U.S. patent application number 10/132601 was filed with the patent office on 2002-11-07 for mattress made of latex foam integrating a structure of springs sacked or held in other supporting material.
Invention is credited to Formenti, Fabio.
Application Number | 20020162173 10/132601 |
Document ID | / |
Family ID | 11447567 |
Filed Date | 2002-11-07 |
United States Patent
Application |
20020162173 |
Kind Code |
A1 |
Formenti, Fabio |
November 7, 2002 |
Mattress made of latex foam integrating a structure of springs
sacked or held in other supporting material
Abstract
It is proposed a new construction system for mattress made of
latex including sacked springs, that allows an assembly without
glueings or fastenings of mechanical type and allows to supply
different bearing surfaces for the human body with different
support densities, suitable for the different zones of human body
in the rest position and related manufacturing method.
Inventors: |
Formenti, Fabio; (Bovisio
Masciago, IT) |
Correspondence
Address: |
OSTROLENK FABER GERB & SOFFEN
1180 AVENUE OF THE AMERICAS
NEW YORK
NY
100368403
|
Family ID: |
11447567 |
Appl. No.: |
10/132601 |
Filed: |
April 25, 2002 |
Current U.S.
Class: |
5/718 ; 5/720;
5/740 |
Current CPC
Class: |
A47C 27/15 20130101;
A47C 27/20 20130101; A47C 31/123 20130101; A47C 27/148
20130101 |
Class at
Publication: |
5/718 ; 5/720;
5/740 |
International
Class: |
A47C 027/20; A47C
023/04 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 27, 2001 |
IT |
MI2001A 000891 |
Claims
1. Mattress made of latex foam including a structure of springs or
other bearing material, that is obtained by a construction system
of mattress including sacked springs, that allows an assembly
without glueings or fastenings of mechanical type or seams, and
allows to create different bearing surfaces for the human body with
different support densities suitable for the different zones of
human body in the rest position, characterised in that a structure
of many sacked springs is included in a block of latex foam, and
that allows to differentiate the surfaces in areas having different
densities or support capacities and forms for including in the more
suitable manner the different human body zones in the rest position
as back, legs, shoulder zone, for getting a complete rest, require
a differentiated support and with different absorption depths and
transpiration of the human body laid on the mattress.
2. Process for the fabrication of the mattress of claim 1,
characterised in that the spring structure is inserted in a closed
mold or mold with hinged cover having dimensions slightly higher
than the ones of the spring structure so that an empty jacket
remains between the mold and the structure in conjuction with each
mattress face, and that over the spring structure there are
foreseen one or more strata of any material having the aim to
insulate better the springs from the latex foam or to increase the
comfort of the mattress or simply to increase its thickness, and
afterwards the mold is closed hermetically by a cover and in that
the mold is supplied with nozzles suitably located so that it is
possible to inject the latex foam through them and in the following
it occurs the injection of the latex foam that causes the filling
of one, some and/or all interspaces over, under and on the sides of
the spring structure, also partially, but not in the inside of
springs, being the springs sacked and made impermeable (completely
or partially) to the latex foam material covering them, and in that
after the injection it is made the normal process for forming a
latex foam block, whatever is the process applied.
3. A mattress according to claim 1 and manufactured by the process
of claim 2, having the following general characteristics: INTERNAL
PART Springs sacked singularly, or in groups, or on the whole.
Springs of any form, type and material and in any number. The
spring structure can be homogeneous or not homogeneous as regards
the spring forms, the density per square meter, and each spring
characteristic. Strata of any material can be put over the springs
and/or on the various faces with a different aim owing to its
position and the used material (to insulate, to increase the
comfort, or to increase the thickness, etc.). EXTERNAL PART The
surface can be smooth or machined for dividing the structure in
zones; alveolar or filled: differentiated or equal on both sides.
The flanks can be filled or supplied with holes or machined. One or
more faces/flanks can be provided also without latex foam. FOAM
COMPOSITION The composition and/or density of used latex foam can
be changed in relation to characteristics of the finished product
that it is wished to obtain, then it can be changed density,
injection temperature, mixture composition, additive adding,
etc.,
4. Mattress and fabrication method according to preceding claims,
characterised in that the mold can be of "opened" type instead of
"closed" type as above described in claim 2; in this case the latex
foam shall be not injected into the mold, but it will be simply
poured into the mold, that is kept opened until its also partial
filling and it is closed only in the following phases, so that the
spring structure is inserted into the latex foam mass after the
filling, also partial of the mold (but before its closing) or
during the filling operation.
