Bed foundation, bed foundation kit, and method for assembling a bed foundation

Abstract

The bed foundation includes a frame and one or more panels disposed on top of the frame to define a top surface of the bed foundation for supporting a mattress. The frame includes a plurality of rails that, when combined, at least partially define the frame. The rails are constructed of thermoplastic foam, which is lighter than wood or other similar or heavy materials commonly utilized in the construction of bed foundations, making the bed foundation easier to ship, lift, carry, and assemble. One or more panels may also be constructed of thermoplastic foam. The frame may further include a plurality of brackets for interconnecting selected rails of the frame. Also provided are a kit for a bed foundation and a method for assembling a bed foundation.

Description

[Technical Field]

[0001] (Related Applications) This application claims priority to U.S. Provisional Patent Application No. 63 / 405,029, filed September 9, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention relates to bed foundations, kits for bed foundations, and methods for assembling bed foundations. In particular, the present invention includes bed foundations that are lighter than wood and utilize thermoplastic components that can be press-fit together to form the foundation. [Background technology]

[0003] A bed assembly typically includes a mattress and a base on which the mattress rests. In recent years, online mattress sales and the use of third-party parcel delivery companies to deliver mattresses to consumers have become increasingly common. To facilitate delivery by third-party delivery companies and to make mattresses easier for consumers to lift and carry, it is now common for mattresses to be packaged in a rolled-up box. This packaging arrangement serves to reduce the spatial footprint of the mattress during transport, thereby reducing transportation costs. However, the various components of a bed base typically must exhibit some form of rigidity to adequately support the mattress and therefore cannot be rolled up to reduce the spatial footprint. Therefore, in terms of both transportation logistics and cost, the ease with which a bed base can be shipped and subsequently lifted and carried by consumers is primarily a function of the weight of the bed base. However, because the structural integrity of a bed base must be sufficient to support a mattress, the main components of a bed base have traditionally been constructed of wood or other heavy materials. As a result, bed foundations have generally been unsuitable for delivery by third-party delivery companies and have remained difficult for consumers to lift, carry, and assemble using conventional fasteners (e.g., screws, nails, nuts, bolts, etc.). Furthermore, because many conventional bed foundations require the use of conventional fasteners to hold the foundation components together, consumers are required to possess certain tools to assemble the delivered bed foundation.

[0004] Therefore, a bed base with features that make it more suitable for shipping by a third-party carrier and that make it easier for the consumer to lift, carry, and assemble the bed base would be highly desirable and beneficial. Summary of the Invention

[0005] The present invention includes bed bases having components constructed from lighter materials than wood or other similar or heavier materials commonly utilized in the construction of bed bases. In particular, the present invention includes bed bases that utilize frames constructed from thermoplastic foam. The reduced weight resulting from the use of thermoplastic materials makes the bed bases of the present invention more suitable for transportation by third-party delivery companies and easier to lift, carry, and assemble than bed bases constructed primarily from wood or other similar or heavier materials.

[0006] In one exemplary embodiment of the present invention, a bed foundation includes a frame and one or more panels disposed on top of the frame to define an upper surface of the foundation for supporting a mattress. The frame includes a plurality of rails constructed of thermoplastic foam, the plurality of rails combining to at least partially define the frame.

[0007] In some embodiments, the frame's rails include a first rail set and a second rail set mated with the first rail set. The first rail set at least partially defines the frame's outer periphery, and the second rail set defines an interior structure within the frame's outer periphery formed by mating each rail of the second rail set with at least one other rail of the second rail set. To facilitate mating of the second rail set, each rail of the second rail set may include a notch for receiving another rail of the second rail set. In some embodiments, the first rail set and the second rail set are mated by a mortise-and-tenon type joint. In this regard, in some embodiments, each end of each rail of the second rail set defines a tenon, and each rail of the first rail set defines one or more openings into which one of the tenons defined by the second rail set is received.

[0008] In some embodiments, the foundation further includes a plurality of brackets. Each bracket is configured to interconnect two rails of the first rail set. In some embodiments, each bracket of the plurality of brackets is constructed from a thermoplastic material to further minimize the weight of the frame attributable to the bracket. In some embodiments, each bracket defines a first slot into which one rail of the first rail set is received and a second slot into which another rail of the first rail set is received. In one such embodiment, each bracket includes a first pair of flanges defining the first slot of the bracket, a second pair of flanges defining the second slot of the bracket, and a central body, with the first pair of flanges and the second pair of flanges extending from the central body. In some embodiments, the central body of each bracket is substantially hollow to further reduce the weight of the frame attributable to the bracket.

[0009] In some embodiments, the bed foundation includes multiple panels, reducing the amount of space required to transport or otherwise transport the bed foundation when it is configured to be disassembled. In some embodiments, each panel is removably secured to the foundation frame using multiple fasteners, such as press fasteners, constructed from recyclable materials, preventing the panels from disengaging from or moving relative to the frame during transportation or use, while facilitating rapid disassembly and subsequent reassembly. In some embodiments, each panel of the foundation is constructed from a thermoplastic foam. Thermoplastic foams suitable for constructing the frame rails and panels include polypropylene (PP) foam, polyethylene (PE) foam, polyethylene terephthalate (PET) foam, polyisocyanurate (polyiso) foam, polyvinyl chloride (PVC) foam, and glass-reinforced polyurethane (PU) foam.

