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

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

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

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 support for the bed comes primarily from the bed frame. The bed frame is typically made of steel angle and offers more than adequate support for any average bed loading. In most applications, the bed frame supports a box springs made of a light, inexpensive wood such as pine. A pattern of springs is included which are supported by slats in the bed frame. The springs are held in place by a wire sub-frame connected to the wooden outer frame. Springs flex along with the mattress.

Alternatively, support for the mattress can come from a mattress foundation. A mattress foundation is a flat, rigid surface for supporting a mattress. A mattress foundation is a zero-deflection unit which is used to increase firmness and stability in a typical mattress. The typical mattress foundation is constructed of wood and has a plurality of support slats.

In the manufacture of wood products generally, and in the manufacture of box springs and mattress foundations specifically, structural integrity is based on the quality of the lumber used. 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.

U.S. Pat. No. 6,966,085 to Cretsinger, et al. discloses a bed frame with cross support members coupled with panel assemblies. The frame includes two rail members and two end rails connected by corner connectors. The corner connectors incorporate a tongue and groove assembly for connection. The Cretsinger device incorporates many intricate parts which complicate the manufacturing process and uses unnecessary amounts of material.

U.S. Pat. No. 5,561,876 to Petruzella discloses a structure of a rigid tubular plastic material such as polyvinyl chloride including a generally rectangular shaped rigid frame, a pair of opposed sides, a pair of opposed ends, frictionally engaged elbows which serve to connect the sides and ends to form the rectangular frame, and a flexible fabric tightly stretched over the frame to form a top and bottom surface wherein the frame is of a type that is easily assembled and disassembled into its component parts. The Petruzella device is not easily re-configurable and does not support a mattress as it is the mattress itself.

U.S. Pat. No. 5,469,589 to Steed, et al. discloses a bed foundation comprising a pair of parallel side rails with ends connected by corner braces to the ends of parallel cross rails thereby defining a rectangular box frame wherein the side rails and cross rails may be constructed from a thermoplastic compound. The Steed device requires additional hardware for assembly.

U.S. Pat. No. 7,003,822 to Sheehy discloses a bed frame assembly formed from extruded plastic components. The bed frame can be disassembled into individual components that can be contained within a conventional shipping container. The Sheehy device requires extra hardware for assembly and incorporates additional connecting pieces between the side rails. Further, the Sheehy device has no steel reinforcement members.

U.S. Pat. No. 6,832,397 to Gaboury, et al. discloses a bed foundation made from blow molded plastic material, having interlocking joints between rails and between joists and rails. When assembled, it has a top panel which overhangs the side rails to accommodate an oversized mattress. It may be assembled without the use of tools. The Gaboury bed foundation requires additional hardware for assembly of the connecting joints.

It is desirable to have a mattress support system that is lightweight, durable, flexible, configurable, is easily manufactured of common inexpensive materials, and minimizes total material used to avoid waste. It is also desirable to have a mattress foundation of sufficient strength to support normal loading without deformation. It is further desirable to have a strong support system that reduces noise when in use. It is also desirable to eliminate the need for a bed frame by strengthening a mattress frame or foundation to support additional loading.

SUMMARY OF INVENTION

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.

In an alternate embodiment, slats are included for added strength and to support springs internal to the mattress frame. The slats can extend from side rail to side rail and from end rail to end rail. Depending on the amount of strength required for a particular use, one or a plurality of slats can be employed. Each slat has a generally U-shaped cross-section and further includes encapsulated strengthening ribs.

An additional alternate embodiment of the apparatus includes a lower tier having a first pair of side rails connected to a first pair of end rails via four end caps and an upper tier having a second pair of side rails connected to a second pair of end rails via four end caps. The upper tier is connected to the lower tier by a plurality of rectangular and cylindrical shaped standoffs to form a lightweight, durable, rigid, and generally rectangular mattress foundation. The side rails and the end rails may vary in length depending on the particular use desired. The first pair of side rails and the first pair of end rails has a unique cross-section shape made up of five sections surrounding a slot. The second pair of side rails and the second pair of end rails has a different unique cross-section shape also made up of five sections surrounding a slot. The end caps are semi-circular and include tabs for insertion into the slots. The side rails and end rails further include encapsulated steel ribs. One or a plurality of slats can be affixed to and extend between the first pair of side rails and the first pair of end rails as well as between the second pair of side rails and the second pair of end rails.

The mattress foundation can rest on a typical bed frame, or in an alternate embodiment, feet may be included to raise the mattress foundation.

Those skilled in the art will appreciate the above-mentioned features and advantages of the invention together with other important aspects thereof upon reading the detailed description that follows in conjunction with the drawings provided.

BRIEF DESCRIPTION OF THE DRAWINGS

In the detailed description of the preferred embodiments presented below, reference is made to the accompanying drawings.

