Apparatus and Method of Use for a PVC Composite Mattress Foundation

Abstract

A lightweight and durable mattress foundation. The apparatus includes a first tier of side rails connected to a first tier of end rails via four end caps and a second tier of side rails connected to a second tier of end rails where the first tier is connected to the second tier via a plurality of standoffs. The side rails and the end rails can vary in length and include strengthening ribs. The first tier side and end rails have a unique cross-section made up of five sections surrounding a slot. The second tier side and end rails have a different unique cross-section. The end caps each include tabs for insertion into the slots of the side and end rails. Slats having a U-shaped cross-section and including strengthening ribs extend from side rail to side rail and/or from end rail to end rail. An alternate embodiment includes feet.

1 . A mattress foundation comprising:
 a first tier comprised of a first end rail and a second end rail connected to a first side rail and a second side rail by a first set of end caps;   a second tier comprised of a third end rail and a fourth end rail connected to a third side rail and a fourth side rail by a second set of end caps;   the first end rail, the second end rail, the first side rail, and the second side rail having a first cross-section;   wherein the first cross-section is comprised of:
 a first section, a second section, a third section, a fourth section, and a fifth section integrally-formed to define a first slot; 
 the fourth section, attached to the first section, adjacent to and extending into the first slot; 
 the fourth section separated from the third section by a first gap; 
 the second section connecting the first section to the third section; and 
 the fifth section attached to the third section and extending away from the first slot; 
   the third section and the fifth section forming a first slat support on the first end rail, a second slat support on the second end rail, a third slat support on the first side rail, and a fourth slat support on the second side rail;   the third end rail, the fourth end rail, the third side rail, and the fourth side rail having a second cross-section;   wherein the second cross-section is comprised of:
 a first side, a second side, a third side, a fourth side, and a fifth side integrally formed to define a second slot; 
 the fourth side, attached to the first side, adjacent to and extending into the second slot; 
 the fourth side separated from the third side by a second gap; 
 the second side connecting the first side to the third side; and 
 the fifth side attached to the third side at the intersection of the second and third sides and extending away from the second slot; 
   the third side and the fifth side forming a fifth slat support on the third end rail, a sixth slat support on the fourth end rail, a seventh slat support on the third side rail, and an eighth slat support on the fourth side rail;   a first set of standoffs adjacent to and connecting the first set of end caps and the second set of end caps;   a second set of standoffs adjacent to and connecting the first end rail to the third end rail and adjacent to and connecting the second end rail to the fourth end rail; and   a third set of standoffs adjacent to and connecting the first side rail to the third side rail and adjacent to and connecting the second side rail to the fourth side rail.   
     
     
         2 . The mattress foundation of  claim 1  further comprising:
 a first strengthening rib, encapsulated in the first section; 
 a second strengthening rib, encapsulated in the third section; 
 a third strengthening rib, encapsulated in the first side; and 
 a fourth strengthening rib, encapsulated in the third side. 
 
     
     
         3 . The mattress foundation of  claim 2  wherein the first strengthening rib, the second strengthening rib, the third strengthening rib, and the fourth strengthening rib are comprised of a material selected from the group of steel, steel mesh, fiberglass, Kevlar®, aluminum and titanium. 
     
     
         4 . The mattress foundation of  claim 2  wherein the first strengthening rib includes a first roughened section and a first plurality of holes encapsulated by the first section, the second strengthening rib includes a second roughened section and a second plurality of holes encapsulated by the third section, the third strengthening rib includes a third roughened section and a third plurality of holes encapsulated by the first side, and the fourth strengthening rib includes a fourth roughened section and a fourth plurality of holes encapsulated by the third side. 
     
     
         5 . The mattress foundation of  claim 2  wherein at least one of the first strengthening rib, the second strengthening rib, the third strengthening rib, and the fourth strengthening rib has an “I”-beam cross-section. 
     
     
         6 . The mattress foundation of  claim 1  further comprises:
 the first side rail has a first set of strengthening ribs; 
 the first end rail has a second set of strengthening ribs; 
 wherein the first set of strengthening ribs are of greater height than the second set of strengthening ribs; 
 the third side rail has a third set of strengthening ribs; 
 the third end rail has a fourth set of strengthening ribs; and 
 wherein the third set of strengthening ribs are of greater height than the fourth set of strengthening ribs. 
 
     
     
         7 . The mattress foundation of  claim 1  wherein the first side rail, the second side rail, the third side rail, the fourth side rail, the first end rail, the second end rail, the third end rail, and the fourth end rail each contain a strengthening channel. 
     
     
         8 . The mattress foundation of  claim 1  further comprising:
 a first set of longitudinal channel slats extending between the first end rail and the second end rail, supported by the first slat support and the second slat support; 
 a first set of lateral channel slats extending between the first side rail and the second side rail, supported by the third slat support and the fourth slat support; 
 a second set of longitudinal channel slats extending between the third end rail and the fourth end rail, supported by the fifth slat support and the sixth slat support; and 
 a second set of lateral channel slats extending between the third side rail and the fourth side rail, supported by the seventh slat support and the eighth slat support. 
 
