U.S. patent application number 10/373908 was filed with the patent office on 2004-08-26 for compressible encasement tray for bedding and method for selectively modifying bedding product with such a tray.
This patent application is currently assigned to The Spring Air Company. Invention is credited to Bryant, Steve, Olinski, Ross.
Application Number | 20040163180 10/373908 |
Document ID | / |
Family ID | 32868760 |
Filed Date | 2004-08-26 |
United States Patent
Application |
20040163180 |
Kind Code |
A1 |
Bryant, Steve ; et
al. |
August 26, 2004 |
Compressible encasement tray for bedding and method for selectively
modifying bedding product with such a tray
Abstract
A bedding product for use as a mattress topper has a tray formed
by a bottom sheet of compressible material with a generally
rectangular frame attached at the periphery of a surface thereof,
formed by rails of compressible material. The tray has a generally
rectangular recess therein formed by the rails, which can be filled
with inserts of selected firmness characteristics, to give the
overall bedding product selected characteristics related to
firmness.
Inventors: |
Bryant, Steve; (Loganville,
GA) ; Olinski, Ross; (Des Plaines, IL) |
Correspondence
Address: |
SCHIFF HARDIN, LLP
PATENT DEPARTMENT
6600 SEARS TOWER
CHICAGO
IL
60606-6473
US
|
Assignee: |
The Spring Air Company
|
Family ID: |
32868760 |
Appl. No.: |
10/373908 |
Filed: |
February 25, 2003 |
Current U.S.
Class: |
5/690 ;
5/691 |
Current CPC
Class: |
A47C 27/15 20130101 |
Class at
Publication: |
005/690 ;
005/691 |
International
Class: |
A47C 027/00; A47C
017/00 |
Claims
We claim as our invention:
1. A bedding product comprising: a tray having outer dimensions
matched to dimensions of a standard size mattress, said tray
consisting of a bottom sheet of compressible material having a
surface with an outer periphery, and a plurality of rails of
compressible material attached to said outer periphery and forming
a substantially rectangular frame with a central, open recess.
2. A bedding product as claimed in claim 1 wherein said rails are
attached to each other by an attachment selected from the group
consisting of glue and double-sided adhesive tape and are adhered
to said bottom sheet by an attachment selected from the group
consisting of glue and double-sided adhesive tape.
3. A bedding product as claimed in claim 1 wherein said
compressible material of said bottom sheet is the same as said
compressible material of said rails, except as to density.
4. A bedding product as claimed in claim 1 wherein at least one of
said compressible material of said bottom sheet and said
compressible material of said rails consists of foam.
5. A bedding product as claimed in claim 1 wherein at least one of
said compressible material of said bottom sheet and said
compressible material of said rails consists of polyester densified
fiber.
6. A bedding product as claimed in claim 1 wherein at least one of
said inserts is a zoned insert.
7. A bedding product as claimed in claim 1 wherein said
compressible material of said rails has a higher density than said
compressible material of said bottom sheet.
8. A bedding product comprising: a tray having outer dimensions
matched to dimensions of a standard size mattress, said tray
consisting of a bottom sheet of compressible material having a
surface with an outer periphery, and a plurality of rails of
compressible material attached to said outer periphery and forming
a substantially rectangular frame with a central, open recess; and
a plurality of inserts, respectively having selected firmness
characteristics, disposed in said recess.
9. A bedding product as claimed in claim 8 wherein said rails are
attached to each other by an attachment selected from the group
consisting of glue and double-sided adhesive tape and are attached
to said bottom sheet by an attachment selected from the group
consisting of glue and double-sided adhesive tape.
10. A bedding product as claimed in claim 8 wherein said
compressible material of said rails has a higher density than said
compressible material of said bottom sheet.
11. A bedding product as claimed in claim 8 wherein the inserts in
said plurality are attached to each other in succession.
12. A bedding product as claimed in claim 8 wherein said inserts
are disposed in said recess with no direct attachment to said
rails.
13. A bedding product as claimed in claim 8 wherein said inserts
are attached to each other in succession and are disposed in said
recess with no direct attachment to said rails.
14. A bedding product as claimed in claim 8 wherein said plurality
of inserts includes a bottommost insert, and wherein said
bottommost insert is attached to said bottom sheet of said
tray.
15. 4. A bedding product as claimed in claim 8 wherein at least one
of said compressible material of said bottom sheet and said
compressible material of said rails consists of foam.
16. A bedding product as claimed in claim 8 wherein at least one of
said compressible material of said bottom sheet and said
compressible material of said rails consists of polyester densified
fiber.
17. A bedding product as claimed in claim 8 wherein at least one of
said inserts is a zoned insert.