FIG. 1 is an isometric view of a preferred embodiment of a mattress frame where a box springs is in shadow.

FIG. 2 is partial isometric view from the bottom of a preferred embodiment of the mattress frame.

FIGS. 3A, 3B, and 3C are cross-sections of preferred embodiments of a side rail taken along line 3-3 of FIG. 1.

FIG. 3D is a side view of a preferred embodiment of a rib.

FIG. 4 is a partial exploded isometric view of a preferred embodiment of an end cap, a side rail, and an end rail.

FIGS. 5A and 5B are cross-sections of a preferred embodiments of a slat taken along line 5-5 of FIG. 1.

FIG. 6 is an isometric view of a preferred embodiment of a mattress frame including longitudinal and lateral slats.

FIG. 7 is an exploded isometric view of an alternate preferred embodiment of a mattress foundation.

FIGS. 8A and 8B are cross-sections of alternate preferred embodiments of a side rail taken along line 8-8 of FIG. 7.

FIG. 9 is an isometric view of an alternate preferred embodiment of a mattress foundation including longitudinal and lateral slats.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In the descriptions that follow, like parts are marked throughout the specification and drawings with the same numerals, respectively. The drawing figures are not necessarily drawn to scale and certain figures may be shown in exaggerated or generalized form in the interest of clarity and conciseness.

FIG. 1 shows mattress frame 100 as would be incorporated within box springs 150 (shown in shadow) where box springs 150 would include springs and fabric cover as is common in the art. A set of feet 195 is included to raise the mattress frame when in use.

Referring to FIGS. 1 and 2, mattress frame 100 is comprised of a pair of side rails 102 and 104 connected to a pair of end rails 106 and 108 via end caps 120, 122, 124, and 126. In the preferred embodiment, the side rails and end rails are made of an extruded polyvinyl chloride (PVC) plastic. Other lightweight, flexible plastics will suffice. In the preferred embodiment, the end caps are made of a fiber reinforced nylon consisting of at least 20% glass or Kevlar® fibers. Side rails 102 and 104 are generally longer in length than end rails 106 and 108 so when assembled form a generally rectangular shape and are comprised of the dimensions typical of bed frames and mattresses found in the industry. It is understood that different dimensions are possible and acceptable.

Side rails 102 and 104 have the same cross-sectional shape as end rails 106 and 108. End cap 120 connects side rail 102 to end rail 106. End cap 122 connects end rail 106 to side rail 104. End cap 124 connects side rail 104 to end rail 108 and end cap 126 connects end rail 108 to side rail 102 to form the four sided mattress frame 100.

Referring to FIG. 3A, cross-section 400 of side rail 104 is shown. The cross-sectional dimensions of side rails 102 and 104 and end rails 106 and 108 are identical.

Cross-section 400 shows that the side rails and end rails are comprised of five sections configured to form and opening leading to a slot. Each side rail and end rail is integrally formed.

Section 404 extends generally perpendicularly from slat support 406. Section 402 extends generally perpendicularly from section 404 in a direction away from slat support 406 and is also generally parallel with slat support 406. Section 408 extends generally perpendicularly from section 402 in a direction towards slat support 406 and is generally parallel with section 404. Tab support 414 extends generally perpendicularly from section 408 in a direction towards slat support 406 and is parallel to section 402 and slat support 406. Between tab support 414 and slat support 406 is gap 410 which leads to slot 412. Slot 412 is surrounded by sections 404, 402, 408, tab support 414, and gap 410. Slot 412 is depicted as rectangular shaped but other polygonal shapes would suffice. It is understood that the shape of slot 412 paired with gap 410 should permit connection with tabs 920 and 922. Section 404 includes encapsulated rib 422. Section 408 includes encapsulated rib 420. The ribs are preferably galvanized steel bars that are integrally formed in the side rails and end rails during manufacture. In a preferred embodiment, the ribs are co-extruded with the sections. In another embodiment, the ribs are bonded in place through induction welding. In an alternate preferred embodiment, in order to reduce weight further, the ribs are not present.

Referring to FIG. 3B, rib 409 is shown. Rib 409 is a steel channel generally, centrally disposed within the side rail or both within the side rail and end rail. In a preferred embodiment, the rib is co-extruded with the side rail or both the side rail and end rail. In another embodiment, the ribs are bonded in place through induction welding.

Referring to FIG. 3C, ribs 411 and 413 have a secondary “I”-beam cross-section for additional strength. In a preferred embodiment, the ribs are co-extruded with the rail. In another embodiment, the ribs are bonded in place through induction welding.

