MATTRESS FOUNDATION KIT

Abstract

Disclosed is a mattress foundation kit configured to be assembled by a user. The mattress foundation kit may include a plurality of rails, wherein each rail is a longitudinal member constructed of a structural foam core connected, for example by being permanently laminated, with at least one supporting material. Further, the mattress foundation kit may include a plurality of interconnecting members corresponding to the plurality of rails. Moreover, the mattress foundation kit may include a plurality of retainer clips attached along a side of at least two rails of the plurality of rails. Yet further, the mattress foundation kit may include a plurality of slats corresponding to the plurality of retainer clips, wherein the plurality of slats is configured to support a mattress, wherein each end of a slat is configured to detachably engage with a corresponding retainer clip.

Description

FIELD OF INVENTION

The present disclosure generally relates to a mattress foundation. More specifically, the present disclosure relates to a knock down mattress foundation kit.

BACKGROUND OF THE INVENTION

Conventional bedding structures commonly have separate bedding components which together form a system having an upper mattress resting on top of a mattress foundation, which in turn rests over a floor surface. In some cases, the mattress foundation may be supported by legs extending from the mattress foundation towards the floor surface. Mattress foundations provide support and firmness to the mattress. Foundations are typically constructed of a frame, such as a rectangular frame including perimeter members and internal members.

With the rise of e-commerce, end users may order mattress foundations online. However, traditional mattress foundations are generally sold as single units. Therefore, they require freight or truck carriers to be delivered to an end user. This causes increased cost and delays in delivering the mattress foundation to end users.

Further, it is challenging to carry the mattress foundations in high rise buildings. The mattress foundations must traverse stairs or freight elevators in the high-rise buildings to arrive to the end user.

Accordingly, there is a need for improved mattress foundations that may be transported easily to end users.

SUMMARY OF THE INVENTION

Disclosed is a mattress foundation kit configured to be assembled by a user. The mattress foundation kit may include a plurality of rails. Further, each rail may be a longitudinal member. In an embodiment, each rail may be constructed of, for example, a structural foam core connected, for example by being permanently laminated, with at least one supporting material. Furthermore, the mattress foundation kit may include a plurality of interconnecting members corresponding to the plurality of rails. Moreover, the mattress foundation kit may include a plurality of retainer clips attached along a side of at least two rails of the plurality of rails. Yet further, the mattress foundation kit may include a plurality of slats corresponding to the plurality of retainer clips. In some embodiments, the plurality of slats may be configured to support a mattress such that each end of a slat may be configured to detachably engage with a corresponding retainer clip.

According to some aspects, a method of manufacturing a mattress foundation kit is disclosed. The method may include permanently laminating at least one supporting material onto each rail of a plurality of rails. Further, each rail may be a longitudinal member. In an embodiment, each rail may be constructed of, for example, a structural foam core. Furthermore, the method may include permanently laminating a plurality of interconnecting members onto the plurality of rails. Additionally, each interconnecting member may be connected, for example by being permanently laminated, to at least one part of a corresponding rail of the plurality of rails. Moreover, a first interconnecting member of a first rail of the plurality of rails may be configured to detachably engage with a second interconnecting member of a second rail of the plurality of rails. Finally, the method may include attaching a plurality of retainer clips along a side of at least two rails of the plurality of rails. Further, each retainer clip may be configured to detachably engage with a slat of a plurality of slats configured to support a mattress.

According to some aspects, a mattress foundation kit is disclosed. The kit may be configured to be assembled by a user. The mattress foundation kit may include a plurality of rails, a plurality of interconnecting members corresponding to the plurality of rails, a plurality of retainer clips attached along a side of at least two rails of the plurality of rails, a plurality of slats and a plurality of securing members.

According to some further aspects, the plurality of interconnecting members includes a plurality of male interconnecting members and a plurality of female interconnecting members. A male interconnecting member may be configured to detachably engage with a female interconnecting member. Further, the plurality of rails may be interconnected using the interconnecting members to form a rectangular-shaped or a square shaped frame.

According to some further aspects, the rectangular-shaped or the square shaped frame may also include one or more mid rails to provide support to the frame.

According to some aspects, the mattress foundation kit may include a plurality of rails, a plurality of interconnecting members corresponding to the plurality of rails, a plurality of retainer clips attached along a side of at least two rails of the plurality of rails, a plurality of slats, a plurality of securing members and a plurality of legs corresponding to the plurality of rails. The plurality of legs may be configured to support the mattress foundation on the ground such that at least one end portion of each leg is configured to be detachably attached to an interconnecting member on a corresponding rail of the plurality of rails.

