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.

The following is claimed: 
     
         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.