[0010] The bed foundations of the present invention can be provided to consumers in a disassembled state. Accordingly, the present invention further includes bed foundation kits that include some or all of the components of the various bed foundation embodiments disclosed herein.

[0011] The present invention further includes a method of assembling a bed foundation. In one exemplary embodiment, the method of assembling a bed foundation includes assembling a plurality of rails constructed from thermoplastic foam to at least partially define a frame of the bed foundation, and placing one or more panels on top of the frame to define an upper surface of the bed foundation for supporting a mattress. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a perspective view of an exemplary bed base made in accordance with the present invention. [Figure 2] FIG. 2 is a perspective view of the frame of the exemplary bed foundation of FIG. 1, but with the panels shown in FIG. 1 removed from the foundation. [Figure 3] 3 is an exploded perspective view of the internal structure of the frame of the exemplary bed base of FIG. 1. FIG. [Figure 4] 4 is a top view of a bracket of the exemplary bed foundation frame of FIG. 1. FIG. [Figure 5] FIG. 5 is a side view of a press fastener that may be used with the exemplary bed foundation of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0013] The present invention includes a bed base with components constructed of lighter materials than wood or other equivalent or heavier materials commonly utilized in the construction of bed bases. In particular, the present invention includes a bed base that utilizes a frame constructed of thermoplastic foam and includes components that can be press-fit together. The reduced weight resulting from using thermoplastic materials makes the bed base of the present invention more suitable for shipping by third-party carriers and easier to lift, transport, and assemble compared to bed bases constructed primarily of wood or other equivalent or heavier materials.

[0014] When referring to foundation components that are "press fit" together, such reference is understood to indicate that the components are typically assembled together without the use of tools or fasteners. Throughout this disclosure, the terms "comprised of" and "constructed of" are used interchangeably. Thus, unless otherwise specified, the term "constructed of," like the term "comprised of," is open-ended and does not exclude the presence of components or materials not explicitly stated.

[0015] 1 and 2, a bed base (or foundation) 10 made in accordance with the present invention includes a frame 20 and one or more panels 42, 44, 46 positionable on top of the frame 20 to define an upper surface of the base 10 for supporting a mattress (not shown). As shown in FIG. 2, the primary structure of the frame 20 is defined by a plurality of rails 21, 22, 23, 24, 25, 26, 27, 28, which may also be characterized as "slats," and thus may be characterized as including a plurality of rails 21, 22, 23, 24, 25, 26, 27, 28. Advantageously, in this exemplary embodiment, both the plurality of rails 21, 22, 23, 24, 25, 26, 27, 28 and the one or more panels 42, 44, 46 are constructed of thermoplastic foam, which is lighter than wood, metal, or other heavy materials traditionally utilized in the construction of bed bases.

[0016] 1-3, the plurality of rails 21, 22, 23, 24, 25, 26, 27, 28 that define the primary structure of frame 20 can be characterized as including two separate rail sets: first rail set 21, 22, 23, 24 and second rail set 25, 26, 27, 28. In this exemplary embodiment, frame 20 includes a total of eight rails, four corresponding to first rail set 21, 22, 23, 24 and four corresponding to second rail set 25, 26, 27, 28. Specifically, first rail set 21, 22, 23, 24 includes opposing vertically oriented first rail sets 21, 22 and opposing horizontally oriented first rail sets 23, 24, which collectively define the perimeter of frame 20. Similarly, second rail sets 25, 26, 27, 28 include opposing vertically oriented second rail sets 25, 26 and opposing horizontally oriented second rail sets 27, 28, which collectively define an interior structure located within the perimeter of frame 20. As best shown in FIG. 2, the main structure of the frame 20 is formed by (i) each of the vertically oriented rails 221, 22 of the first rail set 21, 22, 23, 24 being combined with each of the horizontally oriented rails 27, 28 of the second rail set 25, 26, 27, 28, (ii) each of the horizontally oriented rails 23, 24 of the first rail set 21, 22, 23, 24 being combined with each of the vertically oriented rails 25, 26 of the second rail set 25, 26, 27, 28, and (iii) each of the vertically oriented rails 25, 26 of the second rail set 25, 26, 27, 28 being combined with each of the horizontally oriented rails 27, 28 of the second rail set 25, 26, 27, 28. In this exemplary embodiment, the vertically oriented rails 21, 22 of the first rail set 21, 22, 23, 24 and the vertically oriented rails 25, 26 of the second rail set 25, 26, 27, 28 have a greater length than the horizontally oriented rails 23, 24 of the first rail set 21, 22, 23, 24 and the horizontally oriented rails 27, 28 of the second rail set 25, 26, 27, 28. Thus, the frame 20 in this exemplary embodiment has a substantially rectangular shape.