According to some further aspects, at least one rail of the plurality of rails of the mattress foundation kit may include a drawer opening configured to receive a drawer configured to function as a storage compartment.

According to some further aspects. a knock down mattress foundation kit is disclosed. The mattress foundation kit may be light weight, compact and can be easily assembled by an end user. The mattress foundation kit may be designed for internet sales to accompany internet sales of mattresses. Accordingly, the mattress foundation kit may be stored in a box of a certain volume, such that the mattress foundation kit may be shipped through courier services, such as, but not limited to, FedEx and UPS, without necessarily requiring transport through large vehicles such as trucks. For example, the mattress foundation kit may be capable of being stored within a volume represented by dimensions of 9″, 10″, and 80″.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an illustration of a mattress foundation kit in accordance with some embodiments.

FIG. 1B is an illustration of a plurality of slats comprised in the mattress foundation kit of FIG. 1A.

FIG. 2 is a close-up view of a portion of the mattress foundation kit of FIG. 1A illustrating mating of a male interconnecting member and a female interconnecting member attached to the plurality of rails.

FIG. 3 is a close-up view of a portion of the mattress foundation kit of FIG. 1A illustrating engagement of a mid rail with an end rail.

FIG. 4 is a close-up view of a portion of the mattress foundation kit of FIG. 1A illustrating a plurality of retainer clips attached to a side of a rail.

FIG. 5 is a perspective view of a mattress foundation built using the mattress foundation kit of FIG. 1A.

FIG. 6 is a top view of the mattress foundation of FIG. 5.

FIG. 7 illustrates multiple views of a corner male interconnecting member for a rail of the mattress foundation kit of FIG. 1A.

FIG. 8 illustrates multiple views of a corner female interconnecting member for a rail of the mattress foundation kit of FIG. 1A.

FIG. 9 illustrates multiple views of a mid rail male interconnecting member of the mattress foundation kit of FIG. 1A.

FIG. 10 illustrates multiple views of a mid rail female interconnecting member of the mattress foundation kit of FIG. 1A.

FIG. 11 illustrates multiple views of a securing member for interconnecting the rails of the mattress foundation kit of FIG. 1A.

FIG. 12 is a flowchart depicting a method for manufacturing the mattress foundation kit of FIG. 1A in accordance with some embodiments.

DETAIL DESCRIPTIONS OF THE INVENTION

All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.

This overview is provided to introduce a selection of concepts in a simplified form that are further described below. The overview is not intended to identify key features or essential features of the claimed subject matter. Further, the overview is not intended to be used to limit the claimed subject matter's scope.

The present disclosure relates generally to a knock down mattress foundation kit that may, in some embodiments, be light weight, compact and easily assembled by an end user. The mattress foundation kit may be designed for internet sales to accompany internet sales of mattresses. Accordingly, the mattress foundation kit may be stored in a box of a certain volume, such that the mattress foundation kit may be shipped using courier services, without necessarily requiring transport through large vehicles such as trucks.

Disclosed is a mattress foundation kit 100 configured to be assembled by a user. FIG. 1A illustrating a mattress foundation kit 100 in accordance with some embodiments. The mattress foundation kit 100 includes multiple rails 102, 104, 106, 108, and 110. The multiple rails 102, 104, 106, 108, and 110 may be configured to form, for example, a rectangular frame of a mattress foundation. The multiple rails 102, 104, 106, 108, and 110 may include a pair of side rails 102 and 106, a pair of end rails 104 and 108 and a mid rail 110. Each rail may be a longitudinal member constructed of, for example, but not limited to, a structural foam core connected, for example by being permanently laminated, with a supporting material. In general, the plurality of rails may be constructed of a strong and light weight material. The supporting material may be, but is not limited to, wood, plastic, metal, and composite material. Further, each of a top side and a bottom side of the structural foam core may be connected, for example by being permanently laminated, with the supporting material.

The pair of side rails 102 and 106 may form the longer sides of the rectangular frame of the mattress foundation. Likewise, the pair of end rails 104 and 108 may form the shorter sides of the rectangular frame. A first end portion 112 of the mid rail 110 may be configured to be detachably engaged with one rail (say, the end rail 104) of the pair of end rails 102 and 106. A second end portion 114 of the mid rail 110 may be configured to be detachably engaged with the other rail (say, the end rail 108) of the pair of end rails 102 and 106.

