Plastic mattress foundation
View Patent ↗A mattress assembly supporting a mattress and occupants is constructed substantially of plastic material. A mattress foundation defined by a semi-rigid cavity includes a generally flat top surface and at least one sidewall depending from the top surface. For pliability and structural weight reduction, the foundation may be ribbed, with air spaces formed therein. Ground support members may be used to retain the foundation in a substantially horizontal orientation above ground. To reinforce the foundation's structural integrity, support braces connecting opposing sidewall portions may be used. The braces may be detachable or integrally formed with the foundation. The assembly may include a headboard. To ease transport, casters may be included with the foundation. The assembly may be constructed of extruded or assembled plastic pieces; molded plastic; recyclable plastic; plastic reinforced with metal core, metal fiber, glass fiber, carbon fiber, resin or a combination of these.
1. A mattress assembly constructed substantially of plastic material, comprising:
a. a mattress foundation comprising:
i. a generally planar and essentially rigid top surface having an upper side and a lower side, the lower side of the top surface including at least one reinforcing fin, oriented perpendicularly to the lower side and extending along a portion of the lower side; and
ii. at least one essentially rigid sidewall, having a lower edge and at least one pair of grooves disposed on opposing portions of the at least one sidewall, the sidewall extending substantially along the perimeter of the lower side of the top surface, depending downward from the top surface, defining a cavity;
b. a frame assembly comprising a plurality of ground support members supporting the foundation, depending downward from the lower edge of the at least one sidewall, holding the foundation above ground, and maintaining the top surface in a substantially horizontal orientation; and
c. at least one brace connecting opposing portions of the at least one sidewall, said at least one brace having end sections configured to latchingly engage with the grooves so as to prevent outward deflection of the opposing portions of the at least one sidewall.
2. The assembly of claim 1 , wherein each of the ground support members is removably or irremovably attached to the foundation.
3. The assembly of claim 1 , wherein at least one of the ground support members is attached to the foundation by a mating configuration.
4. The assembly of claim 3 , wherein the mating configuration is selected from the group consisting of: tongue-and-groove, dovetail, and any combination thereof.
5. The assembly of claim 1 , wherein at least one of the ground support members is integrally formed with the foundation.
6. The assembly of claim 1 , wherein each of the ground support members has a cross-sectional shape selected from the group consisting of: +shape, X shape, U shape, D shape, H shape, Z shape, C shape, V shape, M shape, B shape, T shape, circular shape, elliptical shape, L shape, heart shape, and any combination thereof.
7. The assembly of claim 1 , wherein the perimeter of the top surface is polygonal.
8. The assembly of claim 7 , wherein the polygon is selected from the group consisting of: a square and a rectangle.
9. The assembly of claim 8 , wherein the foundation comprises four sidewalls.
10. The assembly of claim 9 , wherein the foundation comprises four ground support members essentially located at four lower corners of the foundation.
11. The assembly of claim 1 , wherein the perimeter of the top surface has a shape selected from the group consisting of: a circle, an ellipse, and a heart.
12. The assembly of claim 1 , wherein the top surface is ribbed, having air spaces formed therein.
13. The assembly of claim 1 , wherein the top surface has at least one region of continuous plastic spanning a substantially central portion of the top surface, tying together opposing portions of the at least one sidewall.
14. The assembly of claim 1 , wherein the at least one sidewall is corrugated.
15. The assembly of claim 1 , wherein the at least one sidewall comprises non-planar components that increase structural resistance to undesirable deflections from load weights.
16. The assembly of claim 1 , further comprising at least one truss structure adjoining, and structurally reinforcing, opposing portions of the at least one sidewall.
17. The assembly of claim 1 , wherein the upper side of the top surface further includes a first mating structure, and an edge region of the at least one sidewall further includes a second mating structure adapted to engage with the first mating structure, thereby allowing a plurality of mattress foundations to be securely stacked.
18. The assembly of claim 1 , further including a headboard tangentially extending vertically along one end of the foundation.
19. The assembly of claim 18 , wherein the headboard is removably attached to the foundation.
20. The assembly of claim 18 , wherein the headboard is integrally formed with the foundation.
21. The assembly of claim 18 , wherein the headboard is constructed substantially of plastic material.
22. The assembly of claim 1 , wherein the foundation further includes a plurality of openings for receiving casters, the casters being used for easy rolling of the foundation.
23. The assembly of claim 22 , wherein each of the plurality of casters is removably attached to the foundation by a latching configuration selected from the group consisting of: tongue-and-groove and dovetail.
24. The assembly of claim 1 , wherein each of the at least one pair of grooves receiving one end of the at least one brace has a dovetail configuration.
25. The assembly of claim 1 , wherein at least one of the at least one brace includes a non-planar reinforcing structure.
26. The assembly of claim 1 , wherein at least one of the at least one brace is ribbed, having air spaces formed therein.
27. The assembly of claim 1 , wherein the lower side of the top surface further comprises at least one reinforcing truss, oriented perpendicularly to the lower side and extending between opposing sides of the at least one sidewall.
28. The assembly of claim 1 , wherein the plastic material comprises recyclable plastic.
29. The assembly of claim 1 , wherein the plastic material comprises molded plastic.
30. The assembly of claim 29 , wherein the molded plastic is constructed by a molding technique selected from the group consisting of: compression molding, injection molding, gas-assisted injection molding, vacuum molding, low-pressure molding, blow molding, and any combination thereof.
31. The assembly of claim 1 , wherein the foundation comprises extruded and assembled plastic pieces.
32. The assembly of claim 1 , wherein the foundation is constructed, at least in part, of at least one non-plastic structural member covered by plastic.
33. The assembly of claim 32 , wherein the at least one non-plastic structural member is metal.
34. The assembly of claim 1 , wherein the plastic material includes reinforced plastic.
35. The assembly of claim 34 , wherein the reinforced plastic contains material selected from the group consisting of: glass fiber, carbon fiber, metal fiber, resin, and any combination thereof.
36. The assembly of claim 1 , wherein the plastic material is selected from the group consisting of: polyurethane, polyethylene, polystyrene, polyvinyl chloride, polypropylene, a moldable plastic, and any combination thereof.
37. A mattress foundation constructed substantially of plastic material, comprising:
a. a generally planar and essentially rigid top surface having an upper side and a lower side, the top surface having at least one reinforcing fin, oriented perpendicularly to the lower side and extending along a portion of the lower side;
b. at least one essentially rigid sidewall extending substantially along the perimeter of the lower side of the top surface downward from the top surface and having at least one pair of grooves disposed on opposing portions of the at least one sidewall, defining a cavity; and
c. at least one structurally reinforcing brace extending along the lower side of the top surface, connecting opposing portions of the at least one sidewall, said at least one brace having end sections configured to latchingly engage with the grooves so as to prevent outward deflection of the opposing portions of the at least one sidewall.
38. The foundation of claim 37 , wherein each of the at least one pair of grooves receives one end of the at least one brace by a mating dovetail configuration.