5. Mattress and fabrication method according to preceding claims,
characterised in that the spring structure is made "impermeable"
(completely or partially) to the latex foam using a sacked spring
structure, but being also used all of types of springs, provided
that the springs are wound or closed in a suitable material, the
winding concerning the whole complete structure or spring blocks or
rows, or each single spring, including also the mixed "naked" and
covered spring solutions.
6. Mattress and fabrication method according to preceding claims,
characterised in that the springs are made impermeable against the
latex foam (completely or partially), by various materials such as
fabric, unweaved fabric, gauze, polyether, polyurethane,
polyethylene, paper or any other material, including jute, hemp,
raffia and cotton suitable for the insulation and/or
impermeabilization aims (completely or partially) of the latex
foam, including plastic materials and films, thin sheets,
bands.
7. Mattress and fabrication method according to preceding claims,
characterised in that instead of integrating a spring structure
into the latex foam it is inserted a block or many blocks of any
other material, such as a block or some blocks of polyurethane foam
eventually and suitably shaped or a block/s of coco fibres, or a
block/s of polyesther fibres for obtaining mattresses "in strata"
(sandwich) and/or divided in zones, including also mixed
solutions.
8. Mattress and fabrication method according to preceding claims,
characterised in that, in the case of use of closed mold, the foam
is injected, from the cover, or in alternative also (or solely)
from the walls and/or also (or solely) from the mold bottom.
9. Mattress and fabrication method according to preceding claims,
characterised in that the mold includes a bulkhead (preferably made
of aluminium alloy) detachable/extractable, that allows to get a
mattress of the type for two persons or, contemporaneously, two
mattresses for a sole person. In the name of Applicant DR. FABIO
FORMENTI The Mandatary
Description
FUNDAMENT OF THE INVENTION
[0001] This invention refers to the manufacturing field of elastic
mattresses made of foamed materials and holding springs for getting
a better support of human body during the rest period. The types of
mattress present on the market are substantially the following
ones:
[0002] 1. Mattresses made with springs and fabric materials,
[0003] 2. Mattresses made of sole wool,
[0004] 3. Mattresses made of sole polyurethane foam or other
artificial foam materials derived from petroleum,
[0005] 4. Mattresses made of natural or artificial latex, without
other supports of different materials.
[0006] Each of above mentioned components, such as springs, wool;
natural and artificial fibres, polyurethane, latex foam and other-
materials are mainly used in combination with other materials in
various percentages and construction forms.
[0007] The main characteristic, that an efficient and ergonomic
mattress must have, is the body support for guaranteeing a correct
support to the spinal column during the rest period and the user's
comfort necessary for a compete muscle relaxation, and it further
avoids the formation of pressure points in which the blood does not
circulate owing to excessive tissue compression.
[0008] Excepting the traditional mattress made of wool and those
ones made of latex foam or polyurethane or other foamed materials,
the actually known spring mattresses supply the elastic support
sometimes by steel springs or springs made of other materials, e.g.
plastic material and natural or artificial fibres.
[0009] In the field of spring mattress types it exists a particular
structure that is commonly termed as "sacked" springs, as each
spring is Inserted singularly in a fabric sack that insulates it
from the other ones. This structure is characterised by its
particular adaptability to the body form as, owing to the sack,
each spring is relatively independent from the adjacent ones and
then it supplies a differentiation of the body support thanks to
the presence of a series of springs near and working in an
independent manner with one another.
[0010] The springs can be completely independent (if they are not
joined with one another) or relatively joined with one another in
any manner and position.
[0011] For making comfortable the body support structure there are
added different strata of materials among which some foam strata
such as of latex, polyurethane, other foamed materials, and the
whole structure is covered by stuffings made of wool, cotton or
other materials and then closed in a fabric envelope or sack.
[0012] The connection of foam strata to the springs occurs by a
mechanical process, e.g. clinching by metallic stitches or by
glueing, these two operations are both costly as they require a
rather long and tedious manual work and that must be made in the
greater part manually by skilled workers.
[0013] The glueing operation can also compromise the mattress
duration as using it for various years the glue can lose its
adhesive capacity; further the manual glueings operation cannot be
made in the correct manner or the glue cannot be applied in uniform
manner on two pieces belonging to the same production lot or simply
on the same piece.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Owing to the disadvantages of precedently used systems we
have thought to integrate a structure of many sacked springs in a
sole latex foam block, avoiding each manual glueing or single
clinching operation, that is not always precise and requires a lot
of labor. Further the new system allows, if it is wished, to make
different all of surfaces in areas having different densities or
support capacities and forms for receiving in the more suitable
manner the different human body zones in the rest position. In fact
back, legs, shoulder zone, for getting a complete rest require a
differentiated support and different absorption depth of the human
body into the mattress.