Referring to FIG. 3D, the ribs of the preferred embodiment include roughened surfaces 700 on both sides to aid in bonding with the plastic encapsulation to achieve a unitary construction. In other embodiments, additional roughened surfaces are included along the rib. The ribs also include holes 702 to reduce weight and aid in bonding to the sections. In a preferred embodiment, the height “X” of ribs is between about 60% and 80% of the height “X”' of each section. In an alternate preferred embodiment, the height “X” of the ribs placed in longer side rails is increased compared to those of the end rails to offset greater bending loads. In a preferred embodiment, the ribs are constructed from the group of steel, steel mesh, fiberglass, Kevlar®, aluminum and titanium.

Referring now to FIG. 4, end cap 120, side rail 102, and end rail 106 are shown. End cap 120 is comprised of a middle section 930 and two tabs 920 and 922. Each end cap is integrally formed. Middle section 930 is shaped in a semi-circle having a generally 90° radius bend. It includes outside curved edge 904, edge 909, inside curved edge 902, edge 906 and an approximately centrally positioned threaded hole 197. The height of outside curved edge 904, edge 909, inside curved edge 902, and edge 906 is generally equal to the height of sections 404 and 408 of the side rails and end rails. Outside curved edge 904 is connected to a first end of edge 906 and a first end of edge 909. Inside curved edge 902 is connected to a second end of edge 906 and a second end of edge 909 and includes hole 197 located generally at the midpoint. Braces 907 and 908 extend radially from inside curved section 902 to outside curved section 904. Edges 906 and 909 extend past inside curved edge 902 to meet and form a generally right angle shown as corner 910. The height of corner 910 is generally equal to the height of slat support 406 and tab support 414 of the side rails and end rails. Extending generally perpendicularly from edge 906 is tab 920. Extending generally perpendicularly from edge 909 and generally perpendicular to tab 920 is tab 922. The tabs include braces 918 and 919. Both tabs 920 and 922 have a generally L-shaped cross-section forming notches 921 and 923 respectively. End caps 122, 124, and 126 are identical to end cap 120 and thus will not be described further.

Four feet 195 are provided, each of which incorporate a single threaded stanchion 196. Threaded stanchion 196 is adapted to engage hole 197. In an alternate embodiment, threaded stanchion 196 extends through hole 197 and is retained in place by a nut 198. The width of each foot 195 is sufficient so that it extends from edge 909 or the base of tab 922 to edge 906 or the base of tab 920, thereby supporting end cap 120.

In use, side rails 102 and 104 are connected to end rails 106 and 108 via end caps 120, 122, 124, and 126. At each corner of mattress frame 100, tabs 920 and 922 are inserted into slots 412 and gaps 410. The corners and ribs are joined with a press fit. The press fit results in a strong, yet quiet attachment. The attachment is particularly strong due to the encapsulated steel ribs and the press fit between the rails and the end caps. Further, the connection is quiet because of the isolation of the steel ribs from other steel parts and the low friction between the joined plastic pieces. Additional tools or connecting hardware are not required to assemble mattress frame 100. Ribs 420 and 422 provide extra strength for the side rails and end rails. Mattress frame 100 is then attached to box springs 150 with staples or adhesive as is common in the art.

The preferred method of manufacture of the end rails and side rails includes extrusion through a co-extrusion die such as is known in the art. In the preferred embodiment, the steel insert is fed into the die. The PVC plastic is then extended through the co-extrusion die as the insert material is deployed from a roll. The steel insert is pre-heated through induction heating, or other methods known in the art, until the plastic adjacent the metal insert fuses around and into the metal insert. After cooling, the side rail or end rail may be considered integrally formed or “encapsulated.” Other methods of molding or encapsulation may be used with equal success.

Referring to FIG. 5A, slat 900 is comprised of three sections forming a “U-shape.” Base section 916 is flanked by sections 912 and 914. Sections 912, 914, and 916 surround channel 928. Sections 912 and 914 are both generally perpendicular to base section 916 and are generally parallel to each other. Section 912 includes rib 962. Section 914 includes rib 960. Ribs 960 and 962 are galvanized steel bars running the full length of slat 900. Ribs 960 and 962 provide extra strength for the slats. Referring to FIG. 5B, in an alternate embodiment, rib 963 is a steel channel generally, centrally disposed in the slat.

Referring to FIG. 6, in an alternate preferred embodiment, a single or a plurality of slats are incorporated in mattress frame 100. Lateral slats 940 are positioned perpendicularly to the side rails and parallel to the end rails. Longitudinal slats 950 are parallel to the side rails and perpendicular to the end rails. One end of slat 900 is adjacent to section 404 and rests on slat support 406 of a side rail or end rail while the opposite end of slat 900 is adjacent section 404 and rests on slat support 406 of an opposing side rail or end rail. The center of each lateral slat is supported by, and bonded to a longitudinal slat. In one preferred embodiment, the longitudinal slats and the lateral slats are placed “back to back.” It will be recognized that the number of longitudinal and lateral slats may vary according to anticipated loading. The slats are attached with rivets, staples, suitable adhesive or inductive welding.