     
     
         9 . The mattress foundation of  claim 8  where each of the first and the second sets of lateral channel slats and each of the first and the second sets of longitudinal channel slats further comprises:
 a base section integrally formed with a first wing section and a second wing section; and 
 the first wing section and the second wing section extending generally perpendicular from the base section forming a channel. 
 
     
     
         10 . The mattress foundation of  claim 9  where the first wing section includes a first strengthening rib and the second wing section includes a second strengthening rib. 
     
     
         11 . The mattress foundation of  claim 9  wherein the first wing section, the second wing section, and the base section encapsulate a strengthening channel 
     
     
         12 . The mattress foundation of  claim 9  further comprising:
 at least one standoff from the second set of standoffs abuts the first slat support and the fifth slat support; 
 at least one standoff from the second set of standoffs abuts the second slat support and the sixth slat support; 
 at least one standoff from the third set of standoffs abuts the third slat support and engages the channel of the second set of lateral channel slats; and 
 at least one standoff from the third set of standoffs abut the fourth slat support and engages the channel of the second set of lateral channel slats. 
 
     
     
         13 . The mattress foundation of  claim 1  where the first set of end caps is comprised of a first end cap, a second end cap, a third end cap, and a fourth end cap; the second set of end caps is comprised of a fifth end cap, a sixth end cap, a seventh end cap, and an eighth end cap; wherein each end cap further comprises:
 a non-metallic arcurate corner having an inside semi-cylindrical wall integrally formed with 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 radial vertical wall and the second radial vertical wall forming a generally right angle; 
 a first tab extending generally perpendicularly from the first radial vertical wall; 
 a second tab extending generally perpendicularly from the second radial vertical wall; 
 the first tab and the second tab forming a first insert and a second insert on the first end cap, a third insert and a fourth insert on the second end cap, a fifth insert and a sixth insert on the third end cap, and a seventh insert and an eighth insert on the fourth end cap; 
 the first tab and the second tab forming a first projection and a second projection on the fifth end cap, a third projection and a fourth projection on the sixth end cap, a fifth projection and a sixth projection on the seventh end cap, and a seventh projection and an eighth projection on the eighth end cap; 
 wherein the first insert removably engages the first side rail and the second insert removably engages the first end rail; the third insert removably engages the first end rail and the fourth insert removably engages the second side rail; the fifth insert removably engages the second side rail and the sixth insert removably engages the second end rail; and the seventh insert removably engages the second end rail and the eighth insert removably engages the first side rail; and 
 wherein the first projection removably engages the third side rail and the second projection removably engages the third end rail; the third projection removably engages the third end rail and the fourth projection removably engages the fourth side rail; the fifth projection removably engages the fourth side rail and the sixth projection removably engages the fourth end rail; and the seventh projection removably engages the fourth end rail and the eighth projection removably engages the third side rail. 
 
     
     
         14 . The mattress foundation of  claim 1  further comprising a plurality of feet, removably secured to the first set of end caps. 
     
     
         15 . A mattress support system comprising:
 a first tier connected to a second tier by a plurality of corner standoffs;   the first tier comprising:
 a first lower side rail connected to a first lower end cap; 
 a first lower end rail connected to the first lower end cap and further connected to a second lower end cap; 
 a second lower side rail connected to the second lower end cap and further connected to a third lower end cap; 
 a second lower end rail connected to the third lower end cap and further connected to a fourth lower end cap; 
 the fourth lower end cap further connected to the first lower side rail; 
 the first lower side rail, the first lower end rail, the second lower side rail, and the second lower end rail each having a first cross-section, where the first cross-section is comprised of:
 a lower tab support, connected to and generally perpendicular with a lower first section, adjacent to and extending into a lower slot; 
 the lower first section connected to and generally perpendicular with a lower second section; 
 the lower second section is connected to and generally perpendicular with a lower third section; 
 a lower slat support, connected to and generally perpendicular with the lower third section, extending away from the lower slot; 
 
   the second tier comprising:   a first upper side rail connected to a first upper end cap;   a first upper end rail connected to the first upper end cap and further connected to a second upper end cap;   a second upper side rail connected to the second upper end cap and further connected to a third upper end cap;   a second upper end rail connected to the third upper end cap and further connected to a fourth upper end cap;   the fourth upper end cap further connected to the first upper side rail;   the first upper side rail, the first upper end rail, the second upper side rail, and the second upper end rail each having a second cross-section, where the second cross-section is comprised of:
 an upper tab support, connected to and generally perpendicular with an upper first section, extending into an upper slot; 
 the upper first section connected to and generally perpendicular with an upper second section; 
 the upper second section connected to and generally perpendicular with an upper third section; 
 an upper slat support, generally perpendicular with and connected to the upper third section at the intersection of the upper second section and the upper third section, extending away from the upper slot; 
   at least one lower lateral slat extending between and connected to the first lower side rail and the second lower side rail;   at least one lower longitudinal slat extending between and connected to the first lower end rail and the second lower end rail;   a set of upper lateral slats extending between and connected to the first upper side rail and the second upper side rail;   a set of upper longitudinal slats extending between and connected to the first upper end rail and the second upper end rail; and   a central standoff connected to the at least one lower lateral slat and connected to an upper longitudinal slat from the set of upper longitudinal slats.   
     