[0017] Although frame 20 is primarily described herein and illustrated in the drawings as including a total of eight rails and maintaining a substantially rectangular shape, it should be understood that frame 20 is not necessarily limited to such a configuration. Rather, the total number of rails in frame 20, the distribution of the rails between a first rail set that primarily defines the perimeter of frame 20 and a second rail set that defines the interior structure of frame 20, and the length of each rail may vary to accommodate mattresses of different sizes, shapes, and / or weights without departing from the spirit and scope of the present invention. For example, alternative embodiments in which second rail sets 25, 26, 27, and 28 that define the interior structure of frame 20 include more than four rails, and alternative embodiments in which second rail sets 25, 26, 27, and 28 that define the interior structure of frame 20 include fewer than four rails, are contemplated by the present invention. Additionally, alternative embodiments in which the rail lengths of frame 20 are such that frame 20 maintains a non-rectangular shape (e.g., square) are also contemplated. The advantages and benefits of constructing the rails of frame 20 from expanded thermoplastic foam are also realized in such alternative embodiments, and one skilled in the art will readily appreciate that such modifications can be made without departing from the spirit and scope of the present invention.

[0018] 2 and 3, in this exemplary embodiment, second rail set 25, 26, 27, 28, which define the interior structure of frame 20, mate with first rail set 21, 22, 23, 24 via mortise-and-tenon type joints. In this regard, each end of each horizontally oriented rail 27, 28 of second rail set 25, 26, 27, 28 defines a tenon 27a, 27b, 28a, 28b (i.e., male member) that can be press-fit into a corresponding opening 22a, 22b defined by the vertically oriented rails 21, 22 of first rail set 21, 22, 23, 24. Thus, in this exemplary embodiment, the horizontally oriented rails 27, 28 of the second rail set 25, 26, 27, 28 define a total of four tenons, and the vertically oriented rails 21, 22 of the first rail set 21, 22, 23, 24 define a total of four openings 22a, 22b, two of which are shown in Figure 2. Similarly, each end of each vertically oriented rail 25, 26 of the second rail set 25, 26, 27, 28 defines a tenon 25a, 25b, 26a, 26b that can be press-fit into a corresponding opening 24a, 24b defined by one of the horizontally oriented rails 23, 24 of the first rail set 21, 22, 23, 24. Thus, in this exemplary embodiment, the vertically oriented rails 25, 26 of the second rail set 25, 26, 27, 28 define a total of four tenons, and the horizontally oriented rails 23, 24 of the first rail set 21, 22, 23, 24 define a total of four openings 24a, 24b, two of which are shown in Figure 2. However, it is of course contemplated that numerous other configurations or shapes, including extruded I-beam shaped rails and the like, may be utilized and used to construct the exemplary bed base without departing from the spirit and scope of the present invention.

[0019] 2 and 3, in addition to being interdigitated with the first rail set 21, 22, 23, and 24, the rails of the second rail set 25, 26, 27, and 28 are interdigitated with each other. Thus, in this exemplary embodiment, the vertically oriented rails 25, 26 of the second rail set 25, 26, 27, and 28 each define two notches. Each vertically oriented rail 25, 26 defines a first notch 25c, 26c that corresponds to one of two notches 28c, 28d defined by one horizontally oriented rail 28 of the second rail set 25, 26, 27, and 28. In turn, each vertically oriented rail 25, 26 further defines a second notch 25d, 26d that corresponds to one of two notches 27c, 27d defined by the other horizontally oriented rail 27 of the second rail set 25, 26, 27, and 28. Thus, the second rail sets 25, 26, 27, 28 can be assembled together by aligning the notches 25c, 25d, 26c, 26d defined by the vertically oriented rails 25, 26 with the corresponding notches 27c, 27d, 28c, 28d defined by the horizontally oriented rails 27, 28 and pressing the vertically oriented rails 25, 26 and the horizontally oriented rails 27, 28 together.

[0020] 1-3, as noted above, the construction of each of the rails 21, 22, 23, 24, 25, 26, 27, and 28 from thermoplastic foam reduces the overall weight of the frame 20 and, therefore, the entire foundation 10. Suitable expanded thermoplastic foams that can be used to construct the rails 21, 22, 23, 24, 25, 26, 27, and 28 of the frame 20 include polypropylene (PP) foam, polyethylene (PE) foam, and other types of structural foams, such as polyethylene terephthalate (PET) foam, polyiso (thermoset) foam, polyvinyl chloride (PVC) foam, and glass-reinforced polyurethane (PU), which are 100% recyclable, waterproof, and significantly lighter than wood or other heavy materials traditionally used in the construction of bed foundations. In this exemplary embodiment, the rails 21, 22, 23, 24, 25, 26, 27, and 28 of the frame 20 are constructed from polyethylene foam. However, regardless of what type of expanded thermoplastic foam is utilized, the reduced weight of the multiple rails 21, 22, 23, 24, 25, 26, 27, 28 not only reduces costs associated with shipping, but also allows individuals to more easily lift and transport the foundation 10 without sacrificing the structural integrity of the foundation 10.

[0021] 2 and 3, each of the rails 21, 22, 23, 24, 25, 26, 27, and 28 of the frame 20 may be initially formed by an extrusion process in which a thermoplastic material, such as polypropylene or polyethylene, is melted, mixed with a blowing agent, such as a halogenated hydrocarbon, and forced through a die. Of course, the initial formation of each of the rails 21, 22, 23, 24, 25, 26, 27, and 28 may be achieved using alternative manufacturing techniques without departing from the spirit and scope of the present invention. For example, in some embodiments, the rails 21, 22, 23, 24, 25, 26, 27, and 28 may be initially formed using an alternative manufacturing process, such as injection molding. Once initially formed, openings 22a, 22b, 24a, 24b for receiving tenons 25a, 25b, 26a, 26b, 27a, 27b, 28a, 28b of second rail set 25, 26, 27, 28 can then be formed in first rail set 21, 22, 23, 24 by removing a portion of the middle portion of first rail set 21, 22, 23, 24. Similarly, once the second rail set 25, 26, 27, 28 is initially formed, tenons 25a, 25b, 26a, 26b, 27a, 27b, 28a, 28b and notches 25c, 25d, 26c, 26d, 27c, 27d, 28c, 28d can be formed in the second rail set 25, 26, 27, 28 by removing portions of the ends and middle portions of the second rail set 25, 26, 27, 28.

