Modular mattress foundation

Abstract

A mattress foundation has a modular configuration that permits the mattress foundation to be packaged in an unassembled state, in a relatively compact shipping container. The mattress foundation can be used to elevate a mattress with or without the use of a frame.

1 . A modular mattress foundation, comprising:
 a first and a second header;   a first side rail removably attached to the first and second headers;   a second side rail removably attached to the first and second headers; and   a support removably attached to the first and second side rails.   
   
   
       2 . The mattress foundation of  claim 1 , further comprising a plurality of legs, wherein each of the legs is removably attached to one of the first header, the second header, the first side rail, and the second side rail. 
   
   
       3 . The mattress foundation of  claim 1 , wherein the first and second headers each comprise a substantially flat upper member, a substantially flat lower member, and a support block positioned between and attached to the upper and lower members. 
   
   
       4 . The mattress foundation of  claim 3 , wherein outer corners of the upper and lower members are rounded. 
   
   
       5 . The mattress foundation of  claim 4 , wherein the first and second headers each further comprise a radius block positioned between and attached to the upper and lower members of the associated first or second header. 
   
   
       6 . The mattress foundation of  claim 5 , wherein a portion of each of the first and second radius blocks has a radius of curvature that substantially matches a radius of curvature of the outer corners of the upper and lower members. 
   
   
       7 . The mattress foundation of  claim 3 , wherein the first and second headers each further comprise an end support positioned between and attached to the upper and lower members of the associated first or second header. 
   
   
       8 . The mattress foundation of  claim 1 , wherein the first and second side rails each comprise an elongated main portion and a sill attached to the main portion. 
   
   
       9 . The mattress foundation of  claim 8 , wherein the support comprises an elongated slat, and a brace attached to the slat. 
   
   
       10 . The mattress foundation of  claim 9 , wherein the slat has a groove formed therein, and the grove receives a portion of the brace. 
   
   
       11 . The mattress foundation of  claim 9 , wherein the first and second side rails each further comprise a channel attached to the main portion thereof, and the channels each receive an associated end the brace when the support is removably attached to the first and second side rails. 
   
   
       12 . The mattress foundation of  claim 1 , further comprising a center support removably attached to the other support. 
   
   
       13 . The mattress foundation of  claim 12 , further comprising a leg removably attached to the center support. 
   
   
       14 . The mattress foundation of  claim 1 , wherein the first and second headers and the support provide supporting surfaces for a mattress. 
   
   
       15 . The mattress foundation of  claim 1 , further comprising a plurality of the supports. 
   
   
       16 . The mattress foundation of  claim 1 , further comprising a drawer positioned between the first and second headers. 
   
   
       17 . The mattress foundation of  claim 16 , wherein the drawer is suspended from at least one of the first and second headers and the first and second side rails. 
   
   
       18 . The mattress foundation of  claim 1 , further comprising a bracket attached to the first or the second header for mounting a headboard or a footboard on the mattress foundation. 
   
   
       19 . A method, comprising:
 providing a modular mattress foundation;   packaging the modular mattress foundation in an unassembled state at a first location; and   sending the modular mattress foundation to a second location in the unassembled state.   
   
   
       20 . The method of  claim 19 , wherein:
 providing a modular mattress foundation comprises providing a header, a side rail capable of being attached to the header, and a support capable of being attached to the side rail;   packaging the modular mattress foundation in an unassembled state at a first location comprises packaging the header, the side rail, and the cross member in the unassembled state at the first location; and   sending the mattress foundation to a second location in the unassembled state comprises sending the header, the side rail, and the cross member to the second location in the unassembled state.   
   
   
       21 . The method of  claim 19 , wherein packaging the mattress foundation in an unassembled state at a first location comprises placing the mattress foundation in a shipping container. 
   
   
       22 . The method of  claim 21 , wherein the shipping container is a cardboard box. 
   
   
       23 . The method of  claim 20 , wherein:
 providing a modular mattress foundation further comprises providing a plurality of legs;   packaging the modular mattress foundation in an unassembled state at a first location further comprises packaging the legs; and   sending the modular mattress foundation to a second location in the unassembled state further comprises sending the header, the side rail, the cross member, and the legs to the second location in the unassembled state.   
   
   
       24 . The method of  claim 23 , wherein at least one of the legs has a first length and another of the legs has a second length different than the first length. 
   
   
       25 . The method of  claim 20 , wherein:
 providing a modular mattress foundation further comprises providing two of the headers, two of the side rails, at least two of the supports, and a center support;   packaging the modular mattress foundation in an unassembled state at a first location further comprises packaging the two headers, the two side rails, the at least two supports, and the center support at the first location in the unassembled state; and   sending the modular mattress foundation to a second location in the unassembled state further comprises sending the two headers, the two side rails, the at least two supports, and the center support to the second location in the unassembled state.   
   