Referring to FIG. 7, mattress foundation 1200 includes upper tier 200. Upper tier 200 is comprised of a pair side rails connected to a pair of end rails via end caps. A plurality of rectangular shaped standoffs connects upper tier 200 to mattress frame 100 forming foundation 1200. Side rails 202 and 204 are generally longer than end rails 206 and 208. When assembled, the rails form a generally rectangular shape and are comprised of the dimensions typical of bed frames and mattresses found in the industry. It is understood that different sizes are possible.

Referring to FIG. 6A, side rails 202 and 204 and end rails 206 and 208 have cross-section 1300. End caps 220 are identical to end caps 120 described previously. End caps 220 connect side rails 202 and 204 to end rails 206 and 208. The cross-sectional dimensions of side rails 202 and 204 are identical to the cross-sectional dimensions of end rails 206 and 208. Cross-section 1300 shows that the side rails and end rails are comprised of five sections arranged to form an opening leading to a slot. Each side rail and end rail are integrally formed.

Section 1304 extends generally perpendicularly from slat support 1306. Section 1302 extends from the intersection of section 1304 and slat support 1306 and is generally perpendicular to section 1304. Section 1308 extends generally perpendicularly from section 1302 and is generally parallel with section 1304. Tab support 1314 extends generally perpendicularly from section 1308 in a direction towards section 1304 and is parallel to sections 1302 and 1306. Between tab support 1314 and section 1304 is gap 1310 which leads _to slot 1312. Slot 1312 is generally rectangular but other polygonal shapes would suffice. It is understood that the shape of slot 1312 paired with gap 1310 permits connection with tabs 920 and 922. Section 1304 includes rib 1322 and section 1308 includes rib 1320. Ribs 1320 and 1322 are galvanized steel bars running the full length of each side rail and end rail.

Referring to FIG. 8B, rib 1309 is shown. Rib 1309 is a steel channel generally, centrally disposed within the side rail or both within the side rail and end rail. In a preferred embodiment, the rib is co-extruded with the side rail or both the side rail and end rail.

In other preferred embodiments, the ribs are constructed from the group of steel, steel mesh, fiberglass, Kevlar , aluminum and titanium. Additionally, the ribs include roughened surfaces on both sides to aid in bonding with the plastic encapsulation. The ribs also include holes to reduce weight and aid in bonding with the plastic encapsulation. In other embodiments, the cross-section shape of the ribs is an “I”-beam in order to withstand additional weight. In an alternate preferred embodiment, in order to reduce weight further, the ribs are not present.

Referring to FIG. 9, a plurality of longitudinal slats 1350 extends between end rails 206 and 208. Longitudinal slats 1350 are placed adjacent section 1304 and slat support 1306 of opposing end rails with the U-shape facing downwards. At least one longitudinal slat 1350 should be affixed at the midpoints of the end rails. Longitudinal slats 1350 are generally parallel and, in the preferred embodiment, are spaced at least three inches from one another and the side rails. Greater space between the slats is possible if desired. In a preferred embodiment, upper tier 200 contains at least two lateral slats 1340. Lateral slats 1340 extend between side rails 202 and 204 with the U-shape facing downwards. Lateral slats 1340 are placed adjacent sections 1306 and 1302 and are flush with section 1308 of both side rails. Additional lateral slats may be incorporated for additional strength. The longitudinal slats and the lateral slats are attached to the respective side rails and end rails with rivets or staples. Additionally, adhesive or inductive welding may also be used.

Rectangular standoffs 216 and 217 are positioned between upper tier 200 and mattress frame 100. One end of each standoff 216 abuts sections 406 and 404 of the side rails of mattress frame 100. The opposite end of each standoff 216 engages channel 928 of lateral slats 1340 of upper tier 200. Standoffs 217 abut sections 406 and 404 of the end rails of mattress frame 100 and contact section 1306 of the end rails of upper tier 200. Standoffs 216 and 217 may also be located such that drawers may be incorporated into mattress foundation 1200. Standoffs 216 and 217 can be pinned to the side rails, end rails, and slats with rivets or staples. Additionally, adhesive or inductive welding may also be used to attach the standoffs to the rails.

Four cylindrical standoffs 218 connect upper tier 200 to mattress frame 100. The four cylindrical standoffs 218 are located at the corners of mattress foundation 1200. An additional cylindrical standoff 222 connects the lateral and longitudinal centers of mattress frame 100 and upper tier 200. Standoffs 218 and 222 can be attached with rivets or similar attachment hardware as is common in the art. Additionally, adhesive or inductive welding may also be used to attach the standoffs to the slats. Standoff 220 may also be attached with through bolts 219 or other means known in the art.

It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.

Claims

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.