[0022] 2, each notch defined by the second rail sets 25, 26, 27, 28 preferably extends approximately 50% of the height of the rail in which the notch is defined. When the second rail sets 25, 26, 27, 28 are combined with one another in the manner described above and combined with such notch configuration, the tops of each rail of the second rail sets 25, 26, 27, 28 lie along a common plane (i.e., the tops of each rail of the second rail sets 25, 26, 27, 28 are coplanar), providing a uniform, flat surface upon which one or more panels 42, 44, 46 can be positioned to support a mattress. In this exemplary embodiment, the tops of the first rail sets 21, 22, 23, 24 also lie coplanar with the tops of the second rail sets 25, 26, 27, 28, and the flat surface provided by the internal structure of the frame 20 extends to the periphery of the frame 20. In this regard, in this exemplary embodiment, the tenons 25a, 25b, 26a, 26b, 27a, 27b, 28a, 28b of the second rail sets 25, 26, 27, 28 and the corresponding openings 22a, 22b, 24a, 24b of the first rail sets 21, 22, 23, 24 are arranged such that when the first rail sets 21, 22, 23, 24 are combined with the second rail sets 25, 26, 27, 28 in the manner described above, the tops of the first rail sets 21, 22, 23, 24 and the tops of the second rail sets 25, 26, 27, 28 lie along a common plane. However, alternative configurations of the frame 20 are envisioned in which the tops of the first rail sets 21, 22, 23, 24 and the tops of the second rail sets 25, 26, 27, 28 do not lie along a common plane. For example, in some alternative embodiments, the tops of the first rail set 21, 22, 23, 24 may be located on a plane that is higher than the plane on which the tops of the second rail set 25, 26, 27, 28 are located when the frame 20 is assembled, so that the internal structure of the frame 20 is recessed relative to the outer periphery of the frame 20.

[0023] 2 and 3, in this exemplary embodiment, a plurality of openings 60 are also formed at the top of the rails (in this case, each rail of both the first rail set 21, 22, 23, 24 and the second rail set 25, 26, 27, 28) on which one or more panels 42, 44, 46 are positioned. The significance of such openings 60 will be discussed further below.

[0024] The openings 22a, 22b, 24a, and 24b in the first rail set 21, 22, 23, and 24, the tenons 25a, 25b, 26a, 26b, 27a, 27b, 28a, and 28b and notches 25c, 25d, 26c, 26d, 27c, 27d, 28c, and 28d in the second rail set 25, 26, 27, and 28, and the openings 60 in both the first rail set 21, 22, 23, and 24 and the second rail set 25, 26, 27, and 28 can be manufactured using known subtractive manufacturing techniques. Subtractive manufacturing techniques suitable for such applications include, but are not necessarily limited to, drilling, stamping, waterjet cutting, CNC milling, and the like. If the first rail set 21, 22, 23, 24 and the second rail set 25, 26, 27, 28 are formed by injection molding, the mold utilized may include features that impart the openings 22a, 22b, 24a, 24b of the first rail set 21, 22, 23, 24, the tenons 25a, 25b, 26a, 26b, 27a, 27b, 28a, 28b of the second rail set 25, 26, 27, 28, the notches 25c, 25d, 26c, 26d, 27c, 27d, 28c, 28d of the second rail set 25, 26, 27, 28, and / or the openings 60 of both the first rail set 21, 22, 23, 24 and the second rail set 25, 26, 27, 28 during the initial formation of the rails.

[0025] 1, 2, and 4, in this exemplary embodiment, frame 20 includes a plurality of brackets 32, 34, 36, and 38 that interconnect first rail set 21, 22, 23, and 24 and define corners, and thus partially define the perimeter, of frame 20. In this regard, brackets 32, 34, 36, and 38 can also be characterized as "corner brackets." As best shown in FIG. 2, each bracket 32, 34, 36, and 38 is configured to interconnect two rails of first rail set 21, 22, 23, and 24. To this end, in this exemplary embodiment, each bracket 32, 34, 36, 38 defines and can thus be characterized as including a central body 32a, 34a, 36a, 38a, a first pair of flanges 32b, 34b, 36b, 38b extending from the central body 32a, 34a, 36a, 38a, and a second pair of flanges 32c, 34c, 36c, 38c extending from the central body 32a, 34a, 36a, 38a, as best shown in FIG. 4. The first pair of flanges 32b, 34b, 36b, 38b of each bracket 32, 34, 36, 38 includes an inner flange and an outer flange. The inner flange and the outer flange are spaced from one another to define a slot into which an end of one rail of the first rail set 21, 22, 23, 24 can be press-fit. The second pair of flanges 32c, 34c, 36c, 38c of each bracket 32, 34, 36, 38 similarly includes inner and outer flanges spaced apart to define a slot into which another rail of the first rail set 21, 22, 23, 24 can be press-fit. As best shown in FIG. 2, the height of brackets 32, 34, 36, 38 corresponds to the height of the first rail set 21, 22, 23, 24.