The multiple rails 102, 104, 106, 108, and 110 may further include multiple interconnecting members 116, 118, 120, 122, 124, 126, 128, 130, 132, 134, 136 and 138. Each interconnecting member may be connected, for example by being permanently laminated, to at least one part of a corresponding rail of the multiple rails 102, 104, 106, 108 and 110. Alternatively, in some embodiments, each interconnecting member may be detachably connectable to a corresponding rail. Additionally, in some embodiments, each of a rail and corresponding one or more interconnecting members may be integrally formed. For example, a rail with a pair of interconnecting members disposed on either ends of the rail may be formed using a single mold, using for instance, an injection molding process. Alternatively, each of the rail and the pair of interconnecting members may be separately formed and connected together thereafter.

Further, a first interconnecting member of a first rail of the multiple rails 102, 104, 106, 108 and 110 may be configured to detachably engage with a second interconnecting member of a second rail of the multiple rails 102, 104, 106, 108 and 110. This is explained in further detail in conjunction with FIGS. 2-4 below which show close-up views of regions 140, 142 and 144.

The multiple interconnecting members 116, 118, 120, 122, 124, 126, 128, 130, 132, 134, 136 and 138 further include multiple corner male interconnecting members 116, 120, 124 and 128, and multiple mid rail male interconnecting members 132 and 136. The multiple interconnecting members 116, 118, 120, 122, 124, 126, 128, 130, 132, 134, 136 and 138 further include multiple corner female interconnecting members 118, 122, 126, and 130, and multiple mid rail female interconnecting members 134 and 138. The multiple male interconnecting members 116, 120, 124, 128, 132 and 136 and the multiple corner female interconnecting members 118, 122, 126, 130 may be connected, for example by being permanently laminated, to an end portion of a corresponding rail. Further, the multiple mid rail female interconnecting members 134 and 138 may be connected, for example by being permanently laminated, to a side portion of the end rails 104 and 108 respectively. A male interconnecting member is configured to detachably engage with a female interconnecting member. Additionally, in some embodiments, the male interconnecting member may be engaged with the female interconnecting member through a locking mechanism in order to secure the engagement against, for example, weight of a mattress and/or a user on the mattress foundation.

The multiple corner male interconnecting members 116, 120, 124 and 128 are explained in detail in conjunction with FIGS. 7A-H. The multiple corner female interconnecting members 118, 122, 126, and 130 are explained in detail in conjunction with FIGS. 8A-H. The multiple mid rail male interconnecting members 132 and 136 are explained in detail in conjunction with FIGS. 9A-H. The multiple mid rail female interconnecting members 134 and 138 are explained in detail in conjunction with FIGS. 10A-H.

The mattress foundation kit 100 may further include multiple slats 146 shown in FIG. 1B. The multiple slats 146 may be configured to support a mattress. This is explained in further detail in conjunction with FIG. 4 below.

Yet further, the mattress foundation kit 100 may include multiple securing members 148, 150, 152 and 154 corresponding to the multiple male interconnecting members 116, 120, 124, 128, 132 and 136, and the multiple female interconnecting members 118, 122, 126, 130, 134 and 138.

Referring to FIG. 2, a close-up view of a portion 140 of the mattress foundation kit 100 is shown. The corner male interconnecting member 120 is shown attached to the end rail 104. The corner female interconnecting member 118 is shown attached to the side rail 102. The corner male interconnecting member 120 may detachably engage with the corner female interconnecting member 118. Thereafter, the securing member 148 may be used to detachably engage with each of the corner male interconnecting member 120 and the corner female interconnecting member 118. Accordingly, the securing member 148 secures the engaged interconnecting members. The securing member 148 may be, but not limited to, a machine screw, a sheet metal screw, a wood screw, an eye bolt, a socket screw, an elevator bolt and a pin. For instance, some mechanisms used for the securing member 148 may be attached and detached without use of tools, while others may require use of a tool. Further, in some embodiments, the securing member 148 may be formed as a wedge.

Referring to FIG. 3, a close-up view of a portion 142 of the mattress foundation kit 100 is shown. The mid rail male interconnecting member 132 is shown attached at the end 112 of the mid rail 110. The mid rail female interconnecting member 134 is shown attached to a side of the end rail 104. The mid rail male interconnecting member 132 may be detachably engaged with the mid rail female interconnecting member 134 by inserting the mid rail male interconnecting member 132 within the mid rail female interconnecting member 134.

