and intersecting generally perpendicularly with the first plurality of non-metallic slats; 
 wherein the first plurality of non-metallic slats and the second plurality of non-metallic slats each comprise:
 a first vertical stanchion; 
 a second vertical stanchion; 
 a horizontal base section, connected to the first vertical stanchion and the second vertical stanchion; 
 a first metallic strengthening strip encapsulated in the first vertical stanchion; and, 
 a second metallic strengthening strip encapsulated in the second vertical stanchion.