[0026] 1, 2, and 3, to help minimize the weight of the brackets 32, 34, 36, and 38, and thus the overall weight of the frame 20, in this exemplary embodiment, the central body 32a, 34a, 36a, and 38a of each bracket 32, 34, 36, and 38 is substantially hollow. To further help minimize the weight of the frame 20, as with the rails 21, 22, 23, 24, 25, 26, 27, and 28, each bracket 32, 34, 36, and 38 is preferably constructed, at least in part, from a thermoplastic material. Suitable thermoplastic materials that may be utilized in the construction of the brackets 32, 34, 36, and 38 include polypropylene, polyethylene, or other types of thermoplastic materials, such as polyethylene terephthalate, polyiso (thermoset), polyvinyl chloride, and polyurethane, which are significantly lighter than wood or other heavy materials traditionally used in the construction of bed foundations. In this exemplary embodiment, each bracket 32, 34, 36, and 38 is constructed from a polyethylene thermoplastic material. Thus, in this exemplary embodiment, each of the components of frame 20 is constructed, in whole or in part, from a thermoplastic material. In some cases, the thermoplastic material utilized in the construction of each component of frame 20 may be infused with various fibers to provide additional strength and durability to such component.

[0027] 1, 2, and 4, similar to rails 21, 22, 23, and 24 of frame 20, brackets 32, 34, 36, and 38 in this exemplary embodiment are formed by an extrusion process in which a thermoplastic material is melted and then forced through a die. Accordingly, the die (or dies) through which brackets 32, 34, 36, and 38 are extruded are adapted so that each bracket 32, 34, 36, and 38 exhibits the characteristics described above when formed. Thus, in this exemplary embodiment, central body 32a, 32b, 32c, and 32d, first flange pair 32b, 34b, 36b, and 38b, and second flange pair 32c, 34c, 36c, and 38c are integrally formed. Of course, brackets 32, 34, 36, and 38 may be formed through different manufacturing processes without departing from the spirit and scope of the present invention. For example, in alternative embodiments, brackets 32, 34, 36, 38 may be formed using different additive manufacturing techniques, such as injection molding and / or 3D printing. It should also be understood that alternative configurations of brackets and / or brackets including different features than the exemplary brackets 32, 34, 36, 38 described above and illustrated in the drawings, but still suitable for interconnecting first rail sets 21, 22, 23, 24, may alternatively be used in alternative embodiments. Indeed, while the use of brackets for added stability in the construction of frame 20 is generally preferred, alternative embodiments are also contemplated herein in which frame 20 is defined solely by first rail sets 21, 22, 23, 24 and second rail sets 25, 26, 27, 28.

[0028] 1 , in this exemplary embodiment, foundation 10 includes three panels: a first panel 42 that defines a left portion of the top surface of foundation 10, a second panel 44 that defines a central portion of the top surface of foundation 10, and a third panel 46 that defines a right portion of the top surface of foundation 10. As shown in this exemplary embodiment, first panel 42, second panel 44, and third panel 46 are sized such that, when placed on the frame, first panel 42, second panel 44, and third panel 46 collectively cover the tops of first rail set 21, 22, 23, 24, second rail set 25, 26, 27, 28, and brackets 32, 34, 36, 38, respectively. Of course, in alternative embodiments in which the top surface of the interior structure of frame 20 and the top surface of the periphery of frame 20 do not lie along a common plane, the dimensions of first panel 42, second panel 44, and third panel 46 can be modified so as to collectively cover only the top surfaces of second rail set 25, 26, 27, 28. Of course, while the use of multiple panels to define the surface of foundation 10 upon which a mattress can rest can be advantageous in terms of reducing the spatial dimensions required for shipping or other transportation of the foundation when disassembled, it is further contemplated that the use of multiple panels or a set number of multiple panels is not necessarily required. Rather, the number of panels utilized can vary without departing from the spirit and scope of the present invention. Accordingly, alternative embodiments in which fewer than three panels (e.g., a single panel) are utilized to define the top surface of foundation 10 for supporting a mattress, as well as embodiments in which more than three panels are utilized to define the top surface of foundation 10 for supporting a mattress, are also contemplated.

[0029] 1 , like rails 21, 22, 23, 24, 25, 26, 27, and 28 of frame 20, in this exemplary embodiment, each panel 42, 44, and 46 is constructed from expanded thermoplastic foam, further reducing the weight of foundation 10 compared to traditional foundations constructed primarily from wood or other similar or heavier materials. Suitable expanded thermoplastic foams that can be utilized in the construction of panels 42, 44, and 46 of frame 20 include polypropylene (PP) foam, polyethylene (PE) foam, and other types of structural foams, such as polyethylene terephthalate (PET) foam, polyiso (thermoset) foam, polyvinyl chloride (PVC) foam, and glass-reinforced polyurethane (PU) foam, which are 100% recyclable, waterproof, and significantly lighter than wood or other heavy materials traditionally used in the construction of bed foundations. In this exemplary embodiment, each panel 42, 44, and 46 is constructed from polyethylene foam. However, regardless of what type of thermoplastic foam is utilized, the reduced weight of the panels 42, 44, 46 compared to other heavier materials, such as wood, not only reduces costs associated with shipping, but also allows individuals to more easily lift and transport the foundation 10 without sacrificing the structural integrity of the foundation 10.

