摘要：
A bed foundation includes a frame and one or more panels positioned on top of the frame to define an upper surface of the bed foundation for supporting a mattress. The frame includes a plurality of rails which, when assembled together, at least partially define the frame. The plurality of rails are comprised of a thermoplastic foam that is lighter than wood or other similarly-or heavier-weighted materials commonly utilized in the construction of bed foundations, thereby facilitating easier shipping, lifting, carrying, and assembly of the bed foundation. The one or more panels can also be comprised of thermoplastic foam. The frame can further include a plurality of brackets to interconnect select rails of the frame. A kit for a bed foundation and a method of assembling a bed foundation are also provided.
权利要求：
CLAIMS
What is claimed is:
1. A bed foundation, comprising: a frame including a plurality of rails, the plurality of rails comprised of thermoplastic foam; and one or more panels positioned on top of the frame to define an upper surface of the bed foundation for supporting a mattress.
2. The bed foundation of claim 1, wherein the plurality of rails includes a first set of rails which at least partially define a perimeter of the frame, and a second set of rails interlocked with the first set of rails, the second set of rails defining an interior structure within the perimeter of the frame, and each rail of the second set of rails being interlocked with at least one other rail of the second set of rails.
3. The bed foundation of claim 2, wherein each rail of the second set of rails defines a notch for receiving another rail of the second set of rails.
4. The bed foundation of claim 2, wherein each end of each rail of the second set of rails defines a tenon, and wherein each rail of the first set of rails defines one or more openings in which one of the tenons defined by the second set of rails is received.
5. The bed foundation of claim 1, wherein the frame further includes a plurality of brackets, with each bracket of the plurality of brackets interconnecting two rails of the first set of rails.
6. The bed foundation of claim 5, wherein each bracket of the plurality of brackets is comprised of a thermoplastic material.
7. The bed foundation of claim 5, wherein each bracket of the plurality of brackets defines a first slot in which one rail of the first set of rails is received and a second slot in which another rail of the first set of rails is received.
8. The bed foundation of claim 7, wherein each bracket of the plurality of brackets includes a first pair of flanges defining the first slot of the bracket, a second pair of flanges defining the second slot of the bracket, and a central body from which the first pair of flanges and the second pair of flanges extend.
9. The bed foundation of claim 8, wherein the central body is substantially hollow.
10. The bed foundation of claim 1, wherein the one or more panels are comprised of thermoplastic foam.
11. The bed foundation of claim 10, wherein the plurality of rails of the frame are comprised of one of polypropylene (PP) foam, polyethylene (PE) foam, polyethylene terephthalate (PET) foam, polyisocyanurate (polyiso) foam, polyvinyl chloride (PVC) foam, and fiberglass- reinforced polyurethane (PU) foam, and wherein the one or more panels are comprised of one of PP foam, PE foam, PET foam, polyiso foam, PVC foam, and fiberglass-reinforced PU foam.
12. The bed foundation of claim 1, wherein the one or more panels include multiple panels.
13. The bed foundation of claim 1, wherein the one or more panels are removably secured to the frame by a plurality of fasteners.
14. The bed foundation of claim 1, wherein the one or more panels are comprised of a medium density fiberboard.
15. A kit for a bed foundation, comprising a plurality of rails configured to interlock with each other to at least partially define a frame of the bed foundation, the plurality of rails comprised of thermoplastic foam; and one or more panels configured to be placed on top of the plurality of rails when the plurality of rails are interlocked, the one or more panels defining an upper surface of the bed foundation for supporting a mattress.
16. The kit of claim 15, wherein the plurality of rails includes a first set of rails and a second set of rails configured to interlock with each other, and wherein each rail of the second set of rails is configured to interlock with at least one other rail of the second set of rails to define an interior structure of the frame.
17. The kit of claim 16, wherein each rail of the second set of rails defines a notch for receiving another rail of the second set of rails.
18. The kit of claim 16, wherein each end of each rail of the second set of rails defines a tenon, and wherein each rail of the first set of rails defines one or more openings configured to receive one of the tenons defined by the second set of rails.
19. The kit of claim 16, further comprising a plurality of brackets, each bracket of the plurality of brackets configured to interconnect two rails of the first set of rails, and the plurality of brackets defining a portion of a perimeter of the frame.
20. The kit of claim 19, wherein each bracket of the plurality of brackets is comprised of a thermoplastic material.
21. The kit of claim 16, wherein the one or more panels are comprised of thermoplastic foam.
22. The kit of claim 21, wherein the plurality of rails are comprised of one of polypropylene (PP) foam, polyethylene (PE) foam, polyethylene terephthalate (PET) foam, polyisocyanurate (polyiso) foam, polyvinyl chloride (PVC) foam, and fiberglass-reinforced polyurethane (PU) foam, and wherein the one or more panels are comprised of one of PP foam, PE foam, PET foam, polyiso foam, PVC foam, and fiberglass-reinforced PU foam.
23. The kit of claim 16, and further comprising a plurality of fasteners configured to removably secure the one or more panels to the frame.
24. The kit of claim 16, wherein the one or more panels are comprised of a medium density fiberboard.
25. A method of assembling a bed foundation, the method comprising: interlocking a plurality of rails to at least partially define a frame of the bed foundation, the plurality of rails of the frame comprised of thermoplastic foam; and positioning one or more panels on top of the frame to define an upper surface of the bed foundation for supporting a mattress.
26. The method of claim 25, wherein interlocking the plurality of rails comprises interlocking a first set of rails of the plurality of rails with a second set of rails of the plurality of rails, the first set of rails at least partially defining the perimeter of the frame, and interlocking a second set of rails of the plurality of rails together to define an interior structure within the perimeter of the frame.
27. The method of claim 26, wherein interlocking the first set of rails with the second set of rails and interlocking the second set of rails together is performed by press fitting the first set of the rails and the second set of rails together.
28. The method of claim 25, further comprising interconnecting the first set of rails together using a plurality of comer brackets, the first set of rails and the plurality of comer brackets defining the perimeter of the frame.
29. The method of claim 25, further comprising removably securing the one or more panels to the frame using a plurality of fasteners.