Referring to FIG. 4, a close-up view of a portion 144 of the mattress foundation kit 100 is shown. Each of the side rails 102 and 106 include multiple retainer clips 156 attached along the length of each side rail 102, 106. The mattress foundation kit 100 includes the multiple slats 146 corresponding to the multiple retainer clips 156. Each end of a slat is configured to detachably engage with a corresponding retainer clip. The multiple slats are configured to support a mattress. The multiple slats 156 may be constructed using one or more of wood, plastic, metal, and composite material. Further, in some embodiments, each slat of the multiple slats 156 may be shaped as a rod.

As mentioned before, the mattress foundation kit 100 of FIG. 1A may be configured to be assembled by a user. The user may first engage the multiple rails 102, 104, 106, 108, and 110 to form, for example, a rectangular frame. For example, the user may engage the side rail 102 with the end rail 104, the end rail 104 with the side rail 106, the side rail 106 with the end rail 108 and the end rail 108 with the side rail 102 to form the rectangular frame of the mattress foundation 500. However, in other embodiments, the mattress foundation kit 100 may enable the user to form a frame in the shape of a regular and/or an irregular polygon. Then, the user may engage the multiple slats 146 with the multiple retainer clips 156 to obtain the mattress foundation 500 shown in FIG. 5. A top view of the mattress foundation 500 is shown in FIG. 6.

FIGS. 7A-H illustrate multiple views of the corner male interconnecting member 120 of the mattress foundation 100. Specifically, FIG. 7A illustrates a front view, 7B a back view, 7C a right side view, 7D a left side view, 7E a top view, 7F a bottom view, 7G a first perspective view and 7H a second perspective view.

The corner male interconnecting member 120 may include a clip 702 with a U-shaped cross-section (shown in FIGS. 7E and 7F). For example, the clip 702 may be made of sheet metal folded over in a U-shaped profile to provide parallel clip faces and one of the clip faces has at least one slit bordering a strip of the sheet metal which is bowed out. The height 704 of the clip 702 may be approximately same as the height of the end rail 104. Further, the width 706 of the clip 702 may be slightly more than the width of the end rail 104, such that the clip 702 can be secured to the end rail 104. The back side of the clip 702 includes a cylindrical sleeve 708. The height of the sleeve 708 may be roughly half the height of the clip 702. The cylindrical sleeve 708 may be located at the center of back of the clip 702. The cylindrical sleeve 708 may be hollow and include a cylindrical hole 710 along the length of the cylindrical sleeve 708 and inside the cylindrical sleeve 708.

FIGS. 8A-H illustrates multiple views of the corner female interconnecting member 118 of the mattress foundation kit 100. Specifically, FIG. 8A illustrates a front view, 8B a back view, 8C a right side view, 8D a left side view, 8E a top view, 8F a bottom view, 8G a first perspective view and 8H a second perspective view.

The corner female interconnecting member 118 may include a clip 802 with a U-shaped cross-section, similar to the clip 702. The height 804 of the clip 802 may be approximately same as the height of the side rail 102. Further, the width 806 of the clip 802 may be slightly more than the width of the side rail 102, such that the clip 802 can be secured to the side rail 102. The back side of the clip 802 includes two cylindrical sleeves 808 and 810. The cylindrical sleeve 808 is hollow and includes a cylindrical hole 812 along the length of the cylindrical sleeve 808 and inside the cylindrical sleeve 808. Similarly, the cylindrical sleeve 810 is hollow and includes a cylindrical hole 814 along the length of the cylindrical sleeve 810 and inside the cylindrical sleeve 810. The combined total height of the two sleeves 808 and 810 may be roughly half the height of the clip 802. The cylindrical sleeves 808 and 810 may be separated, which creates a receptacle 816 between them. The height of the receptacle 816 may be slightly more than the height of the sleeve 708, such that the receptacle 816 may receive the cylindrical sleeve 708. When the cylindrical sleeve 708 is placed in the receptacle 816, the three cylindrical holes 710, 812 and 814 align, such that a securing member 148 (such as the pin 148) may pass through the three cylindrical holes 710, 812 and 814. Accordingly, the pin may secure the side rail 102 and the end rail 104. Similarly, the end rail 104 and the side rail 106 may be secured. Further, the side rail 106 and the end rail 108 may be secured. Finally, the end rail 108 and the side rail 102 may be secured to form, for example, a rectangular frame of the mattress foundation 500.