[0030] With further reference to FIG. 1 , similar to rails 21, 22, 23, 24, 25, 26, 27, and 28 of frame 20, each panel 42, 44, and 46 may be initially formed via an extrusion process in which a thermoplastic material, such as polypropylene or polyethylene, is melted, mixed with a blowing agent, such as a halogenated hydrocarbon, and extruded through a die. Of course, the initial formation of each panel 42, 44, and 46 may be achieved using alternative manufacturing techniques without departing from the spirit and scope of the present invention. For example, in some embodiments, each panel 42, 44, and 46 may be initially formed using an alternative manufacturing process, such as injection molding. In this exemplary embodiment, following initial formation, multiple openings (not shown) are formed in each panel 42, 44, and 46 to correspond to openings 60 at the tops of first rail set 21, 22, 23, and 24 and second rail set 25, 26, 27, and 28. While not shown in the drawings, the presence of such openings can be readily discerned by the placement of fasteners 50 in FIG. 1 . The openings in the panels 42, 44, 46 can be implemented using known subtractive manufacturing techniques, such as drilling. If the panels 42, 44, 46 are formed by injection molding, such openings may be provided during the initial formation of the panels 42, 44, 46. If the initially formed panels 42, 44, 46 do not match the contours of the frame 20 (e.g., the portions of the frame 20 corresponding to the brackets 32, 34, 36, 38), some or all of the panels can be optionally cut to accommodate such contours using known subtractive manufacturing techniques (e.g., waterjet cutting, CNC milling, sawing, etc.).

[0031] 1 and 5, to prevent panels 42, 44, 46 from disengaging from or moving relative to frame 20 during use while still facilitating rapid disassembly and subsequent reassembly of foundation 10, in this exemplary embodiment, each panel 42, 44, 46 is removably secured to frame 20 by a plurality of fasteners 50. To allow for rapid assembly and disassembly of foundation 10 as needed, and to allow for subsequent recycling of each component of foundation 10, each fastener 50 is preferably a press fastener (sometimes referred to as a "push fastener" or "plastic rivet") constructed of a recyclable plastic (e.g., nylon), as shown in FIG. 5, which can be installed by simply manually pushing fastener 50 through one of the openings in panel 42, 44, 46 and into opening 60 in frame 20.

[0032] Various press fasteners are known in the art and may be utilized to secure the panels 42, 44, 46 to the frame 20. As such, it should be understood that the fasteners that may be utilized in the present invention are not limited to the configuration illustrated in FIG. 5. While the use of press fasteners is generally preferred, it should also be understood that other fasteners (e.g., snap fasteners, hook-and-loop fasteners, etc.) configured to releasably secure the panels 42, 44, 46 to the frame 20 without the use of tools may alternatively be used without departing from the spirit and scope of the present invention. Furthermore, while the ease of shipping, lifting, and transporting the foundation 10 is primarily due to the lightweight construction of the frame 20 and, in at least some embodiments, the lightweight structure of the panels 42, 44, 46, it should also be understood that alternative embodiments using fasteners that require the use of tools (e.g., screws) for installation are also contemplated herein and still offer certain advantages over conventional bed foundations constructed of wood or other heavy materials. Additionally, although securing the panels 42, 44, 46 to the frame 20 is advantageous in preventing the panels 42, 44, 46 from disengaging from or moving relative to the frame 20, in some embodiments the panels 42, 44, 46 may be placed on top of the frame 20 without being secured to the frame 20, and still provide a surface sufficient to support a mattress. Accordingly, alternative embodiments are also contemplated herein in which the assembled foundation 10 does not include fasteners 50, and the panels 42, 44, 46 and rails 21, 22, 23, 24, 25, 26, 27, 28 do not include corresponding openings for the fasteners 50.

[0033] Contemplated herein are embodiments in which the rails 21, 22, 23, 24, 25, 26, 27, 28 and / or panels 42, 44, 46 are entirely constructed from thermoplastic foam, as well as embodiments in which only a portion of the rails 21, 22, 23, 24, 25, 26, 27, 28 and / or panels 42, 44, 46 are constructed from thermoplastic foam (e.g., combined with fiber or other structural additives for added strength or durability).Similarly, embodiments in which the brackets 32, 34, 36, 38 are entirely constructed from thermoplastic material, as well as embodiments in which only a portion of the brackets are constructed from thermoplastic material (e.g., combined with fiber or other structural additives for added strength or durability), are also contemplated herein.

[0034] The exemplary foundation 10 described above is configured to accommodate a queen-sized mattress. However, it should be understood that the number and / or dimensions of the rails, the notches defined in the rails, and / or the number or dimensions of the panels of the foundation 10 may be modified to accommodate a different size mattress. For example, to accommodate a king-sized mattress, the number and / or dimensions of the rails and panels may be increased beyond those described above and illustrated in the drawings.

