MATTRESS FOUNDATIONS, MATTRESS FOUNDATION KITS AND RELATED METHODS
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.
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This application claims the benefit of U.S. Provisional Patent Application No. 61/203,335, which was filed on Dec. 22, 2008 in the name of Tony Marion Pearce, the disclosure of which is incorporated herein in its entirety by this reference.
BRIEF SUMMARYIn some embodiments, a mattress foundation kit may include four frames, at least four corner members, at least one interior support member, and at least two deck panels. Each frame may include 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. The corner members may be configured to couple a frame of the four frames to another frame of the four frames. At least two of the four frames may be configured to support an end of each 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.
In additional embodiments, a mattress foundation may include four frames, at least four corner members, at least one interior support member, and at least two deck panels. Each frame may include 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. The corner members may couple the ends of each of the elongated members of the four frames to another of the elongated members of the four frames. Each support member may extend between and be supported by at least two frames of the four frames. Additionally, each deck panel may extend at least partially over and be supported by at least two of the four frames and the at least one interior support member.
In further embodiments, a method of transporting a mattress foundation may include 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. The method may further include positioning eight corner members, each corner member having end portions configured to couple with a tube of the four frames, within the shipping box. Additionally, 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, may be positioned within the shipping box. At least two deck panels configured to couple to at least two of the four frames and at least one interior support member may also be positioned within the shipping box, and 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 may be transported to a point-of-use location.
In some embodiments, such as shown in
As shown in
The first elongated member 34 and second elongated member 36 may each include discrete coupling features 44, such as apertures. For example, the first and second elongated members may each include discrete coupling features 44 formed near the first ends and the second ends thereof for coupling the elongated members 34, 36 with the corner members 18. The first elongated member 34 may also include discrete coupling features, such as apertures 26 (
As shown in
The end frames 14 may additionally include coupling features for coupling the end frames 14 to the interior support members 16. In some embodiments, as shown in
As shown in
As shown in
In additional embodiments, the corner members 18 may be formed integrally with one or more of the side frames 12 and the end frames 14. For example, and as shown in
In further embodiments, and as shown in
The end segments 64 may include apertures 66 (
In some embodiments, the deck panels 20, 22 may be coupled to the upper support surfaces 24 of the end frames 14, side frames 12 and interior support members 16 with fastener assemblies 30, such as that shown in
As shown in
Optionally, a cover 86 (shown schematically in
As shown in
In some embodiments, the shipping box 90 may have a generally rectangular shape (i.e., the shape of a rectangular prism), and may have a height, a length, and a width. The total sum of the length and the girth (the girth is the sum of the two widths and the two heights) may be about 130 inches or less in some embodiments of the invention. Referring to
In some embodiments, as shown in
In some embodiments, a kit 88 for a mattress foundation 10 as described herein may have a total weight of about 100 pounds or less. In additional embodiments, a kit 88 for a mattress foundation 10 as described herein may have a total weight of about 90 pounds or less. As a non-limiting example, a kit 88 that includes a mattress foundation 10 as illustrated in
In view of the relatively small size and weight of the mattress kits 88 described herein, the mattress kits 88 may be transported via courier services, such as UNITED PARCEL SERVICE® at their standard rates, which are substantially less expensive than their rates for oversize packages (for example, packages having more than 130 inches in length plus girth). The mattress kits 88 may also be transported with passenger vehicles, such as passenger cars, passenger vans and passenger sports-utility vehicles. Additionally, after using a mattress foundation 10, the mattress foundation 10 may be disassembled for removal and transportation to a new location where it may be assembled again. A disassembled mattress foundation 10 boxed as a kit 88 may also allow a relatively large number of mattress foundations 10 to be stored in a warehouse or retail storeroom when compared to the space requirement for conventional box springs using to support mattresses. Thus, embodiments of the present invention provide many advantages over conventional box springs used to support mattresses.
The mattress foundation 10 may be assembled at a point-of-use location, which may allow the mattress foundation 10 to be assembled in locations that may not be accessible with conventional box springs. If the mattress foundation kit 88 is contained within a shipping box 90, the kit 88 may be removed from the box 90. As shown in
After securing each of the corner members 18 with the side frames 12 and end frames 14, the interior support members 16 may be coupled to at least two opposing frames, such as to the opposing end frames 14. As shown in
Next, the deck panels 20, 22 may be positioned on the upper support surfaces 24 of each of the end frames 14, side frames 12, and interior support members 16. As shown in
Optionally, corner plates 100 may be positioned over the corner members 18 of the mattress foundation 10, such as shown in
Finally, the cover 86 may be positioned over the deck surface 32 and frames 12, 14 and optionally secured thereto. Upon assembly, the mattress foundation 10 may be positioned on a conventional bed frame (not shown) and utilized in a manner similar to a conventional box spring. Additionally, the mattress foundation 10 may be positioned directly on a floor (not shown) and a bed frame may not be utilized. In yet further embodiments, castor wheels or leg supports (not shown) may be attached directly to the mattress foundation 10 to support the mattress foundation above the surface of a floor without the use of a bed frame. In some embodiments, the mattress foundation may be completely assembled without the use of any tools.
Example Mattress Foundation Kits:
California King:
Overall assembled mattress foundation dimensions about 83.5×71.5×8.25 (inches).
King:
Overall assembled mattress foundation dimensions about 79×75.5×8.25 (inches).
Queen:
Overall assembled mattress foundation dimensions about 79×59.5×8.25 (inches).
Full-XL:
Overall assembled mattress foundation dimensions about 79×52.5×8.25 (inches).
Twin-XL:
Overall assembled mattress foundation dimensions about 79×37.5×8.25 (inches).
Full:
Overall assembled mattress foundation dimensions about 73.5×52.5×8.25 (inches).
Twin:
Overall assembled mattress foundation dimensions about 73.5×37.5×8.25 (inches).
Embodiments of the invention may be susceptible to various modifications and alternative forms. Specific embodiments have been shown in the drawings and described in detail herein to provide illustrative examples of embodiments of the invention. However, the invention is not limited to the particular forms disclosed herein. Rather, embodiments of the invention may include all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the following appended claims. Furthermore, elements and features described herein in relation to some embodiments may be implemented in other embodiments of the invention, and may be combined with elements and features described herein in relation to other embodiments to provide yet further embodiments of the invention.
Claims
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.
Type: Application
Filed: Dec 22, 2009
Publication Date: Jun 24, 2010
Applicant: TNT HOLDINGS, LLC (Alpine, UT)
Inventor: Tony M. Pearce (Alpine, UT)
Application Number: 12/645,056
International Classification: A47C 19/02 (20060101); B65B 5/12 (20060101);