     
         16 . The mattress support system of  claim 15  further comprises:
 the lower slat support and the lower third section forming a first shelf on the first lower end rail, a second shelf on the second lower end rail, a third shelf on the first lower side rail, and a fourth shelf on the second lower side rail; 
 the upper slat support and the upper third section forming a fifth shelf on the first upper end rail, a sixth shelf on the second upper end rail, a seventh shelf on the first upper side rail, and an eighth shelf on the second upper side rail; 
 the at least one lower longitudinal slat connected to first shelf and the second shelf; 
 the at least one lower lateral slat connected to the third shelf and the fourth shelf; 
 at least one upper longitudinal slat from the set of upper longitudinal slats connected to the fifth shelf and the sixth shelf; 
 at least one upper lateral slat from the set of upper lateral slats connected to seventh shelf and the eighth shelf. 
 
     
     
         17 . The mattress support system of  claim 15  wherein the first lower end cap, the second lower end cap, the third lower end cap, the fourth lower end cap, the first upper end cap, the second upper end cap, the third upper end cap, and the fourth upper end cap each comprise:
 a middle section having an outside curved edge connected to an inside curved edge by a first edge, a first brace, a second brace, and a second edge; 
 wherein the first edge connects to the second edge to form a corner; 
 a threaded hole integrally formed with the inside curved edge; 
 a first tab extending generally perpendicularly from the first edge and a second tab extending generally perpendicularly from the second edge; 
 the first tab and the second tab form a first insert and a second insert on the first lower end cap, a third insert and a fourth insert on the second lower end cap, a fifth insert and a sixth insert on the third lower end cap, and a seventh insert and an eighth insert on the fourth lower end cap; 
 the first tab and the second tab form a first projection and a second projection on the first upper end cap, a third projection and a fourth projection on the second upper end cap, a fifth projection and a sixth projection on the third upper end cap, and a seventh projection and an eighth projection on the fourth upper end cap; 
 wherein the first insert frictionally engages the first lower side rail and the second insert frictionally engages the first lower end rail; the third insert frictionally engages the first lower end rail and the fourth insert frictionally engages the second lower side rail; the fifth insert frictionally engages the second lower side rail and the sixth insert frictionally engages the second lower end rail; and the seventh insert frictionally engages the second lower end rail and the eighth insert frictionally engages the first lower side rail; and 
 wherein the first projection frictionally engages the first upper side rail and the second projection frictionally engages the first upper end rail; the third projection frictionally engages the first upper end rail and the fourth projection frictionally engages the second upper side rail; the fifth projection frictionally engages the second upper side rail and the sixth projection frictionally engages the second upper end rail; and the seventh projection frictionally engages the second upper end rail and the eighth projection frictionally engages the first upper side rail. 
 
     
     
         18 . The mattress support system of  claim 15  wherein the lower first section, the lower second section, the lower third section, the lower slat support, and the lower tab support are integrally formed as one piece construction and the upper first section, the upper second section, the upper third section, the upper slat support, and the upper tab support are integrally formed as one piece construction. 
     
     
         19 . The mattress support system of  claim 15  wherein the upper first section includes a first strengthening rib, the lower first section includes a second strengthening rib, the upper third section includes a third strengthening rib, and the lower third section includes a fourth strengthening rib. 
     
     
         20 . The mattress support system of  claim 19  wherein at least one of the first strengthening rib, the second strengthening rib, the third strengthening rib, and the fourth strengthening rib has an “I”-beam cross-section. 
     
     
         21 . The mattress support system of  claim 15  wherein the at least one lower lateral slat, the at least one lower longitudinal slat, the set of upper lateral slats, and the set of upper longitudinal slats each comprise:
 a first vertical stanchion connected to a horizontal base section; and 
 the horizontal base section further connected to a second vertical stanchion where the horizontal base section, the first vertical section, and the second vertical section are integrally formed and define a channel; 
 
     
     
         22 . The mattress support system of  claim 21  further comprising:
 a first strengthening strip encapsulated in the first vertical stanchion; and, 
 a second strengthening strip encapsulated in the second vertical stanchion. 
 
     
     
         23 . The mattress support system of  claim 21  wherein the first vertical stanchion, the second vertical stanchion, and the horizontal base section encapsulate a strengthening channel 
     
     
         24 . The mattress support system of  claim 21  further comprising:
 a set of side rail standoffs connecting at least one of the set of upper lateral slats to the first lower side rail and the second lower side rail, where the set of side rail standoffs abut the channel of at least one of the set of upper lateral slats; 
 a set of end rail standoffs connecting the first lower end rail to the first upper end rail and connecting the second lower end rail to the second upper end rail. 
 
     
     
         25 . The mattress support system of  claim 15  where at least one of the first lower side rail, the first lower end rail, the second lower side rail, the second lower end rail, the first upper side rail, the first upper end rail, the second upper side rail, and the second upper end rail contains a strengthening channel.