Invention Process
[0015] The spring structure is inserted in a mold preferably made
of aluminium alloy having dimensions slightly higher than the ones
of the spring structure so that it remains an empty interspace
between the mold and the structure in conjuction with each face,
but not necessarily in conjuction with all faces.
[0016] One or many strata of any material can be put over the
spring structure with the aim, for example, to insulate better the
springs from the latex foam or to increase the mattress comfort or
simply to increase its thickness
[0017] The mold is closed hermetically by a cover on which there
are applied "nozzles" suitably positioned so that they can inject
the latex foam The latex foam injection establishes the filling of
all of interspaces over, under and on the flanks of the spring
structure but not in the inside thereof, as the springs are sacked
and the covering material causes them to become "impermeable"
(completely or partially) against the latex foam, that is rather
dense.
[0018] After the injection there will be made the process for the
fabrication of a latex foam block, independently from the applied
method
Product Characteristics
Internal Part
[0019] Springs sacked singularly, or in groups, or on the whole
[0020] Springs of any form, type and material and in any
number.
[0021] The spring structure can be homogeneous or not homogeneous
as regards the spring forms, the density per square meter, each
spring characteristic.
[0022] Strata of any material can be put on the springs with a
different aim owing to the used material (to insulate, to increase
the comfort or other properties).
External Part
[0023] The surface, or the rest plane, can be smooth or machined
for dividing the structure in zones: alveolar or filled;
differentiated of equal on both sides
[0024] The flanks can be filled or supplied with holes or
machined
Foam Composition
[0025] The composition and/or density of used latex foam can be
changed in relation to characteristics of the finish'ed product
that it is wished.
Possible Variants
[0026] The mold can be of "opened" type instead of "closed" type as
above described; in this case the latex foam shall not be injected
after the cover closing, but it shall be simply poured into the
inside of the mold that will be kept opened until its also partial
filling and it will be closed only in the following phases.
[0027] In this manner the spring structure can be inserted after
the filling, also partial, of the mold (but before its closing) or
during the filling operation.
[0028] In the case of "naked" spring structure, very great empty
spaces exist among the springs that in some way must be made
"impermeable" (completely or partially) to the latex foam. The more
simple solution is that of using a sacked spring structure among
the ones found usually on the market, but all of spring types
existing on the market can be used, provided that the springs are
wound or closed into a suitable material.
[0029] The winding can concern the whole complete structure or
blocks or rows of springs, or each single spring and can also
regard only some parts of spring structure.
[0030] The material that makes impermeable the springs against the
latex foam (completely or partially), can be fabric, unweaved
fabric, galize, polyether, polyurethane, polyethylene, paper or any
other material suitable for this aim, including jute, hemp, raffia
and cotton.
[0031] Instead of integrating (plunging) into the latex foam a
spring structure, we can insert a block of any other material, for
example, a block of polyurethane foam eventually and suitably
shaped or a block of coco fibres or a block of polyester fibres for
obtaining mattresses "in strata" (sandwich) and/or in zone
form.
[0032] In the case of closed mold the foam can be injected, through
the cover and also (or solely) through the walls and/or also (or
solely) through the mold bottom.
[0033] For a better comprehension of this invention and for showing
as the same one can applied, it shall be made reference, as sole
example aim, to the annexed drawings, in which.
[0034] FIG. 1 shows the normal position that a person assumes on an
elastic mattress supplied with springs and having a traditional
structure;
[0035] FIG. 2 shows a solution of sacked springs as they are
foreseen for the assembly in the mattress of the present
invention;
[0036] FIG. 3 shows a final structure of strata that is possible in
a mattress structure of the previous technics, that can be broken
easily,
[0037] FIG. 4 shows a possible structure of holes for getting
different densities on the rest plane/s;
[0038] FIG. 5 shows a possible structure of mold for the injection
and the fulfilment of a mattress with springs embodied into the
rubber latex, according to the present invention;
[0039] FIG. 6 shows a detail of the position of sacked springs laid
on suitable cylindrical or conical pins or having another form
present in the mold;
[0040] FIG. 7 shows a mold structure in perspective view in opened
condition including the cover and pins for generating in the
mattress, after the extraction, some holes for the lateral
aerification.
[0041] FIG. 8 shows a possible final external structure of the new
mattress with differentiated surface and density and with
transpiration holes on the lateral surfaces;
[0042] FIG. 9 shows a further mattress layout in the mold with an
internal structure made of various natural or artificial material
in fibre foam or made of expansible material
[0043] Making now reference to the FIG. 1, it is shown the normal
position that a person assumes on an elastic mattress supplied with
springs and having a traditional structure, in which M indicates
the finished mattress, PE indicates a person lying on his/her back
side and the arrows A1, B1 show the deformation actions of the
mattress when it is submitted to the weight of the various body
parts. Evidently the central part corresponding to the body
barycenter or to the pelvis and to the shoulders are more "hard" as
they must support a greater weight, while the zones of arms and
head can be made more soft as they are submitted to a lower
weight.
