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.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a Continuation-In-Part claiming priority benefit from U.S. patent application Ser. No. 13 / 136,197, filed Jul. 26, 2011, entitled “Apparatus and Method of Use for a PVC Composite Mattress Frame.”FIELD OF THE INVENTION[0002]The present invention relates generally to bed structures. In particular, the invention relates to a lightweight and high strength extruded polyvinyl chloride (PVC) composite mattress support apparatus.BACKGROUND OF THE INVENTION[0003]A mattress frame, commonly known as a set of box springs, is a type of bed base typically consisting of a sturdy wooden frame covered in fabric, and containing springs. In use, the mattress frame or box spring is placed on a metal bed frame which supports the mattress frame and acts as a stand to raise the bed frame to a desirable height. The mattress frame supports a mattress. The bed frame, mattress frame and mattress make up a standard bed structure. Structural suppor...

AI Technical Summary

Benefits of technology

[0013]An embodiment of the apparatus includes a pair of side rails connected to a pair of end rails via four end caps to form a lightweight, durable, and flexible mattress frame in generally rectangular shape which minimizes the amount of material used and eliminates extra fastening hardware. The side rails and the end rails may vary in length depending on the particular use desired but 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 are semi-circular and include two tabs for insertion into the slots. The side rails and end rails further include encapsulated steel ribs. Feet may be attached to the underside of the end caps to raise the mattress frame in order to eliminate the need for a bed frame.

Problems solved by technology

However, the rejection rate of the wood used to manufacture a typical mattress foundation can be as high as 15% due to natural faults in the wood leading to unacceptable amounts of waste and increased cost.

In the use of the steel bedframes of the past, a principle problem is that they are noisy.

Steel bedframes are fastened with rivets or adjustable screws that often produce squeaks.

Further, the plastic bedframes of the prior art, while potentially less noisy, lack the strength of steel bedframes, and can often collapse.

The Cretsinger device incorporates many intricate parts which complicate the manufacturing process and uses unnecessary amounts of material.

The Petruzella device is not easily re-configurable and does not support a mattress as it is the mattress itself.

Further, the Sheehy device has no steel reinforcement members.

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