[0035] To evaluate the extent to which exemplary foundation 10 reduces the loads or strain associated with shipping, lifting, and transporting currently available bed foundations, a preliminary weight comparison was conducted between the above-described foundation 10 and currently available bed foundations constructed primarily of wood. As previously indicated, in exemplary foundation 10, first rail set 21, 22, 23, 24, second rail set 25, 26, 27, 28, and panels 42, 44, 46 are each constructed of extruded polyethylene foam, brackets 32, 34, 36, 38 are each constructed of extruded polyethylene, and fasteners 32 securing panels 42, 44, 46 to frame 20 are constructed of nylon. The weight comparison revealed that the exemplary bed foundation constructed in accordance with the present invention weighed only 29 pounds (29 lbs), approximately one-third (1 / 3) of the weight of a currently available wooden bed foundation of the same size. Of course, those skilled in the art will appreciate that while the exemplary foundation 10 shows both the panels 42, 44, and 46 and each component of the frame 20 constructed from a thermoplastic material, alternative embodiments are possible in which only the frame 20 or the panels 42, 44, and 46 are constructed from a thermoplastic material, and / or only some of the components of the frame 20 and / or some of the panels 42, 44, and 46 are constructed from a thermoplastic material, and such embodiments would still provide a reduced weight advantage over a similarly constructed foundation constructed from wood or other equivalent or heavier materials. For example, in one alternative embodiment, the panels 42, 44, and 46 of the foundation 10 are constructed from fiberboard, while each component of the frame 20 is constructed from thermoplastic foam.

[0036] In one exemplary embodiment, foundation 10 is assembled by first assembling frame 20 and then securing panels 42, 44, 46 to the top of frame 20 using multiple fasteners 50. To assemble frame 20, second rail sets 25, 26, 27, 28 are preferably first assembled together to form the interior structure of frame 20, initially maintaining the octothorpe shape. As described above, second rail sets 25, 26, 27, 28 are assembled by aligning notches 25c, 25d, 26c, 26d in the vertically oriented rails 25, 26 of second rail sets 25, 26, 27, 28 with corresponding notches 27c, 27d, 28c, 28d in the horizontally oriented rails 27, 28 of second rail sets 25, 26, 27, 28 and press-fitting such rails together. After the second rail sets 25, 26, 27, 28 are assembled together, the tenons 25a, 25b, 26a, 26b, 27a, 27b, 28a, 28b defined by the second rail sets 25, 26, 27, 28 are then inserted into the corresponding openings 22a, 22b, 24a, 24b defined by the first rail sets 21, 22, 23, 24, and the first rail sets 21, 22, 23, 24 and the second rail sets 25, 26, 27, 28 are press-fitted together, thereby assembling the first rail sets 21, 22, 23, 24 to the ends of the second rail sets 25, 26, 27, 28, thereby establishing the main structure of the frame 20. Assembly of frame 20 is then completed by inserting the ends of first rail set 21, 22, 23, 24 into the slots of one of brackets 32, 34, 36, 38, thereby press-fitting brackets 32, 34, 36, 38 and first rail set 21, 22, 23, 24 together. Once frame 20 is assembled, panels 42, 44, 46 are secured together by manually inserting fasteners 32 into corresponding openings 60 in frame 20 and panels 42, 44, 46 without the use of tools. In this exemplary embodiment and implementation, frame 20, when fully assembled, defines a 3x3 grid, as shown in FIG. 2.Of course, the shape of the assembled frame 20 may vary from that shown in Figure 2 if modified to accommodate different size mattresses.

[0037] Unless otherwise specified or the context dictates, the method steps disclosed herein for assembling the exemplary foundation 10 can be performed in any order. Furthermore, those skilled in the art will understand that in alternative embodiments in which brackets 32, 34, 36, 38 and / or fasteners 50 are omitted from the foundation, the assembly steps associated with the use of such components are similarly omitted. Furthermore, while it is contemplated that the foundation embodiments described herein are constructed entirely or substantially of thermoplastic materials and typically can be assembled without the use of tools, it is further contemplated that certain aspects, features, or portions of the foundation can also be constructed of more traditional materials used for bed foundations, such as wood, cardboard, medium-density fiberboard, etc., and can be assembled using conventional tools and fastening methods (e.g., screws, adhesives, hook-and-loop fasteners, heat welding, etc.) without departing from the spirit and scope of the present invention.

[0038] Although the foundation 10 is sometimes described herein in the context of being an assembled item, it is understood that the foundation 10 may be provided to a consumer in an unassembled state for subsequent assembly, for example, according to the exemplary assembly method described above. Accordingly, another aspect of the present invention is directed to a bed foundation kit, which includes some or all of the foundation components that correspond to the components described above in an unassembled state. For example, in some embodiments, the kit may include each of the components of the exemplary foundation 10 described above. In other embodiments, the kit may include only the rails 21, 22, 23, 24, 25, 26, 27, and 28 and panels 42, 44, and 46 of the frame 20.

[0039] Those skilled in the art will recognize that additional embodiments and implementations are possible without departing from the teachings of this invention or the scope of the claims that follow. This detailed description, and in particular the specific details of the exemplary embodiments disclosed herein, are given primarily for clarity of understanding, and no unnecessary limitations are to be understood therefrom; modifications will become apparent to those skilled in the art upon reading this disclosure, and may be made without departing from the spirit or scope of the invention as claimed.

Claims

1. a frame including a plurality of rails, the plurality of rails being constructed from thermoplastic foam; one or more panels disposed on top of the frame to define an upper surface of a bed base for supporting a mattress; A bed foundation.