[0044] The FIG. 2 shows a typical structure of sacked springs as
they are foreseen for the assembly of mattress of the present
invention. It must be noticed that, in previous technics, these
springs might be wound in wool or cotton wadding mass, or made of
any other material foreseen for increasing the comfort.
[0045] In the case of the present invention the springs are wound
by a proper material on each side, therefore they remain internally
empty and then they can apply more efficiently the flexibility
action on the user's body PE. M shows the spring and EL shows the
external material, of various compositions, but in any case
impermeable (completely or partially) against the latex foam.
[0046] The FIG. 3 shows a possible structure of a mattress made by
the previous technics, that can be easily broken, as the various
parts are glued, sawn or clinched and the same springs are glued or
sewn or clinched in various manners to a sole latex stratum
obtained precedently, then subject to breackages or to drawback of
breakaway of glued, sewn or clinched parts.
[0047] The FIG. 4 shows a possible hole structure suitable for
getting the density variation.
[0048] These holes are obtained, in the present invention, using
the cover and mold bottom structures, that are supplied with pins
having dimensions suitable for the various types of holes, that
will be described in relation to FIGS. 5, 6, 7, 8.
[0049] The FIG. 5 shows a possible mold structure for the injection
1 and the fulfilment of a mattress structure with springs embodied
in the rubber latex, according to the present invention.
[0050] The mold is made up of the walls 2, 3, the wall 6 in the
sheet plane and the wall 7 in the plane behind the sheet, a bottom
4, a cover 5 and the elements 8 for the aeration holes. The bottom
4 or the cover 5, in its internal sides, are supplied with pins 11
having sections suitable for creating the differentiated holes of
the mattress that were described with reference to FIG. 4 and are
laid on the faces 12 of the springs There are foreseen nozzles 9,
10 for introducing the latex foam, in a various number, for
distributing in a regular manner the latex foam within the mold.
The springs 13 are sacked in any suitable material 14 (FIG. 6) for
getting that the latex foam remains out (completely or partially)
of the internal spring space. This allows a better flexibility and
comfort,
[0051] The four lateral walls 2, 3, 6, 7 (FIG. 7) can be tilted in
the moment of mattress extraction from the mold.
[0052] The springs 13 (FIG. 6) at the moment of preparation for the
injection are laid onto internal pins 11.
[0053] It is foreseen also another possible spring structure
covered by protection material against the latex foam (completely
or partially), this material being a fabric, unweaved fabric,
gauze, polyethylene, polyurethane, polyethylene, paper or any other
material suitable for this aim, including lute, hemp, raffia and
cotton, suitable to insulate the spring/s (completely or partially)
with respect to the latex foam for avoiding that the spring/s
is/are buried in latex foam and that in this manner the flexibility
of the spring structure is reduced.
[0054] The FIG. 6 shows the rest situation of springs 13, covered
by impermeable material (completely or partially) onto latex foam
14 on all of sides. The zones 20 adjacent to horizontal faces of
springs are naturally filled with latex foam, therefore the springs
are suspended on the pins 11 during the injection. The pins 11 form
also the support of springs for making them stable during the
injection.
[0055] The FIG. 7 shows a structure mold in perspective view in
opened condition including the cover 5 and the pins for lateral
aeration holes The shown mold includes a division wall 22
extractable/removable (preferably made of aluminium alloy) that
allows to make the bed mattress for a sole person obtaining two
mattresses contemporaneously, while extracting this wall it is
possible to make a mattress for two persons with the same
production modalities.
[0056] The cover 5 can be lifted for the insertion of springs into
the mold and is closed and locked again when said load of springs
is made. The springs due to its weight and due to a light pressure
applied by pins 11 remain stable during the injection.
[0057] The FIG. 8 shows a possible final external structure of the
mattress in a sole block with zones having different densities F1,
F2, F3 substantially as the ones indicated in FIG. 4, and indicates
the holes 8 generated by pins 8, after having extracted the
mattress from the mold These holes make easier the air
transpiration across the finished mattress.
[0058] The FIG. 9 shows a further layout of the mattress in the
mold with an internal structure UR made of various natural or
artificial materials made of fibres or other expandable material,
of polyurethane foam, or coco fibres or wool or polyester fibres
for manufacturing a mattress in strata (sandwich) and/or with
different zones.
[0059] Although this invention was described with reference to some
of its particular embodiments, many other variants and
modifications and other uses shall be evident to the skilled
technicians.
* * * * *