Bed foundation

Abstract

A bed foundation has a rectangular top panel and opposite side and end panels depending downwardly from the top panel to form a box-like enclosure having an open lower end, the panels being formed integrally. A support structure of raised ribs in a predetermined regular pattern is formed integrally on the lower surface of the top panel. The foundation is made entirely or substantially entirely from an expanded rigid plastic foam material with high flame retardancy.

1 . A bed foundation, comprising: 
 a rectangular top panel having opposite sides, opposite ends, and four corners, a pair of side panels depending downwardly from opposite sides of the top panel, and a pair of end panels depending downwardly from opposite ends of the panel;    the panels being formed integrally to form a unitary box-like enclosure having an open lower end, and being of expanded rigid plastic foam material;    the top panel having an upper surface and a lower surface; and    a support structure formed integrally on the lower surface of the top panel, the support structure comprising raised ribs forming a predetermined regular pattern.    
     
     
         2 . The foundation as claimed in  claim 1 , wherein the support structure comprises first and second sets of parallel ribs which intersect at an angle to one another to form a lattice.  
     
     
         3 . The foundation as claimed in  claim 1 , wherein some of the ribs are thicker than others.  
     
     
         4 . The foundation as claimed in  claim 2 , wherein the lattice has a rectangular pattern.  
     
     
         5 . The foundation as claimed in  claim 3 , wherein the lattice has a triangular pattern.  
     
     
         6 . The foundation as claimed in  claim 1 , wherein the support structure has a hexagonal pattern.  
     
     
         7 . The foundation as claimed in  claim 1 , wherein the support structure has an octagonal pattern.  
     
     
         8 . The foundation as claimed in  claim 1 , wherein the foam is selected from the group consisting of phenolic, urethane, and poly-isocyanate rigid foam.  
     
     
         9 . The foundation as claimed in  claim 8 , wherein the foam contains at least one additive selected from the group consisting of anti-oxidants, dyes, and mold release agents.  
     
     
         10 . The foundation as claimed in  claim 1 , wherein the top panel has a plurality of air holes extending over its entire area for providing airflow to a mattress supported on the foundation.  
     
     
         11 . The foundation as claimed in  claim 10 , wherein each air hole has a diameter in the range from 0.5 inches to 4 inches.  
     
     
         12 . The foundation as claimed in  claim 1 , wherein at least one of the side and end panels has an opening, and a drawer is slidably mounted in the opening for movement between open and closed positions.  
     
     
         13 . The foundation as claimed in  claim 1 , wherein the side and end panels have outer surfaces which are textured to produce a predetermined pattern.  
     
     
         14 . The foundation as claimed in  claim 13 , wherein the pattern simulates a quilted pattern.  
     
     
         15 . The foundation as claimed in  claim 1 , wherein the top panel has a textured, slip resistant upper surface.  
     
     
         16 . The foundation as claimed in  claim 1 , further comprising a leg adapter at each corner of the enclosure, each leg adapter having a lower open end and a bore extending upwardly from the lower open end for receiving the end of a support leg for supporting the enclosure at a position raised above a floor surface.  
     
     
         17 . The foundation as claimed in  claim 16 , wherein an additional leg adapter is provided at the center of the enclosure.  
     
     
         18 . The foundation as claimed in  claim 16 , wherein each leg adapter comprises a hollow post of square cross-section extending from the upper panel to the open lower end of the enclosure.  
     
     
         19 . The foundation as claimed in  claim 1 , wherein the side panels each have at least one opening.  
     
     
         20 . The foundation as claimed in  claim 19 , wherein the openings are rectangular.  
     
     
         21 . The foundation as claimed in  claim 20 , including two drawer units, each drawer unit being adapted for releasable slidable engagement through the opening in a respective side panel.  
     
     
         22 . The foundation as claimed in  claim 19 , wherein the openings are circular.  
     
     
         23 . The foundation as claimed in  claim 19 , wherein the openings extend over at least 50% of the total surface area of the respective panel.  
     
     
         24 . The foundation as claimed in  claim 1 , wherein one end panel has horizontal slots for mounting of a head board.  
     
     
         25 . The foundation as claimed in  claim 1 , wherein the foam is of the closed cell variety.  
     
     
         26 . The foundation as claimed in  claim 1 , wherein the foam has a density in the range from 5 to 20 pounds per cubic foot.  
     
     
         27 . The foundation as claimed in  claim 2 , wherein the two sets of ribs comprise a first set of spaced longitudinal ribs extending between the opposite end panels and a second set of spaced transverse ribs extending between the opposite side walls.  
     
     
         28 . The foundation as claimed in  claim 27 , wherein at least the transverse ribs are of varying height, the transverse ribs having a height which increases from a minimum height at the end wall to a maximum height at the center of the enclosure.  
     
     
         29 . The foundation as claimed in  claim 27 , wherein each rib has opposite ends at a junction with the respective opposite side or end panels of the enclosure, each end having an extension extending towards the open end of the enclosure for providing edge support to the foundation.  
     
     
         30 . The foundation as claimed in  claim 1 , wherein the foam material is a composite material containing a filler material which is s elected from the group consisting of particulate and fibrous fillers for plastic composite materials.  
     
     
         31 . The foundation as claimed in  claim 30 , wherein the filler material is in the range from 1% by weight to 49% by weight.  
     
     
         32 . A bed foundation, comprising: 
 the top panel, and a pair of end panels depending downwardly from opposite ends of the panel to form a box-like enclosure having an open lower end, the panels being of plastic material; 
 at least one of the side or end panels having an opening; and  
 a drawer slidably mounted in the opening for movement between an open position providing access to the drawer, and a closed position flush with the respective panel.  
   
     
     
         33 . The foundation as claimed in  claim 32 , wherein the box like enclosure and drawer are formed of expanded rigid plastic foam material.  
     
     
         34 . The foundation as claimed in  claim 33 , wherein the top panel, side and end panels each have an inner surface, and a lattice support structure comprising first and second sets of intersecting ribs is formed integrally on the inner surface of the support panel and extends up to the inner surfaces of the side and end panels.  
     
     
         35 . The foundation as claimed in  claim 32 , wherein the top panel has a plurality of air holes extending over its entire surface.  
     
     
         36 . A bed foundation, comprising: 
 a rectangular top panel having opposite sides and opposite ends;    a pair of side panels and a pair of end panels depending downwardly from the sides and ends of the top panel, respectively, to form a box-like enclosure having an open lower end;    the top panel, side panels, and end panels being molded integrally in one piece from expanded rigid plastic foam material; and    the top panel having a plurality of openings.