2. The plurality of rails include: a first set of rails at least partially defining an outer periphery of the frame; a second rail set mated with the first rail set, the second rail set defining an interior structure within the outer periphery of the frame, each rail of the second rail set mated with at least one other rail of the second rail set; The bed foundation of claim 1 , comprising:

3. 3. The bed foundation of claim 2, wherein each rail of the second rail set defines a notch for receiving another rail of the second rail set.

4. 3. The bed foundation of claim 2, wherein each end of each rail of the second rail set defines a tenon, and each rail of the first rail set defines one or more openings into which one of the tenons defined by the second rail set is received.

5. the frame further includes a plurality of brackets; The bed foundation of claim 1 , wherein each bracket of the plurality of brackets interconnects two rails of the first rail set.

6. The bed foundation of claim 5 , wherein each bracket of the plurality of brackets is constructed from a thermoplastic material.

7. 6. The bed foundation of claim 5, wherein each bracket of the plurality of brackets defines a first slot into which one rail of the first rail set is received and a second slot into which another rail of the first rail set is received.

8. Each bracket of the plurality of brackets comprises: a first pair of flanges defining the first slot of the bracket; a second pair of flanges defining the second slot of the bracket; a center body from which the first pair of flanges and the second pair of flanges extend; The bed foundation of claim 7, comprising:

9. 9. The bed base of claim 8, wherein the central body is substantially hollow.

10. The bed foundation of claim 1 , wherein the one or more panels are constructed from thermoplastic foam.

11. the rails of the frame are constructed from one of polypropylene (PP) foam, polyethylene (PE) foam, polyethylene terephthalate (PET) foam, polyisocyanurate (polyiso) foam, polyvinyl chloride (PVC) foam, and glass fiber reinforced polyurethane (PU) foam; 11. The bed foundation of claim 10, wherein the one or more panels are constructed from one of PP foam, PE foam, PET foam, polyiso foam, PVC foam, and glass fiber reinforced PU foam.

12. The bed base of claim 1 , wherein the one or more panels include a plurality of panels.

13. The bed foundation of claim 1 , wherein the one or more panels are removably secured to the frame by a plurality of fasteners.

14. 10. The bed base of claim 1, wherein the one or more panels are constructed of medium density fiberboard.

15. a plurality of rails configured to interlock with one another to at least partially define a frame of a bed base, the plurality of rails being constructed from thermoplastic foam; one or more panels configured to be placed on top of the rails when the rails are assembled, the one or more panels defining an upper surface of the bed foundation for supporting a mattress; A bed foundation kit comprising:

16. 16. The kit of claim 15, wherein the plurality of rails includes a first rail set and a second rail set configured to mate with each other, each rail of the second rail set configured to mate with at least one other rail of the second rail set to define an interior structure of the frame.

17. 17. The kit of claim 16, wherein each rail of the second rail set defines a notch for receiving another rail of the second rail set.

18. 17. The kit of claim 16, wherein each end of each rail of the second rail set defines a tenon, and each rail of the first rail set defines one or more openings configured to receive one of the tenons defined by the second rail set.

19. 17. The kit of claim 16, further comprising a plurality of brackets, each bracket of the plurality of brackets configured to interconnect two rails of the first rail set, the plurality of brackets defining a portion of an outer periphery of the frame.

20. 20. The kit of claim 19, wherein each bracket of the plurality of brackets is constructed from a thermoplastic material.

21. 17. The kit of claim 16, wherein the one or more panels are constructed from thermoplastic foam.

22. the plurality of rails are constructed from one of polypropylene (PP) foam, polyethylene (PE) foam, polyethylene terephthalate (PET) foam, polyisocyanurate (polyiso) foam, polyvinyl chloride (PVC) foam, and glass fiber reinforced polyurethane (PU) foam; 22. The kit of claim 21, wherein the one or more panels are constructed from one of PP foam, PE foam, PET foam, polyiso foam, PVC foam, and glass fiber reinforced PU foam.

23. The kit of claim 16, further comprising a plurality of fasteners configured to removably secure the one or more panels to the frame.

24. 17. The kit of claim 16, wherein the one or more panels are constructed from medium density fiberboard.

25. 1. A method of assembling a bed foundation, the method comprising: a plurality of rails assembled to at least partially define a frame of the bed base, the plurality of rails of the frame being constructed from thermoplastic foam; One or more panels are placed on top of the frame to define the upper surface of the bed foundation for supporting a mattress. A method comprising:

26. Combining the plurality of rails includes: a first rail set of the plurality of rails combined with a second rail set of the plurality of rails, the first rail set at least partially defining an outer periphery of the frame; The second set of rails of the plurality of rails are interlocked together to define an interior structure within the perimeter of the frame.

26. The method of claim 25, comprising:

27. 27. The method of claim 26, wherein the combining of the first rail set with the second rail set and the combining of the second rail set with one another is performed by press-fitting the first rail set with the second rail set with one another.

28. 26. The method of claim 25, further comprising interlocking the first set of rails with a plurality of corner brackets, the first set of rails and the plurality of corner brackets defining the perimeter of the frame.

29. 26. The method of claim 25, further comprising removably securing the one or more panels to the frame with a plurality of fasteners.

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