FIGS. 9A-H illustrates multiple views of the mid rail male interconnecting member 132 of the mattress foundation kit 100. Specifically, FIG. 9A illustrates a right side view, 9B a left side view, 9C a front view, 9D a back view, 9E a top view, 9F a bottom view, 9G a first perspective view and 9H a second perspective view.

The mid rail male interconnecting member 132 includes a clip 902 with a U-shaped cross-section, similar to the clip 702. The height 904 of the clip 902 may be approximately same as the height of the mid rail 110. Further, the width 906 of the clip 902 may be slightly more than the width of the mid rail 110, such that the clip 902 may be secured to the mid rail 110. The back side of the clip 902 may include a rectangular projection 908.

FIGS. 10A-H illustrates multiple views of the mid rail female interconnecting member 134 of the mattress foundation kit 100. Specifically, FIG. 10A illustrates a front view, 10B a back view, 10C a left side view, 10D a right side view, 10E a top view, 1° F. a bottom view, 10G a first perspective view and 10H a second perspective view.

The mid rail female interconnecting member 134 may generally have a rectangular shape with a rectangular depression 1002 in the middle of the mid rail female interconnecting member 134. The rectangular depression 1002 is closed from five sides. However, it is an opening 1004. Further, the size of the rectangular depression 1002 may be slightly bigger than the rectangular projection 908 such that at least a portion of the rectangular projection 908 fits inside the rectangular depression 1002.

The rectangular depression 1002 may also have two holes 1006, 1008 on two opposite sides of the rectangular depression 1002. Further, the rectangular projection 908 may have a hole (not shown) across its breadth. When the rectangular projection 908 is placed inside the rectangular depression 1002, the hole on the rectangular projection 908 and the two holes 1006, and 1008 may align such that a pin may secure the mid rail male interconnecting member 132 and the mid rail female interconnecting member 134 together.

FIGS. 11A-E illustrates multiple views of the securing member 148 for interconnecting the rails of the mattress foundation kit 100. Specifically, FIG. 11A illustrates a side view, 11B a top view, 11C a bottom view, 11D a first perspective view and 11E a second perspective view.

The securing member 148 may have sufficient length to be able to pass through the holes in the respective interconnecting members (for example, the holes 710, 812, 814) and secure the same. In some embodiments, the securing member 148 may have a threaded portion that may engage with a nut. Alternatively, the holes in the respective interconnecting members (for example, the holes 710, 812, 814) may be threaded from inside to engage with the threads on the securing member 148. Further, securing member 148 may be hollow along the length of the securing member 148, such that in includes a hole 1102.

FIG. 12 is a flowchart depicting a method 1200 for manufacturing the mattress foundation kit of FIG. 1A in accordance with some embodiments. At step 1202, the method 1200 includes permanently laminating at least one supporting material onto each rail of the multiple rails (for example the multiple rails 102, 104, 106, 108 and 110). Each rail is a longitudinal member constructed of, for example, but not limited to, a structural foam core.

Next, at step 1204, the method 1200 includes permanently laminating multiple interconnecting members (for example, the multiple interconnecting members 116, 118, 120, 122, 124, 126, 128, 130, 132, 134, 136 and 138) onto the multiple rails. Each interconnecting member is connected, for example by being permanently laminated, to at least one part of a corresponding rail of the multiple rails. Further, a first interconnecting member of a first rail of the plurality of rails is configured to detachably engage with a second interconnecting member of a second rail of the multiple rails.

Finally, at step 1206, the method 1200 includes attaching multiple retainer clips along a side of at least two rails of the multiple rails. Each retainer clip is configured to detachably engage with a slat of multiple slats configured to support a mattress.

Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention. Obvious changes, modifications, and substitutions may be made by those skilled in the art to achieve the same purpose the invention. The exemplary embodiments are merely examples and are not intended to limit the scope of the invention. It is intended that the present invention cover all other embodiments that are within the scope of the descriptions and their equivalents.

Claims

1. A mattress foundation kit configured to be assembled by a user, the mattress foundation kit comprising:

a plurality of rails, wherein each rail is a longitudinal member;

a plurality of interconnecting members corresponding to the plurality of rails, wherein each interconnecting member is connected to at least one part of a corresponding rail of the plurality of rails, wherein a first interconnecting member of a first rail of the plurality of rails is configured to detachably engage with a second interconnecting member of a second rail of the plurality of rails;

a plurality of retainer clips attached along a side of at least two rails of the plurality of rails; and

a plurality of slats corresponding to the plurality of retainer clips, wherein each end of a slat is configured to detachably engage with a corresponding retainer clip.