   
       26 . The method of  claim 25 , wherein:
 the first and second headers each comprise a substantially flat upper member; a substantially flat lower member; a support block positioned between and attached to the upper and lower members; a radius block positioned between and attached to the upper and lower members; and an end support positioned between and attached to the upper and lower members; and   the first and second side rails each comprise an elongated main portion and a sill attached to the main portion.   
   
   
       27 . The method of  claim 19 , wherein sending the components of the mattress foundation to a second location in the unassembled state comprises shipping the components to the second location via a commercial package-delivery service. 
   
   
       28 . The method of  claim 19 , wherein the first location is a place of manufacture for the modular mattress foundation. 
   
   
       29 . The method of  claim 19 , wherein the first location is a centrally-located distribution center. 
   
   
       30 . A method, comprising receiving an order for a modular mattress foundation from a purchaser, and sending the modular mattress foundation to the purchaser in an unassembled condition. 
   
   
       31 . The method of  claim 30 , wherein sending the modular mattress foundation to the purchaser in an unassembled condition comprises sending the modular mattress foundation to the purchaser in a shipping container. 
   
   
       32 . The method of  claim 31 , further comprising packing the modular mattress foundation in the shipping container in the unassembled condition. 
   
   
       33 . The method of  claim 30 , wherein sending the modular mattress foundation to the purchaser in an unassembled condition comprises shipping the modular mattress directly to the purchaser from a place of manufacture of the mattress foundation. 
   
   
       34 . The method of  claim 30 , wherein sending the modular mattress foundation to the purchaser in an unassembled condition comprises shipping the modular mattress directly to the purchaser from a centrally-located distribution center. 
   
   
       35 . The method of  claim 30 , further comprising providing the modular mattress foundation, wherein the modular mattress foundation comprises a first and a second header; a first side rail capable of being removably attached to the first and second headers; a second side rail capable of being removably attached to the first and second headers; and a support capable of being removably attached to the first and second side rails. 
   
   
       36 . The method of  claim 30 , further comprising selecting legs of a predetermined length as part of the modular mattress foundation to provide the mattress foundation with a height specified in the order, and sending the legs to the purchaser as part of the mattress foundation. 
   
   
       37 . A mattress foundation kit, comprising a header, a side rail capable of being removably attached to the header, and a support capable of being removably attached to the side rail. 
   
   
       38 . The kit of  claim 37 , further comprising a shipping container, wherein the header, the side rail, and the support are packed in the shipping container. 
   
   
       39 . The kit of  claim 38 , wherein the shipping container is a cardboard box. 
   
   
       40 . The kit of  claim 37 , further comprising two of the headers, two of the side rails, and at least two of the supports. 
   
   
       41 . The kit of  claim 40 , further comprising a plurality of legs each capable of being removably attached to one or more of the headers and the side rails. 
   
   
       42 . The kit of  claim 41 , wherein the plurality of legs comprises a first set of the legs each having a first length, and a second set of the legs each having a second length different than the first length. 
   
   
       43 . The kit of  claim 40 , wherein the headers each comprise a substantially flat upper member, a substantially flat lower member, and a support block positioned between and attached to the upper and lower members. 
   
   
       44 . The kit of  claim 43 , wherein outer corners of the upper and lower members are rounded, and each of the headers further comprises a radius block positioned between and attached to the upper and lower members of the associated header. 
   
   
       45 . The kit of  claim 44 , wherein a portion of each of the first and second radius blocks has a radius of curvature that substantially matches a radius of curvature of the outer corners of the upper and lower members. 
   
   
       46 . The kit of  claim 40 , wherein each of the headers further comprises an end support positioned between and attached to the upper and lower members of the associated header. 
   
   
       47 . The kit of  claim 40 , wherein the side rails each comprise an elongated main portion and a sill attached to the main portion. 
   
   
       48 . The kit of  claim 40 , wherein each of the supports comprises an elongated slat, and a brace attached to the slat. 
   
   
       49 . The kit of  claim 48 , wherein each of the side rails further comprises a channel attached to the main portion of the side rail, and each of the channels is capable of receiving an end of the brace of an associated one of the supports when the support is removably attached to the side rail. 
   
   
       50 . The mattress foundation of  claim 40 , further comprising a center support capable of being removably attached to the other supports. 
   
   
       51 . The kit of  claim 37 , further comprising a drawer. 
   
   
       52 . The kit of  claim 37 , further comprising a bracket capable of being attached to the header for mounting a headboard or a footboard on the header.