2. The mattress foundation kit of claim 1, wherein each rail is a longitudinal member constructed of a structural foam core connected with at least one supporting material.

3. The mattress foundation kit of claim 2, wherein the at least one supporting material comprises at least one of wood, plastic, metal, and composite material.

4. The mattress foundation kit of claim 2, wherein each of a top side and a bottom side of the structural foam core is connected with the at least one supporting material.

5. The mattress foundation kit of claim 1, wherein the plurality of interconnecting members comprises a plurality of male interconnecting members and a plurality of female interconnecting members, wherein a male interconnecting member is configured to detachably engage with a female interconnecting member.

6. The mattress foundation kit of claim 5 further comprising a plurality of securing members corresponding to the plurality of male interconnecting members and the plurality of female interconnecting members, wherein a securing member is configured to detachably engage with each of a corresponding male interconnecting member and a corresponding female interconnecting member.

7. The mattress foundation kit of claim 6, wherein a securing member comprises a pin.

8. The mattress foundation kit of claim 7, wherein the pin is formed as a wedge.

9. The mattress foundation kit of claim 1, wherein each interconnecting member is connected to an end portion of a corresponding rail.

10. The mattress foundation kit of claim 1, wherein at least one interconnecting member is connected to a side portion of a corresponding rail.

11. The mattress foundation kit of claim 10, wherein at least two interconnecting members are connected to the side portion of the corresponding rail.

12. The mattress foundation kit of claim 1, wherein the plurality of slats is constructed of at least one of wood, plastic, metal, and composite material.

13. The mattress foundation kit of claim 1, wherein each slat of the plurality of slats is shaped as a rod.

14. The mattress foundation kit of claim 1, wherein the plurality of rails comprises each of a pair of side rails, a pair of end rails and a mid-rail, wherein the plurality of rails is configured to form a rectangular frame, wherein the pair of side rails forms the longer sides of the rectangular frame, wherein the pair of end rails forms the shorter sides of the rectangular frame, wherein a first end portion of the mid rail is configured to be detachably engaged with one rail of the pair of end rails, wherein a second end portion of the mid rail is configured to be detachably engaged with the other rail of the pair of end rails.

15. The mattress foundation kit of claim 1, wherein at least one of a side rail, an end rail and a mid rail comprises of a plurality of rails.

16. The mattress foundation kit of claim 1 further comprising a plurality of legs corresponding to the plurality of rails, wherein the plurality of legs is configured to support the mattress foundation on the ground, wherein at least one end portion of each leg is configured to be detachably attached to an interconnecting member on a corresponding rail of the plurality of rails.

17. The mattress foundation kit of claim 1, wherein at least one rail of the plurality of rails comprises a drawer opening configured to receive a drawer configured to function as a storage compartment.

18. The mattress foundation kit of claim 1, wherein at least one rail of the plurality of rails is integrally formed with at least one corresponding interconnecting member of the plurality of interconnecting members.

19. A method of manufacturing a mattress foundation kit, the method comprising:

permanently laminating an at least one supporting material onto each rail of a plurality of rails, wherein each rail of the plurality of rails is a longitudinal member constructed of a structural foam core;

permanently laminating a plurality of interconnecting members onto the plurality of rails, wherein each interconnecting member is connected to at least one part of a corresponding rail of the plurality of rails, wherein a first interconnecting member of a first rail of the plurality of rails is configured to detachably engage with a second interconnecting member of a second rail of the plurality of rails; and

attaching a plurality of retainer clips along a side of at least two rails of the plurality of rails, wherein each retainer clip is configured to detachably engage with a slat of a plurality of slats configured to support a mattress.

20. The method of claim 19, wherein the at least one supporting material comprises at least one of wood, plastic, metal, and composite material.

21. The method of claim 19, wherein each of a top side and a bottom side of the structural foam core is connected with the at least one supporting material.

22. The method of claim 19, wherein the plurality of interconnecting members comprises a plurality of male interconnecting members and a plurality of female interconnecting members, wherein a male interconnecting member is configured to detachably engage with a female interconnecting member.

23. The method of claim 22, wherein each of a male interconnecting member and a female interconnecting member are configured to be secured together by a securing member.

24. The method of claim 23, wherein the securing member comprises a pin.