18. A bedding product as claimed in claim 8 wherein said inserts
are selected from the group consisting of 11/2".times.1/2" CV,
2".times.1" CV, 11/2".times.3/4" XL 21 ILD CV, 1" latex, 2" visco,
1" XL 21 ILD, 7/8".times.3/8" convoluted foam, 1" visco.
19. A method for making a bedding product comprising the steps of:
providing a tray consisting entirely of compressible material,
having a tray bottom and a rectangular peripheral frame attached to
said tray bottom with a central, substantially rectangular opening
therein; inserting a plurality of inserts in said opening, having
respectively different firmness characteristics, to produce a
bedding product having selected overall bedding product firmness
characteristics.
20. A method as claimed in claim 19 comprising employing
compressible material for said frame having a higher density than
said compressible material of said bottom sheet.
21. A method as claimed in claim 19 comprising attaching said rails
to said bottom sheet by an attachment selected from the group
consisting of glue and double-sided adhesive tape.
22. A method as claimed in claim 19 comprising attaching said
plurality of inserts to each other in succession to form an insert
combination, and disposing said insert combination in said
recess.
23. A method as claimed in claim 22 comprising disposing said
insert combination in said recess with no direct attachment to said
frame.
24. A method as claimed in claim 19 comprising disposing said
plurality of inserts in said recess with no direct attachment to
said frame.
25. A method as claimed in claim 19 comprising employing inserts in
said plurality with respectively different firmness characteristics
selected from the group consisting of density and
compressibility.
26. A method as claimed in claim 19 comprising selecting said
inserts in said plurality from the group consisting of
11/2".times.1/2" CV, 2".times.1" CV, 11/2".times.3/4" XL 21 ILD CV,
1" latex, 2" visco, 1" XL 21 ILD, 7/8".times.3/8" convoluted foam,
1" visco.
27. A method as claimed in claim 19 comprising employing foam
material as said compressible material for at least one of said
tray bottom and said frame.
28. A method as claimed in claim 19 comprising employing polyester
densified fiber material as said compressible material for at least
one of said tray bottom and said frame.
29. A method as claimed in claim 19 comprising employing a zoned
insert as at least one insert in said plurality of inserts.
30. A method as claimed in claim 19 wherein said plurality of
inserts includes a bottommost insert, and comprising the step of
attaching said bottommost insert to said tray bottom.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed to a encasement tray of
compressible material suitable for use as a mattress topper, as
well as to a method for selectively modifying a bedding product
using such a tray.
[0003] 2. Description of the Prior Art
[0004] Various types of bedding products are known which have a
frame or frame-like structure with a recess therein, with an insert
being disposed in the recess to give the overall bedding product
desired features. U.S. Pat. No. 1,371,362, for example, discloses a
mattress having a rectangular box spring frame with a central
recess. A top cushion is supported by springs in the rectangular
frame. An inner mattress section is removably fitted in the recess,
resting on slats, which are a part of the rectangular frame. The
inner mattress also contains spiral springs, which have a different
spring constant from the springs in the outer frame, so that the
outer frame affords more resistance to compression, to better
accommodate persons seated at the edge of the mattress.
[0005] A mattress with a removable insert is disclosed in U.S. Pat.
No. 5,107,558 wherein a one-piece base of hollow fibers or
polyurethane foam is provided with a rectangular recess at an upper
side thereof, in a region, which supports the torso of a person
lying on the mattress. This recess is filled by a removable insert,
which is formed as a fabric envelope containing fragmentized
polyurethane foam and polypropylene beads, or superimposed layers
of foamed plastic material having different specific gravities
and/or hardnesses.
[0006] U.S. Pat. No. 5,704,085 discloses an edge support for a
mattress in the form of an upholstery topper composed of multiple
layers, including at least one foam layer. This foam layer has a
firming edge of foam around its perimeter, again for the purpose of
providing more support at the edge of the mattress.
[0007] A mattress is disclosed in U.S. Pat. No. 2,069,415 having a
basic metal spring assembly with fabric padding at the top surface
thereof. The padding includes a marginal portion proceeding around
the periphery of the top of the mattress, which is filled with
filler material so as to give this marginal region more resistance
to compression. The padding is covered with fabric stitched
together so as to form a central region surrounded by the
aforementioned marginal region.
[0008] Although the above products in some instances, allow a
certain amount of selectivity in the material or layers which will
be used as inserts, in most cases the structure is fixed at the
time of manufacture, and the components of different densities or
compressibility are thus built into the overall structure, or at
least cannot be easily removed or interchanged. Moreover, the
products themselves are intended to serve as a mattress in a bed,
rather than as an accessory or attachment to a mattress.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide a
mattress topper, having dimensions adapted to any of the
standard-sized mattresses which are commercially available which
provides edge support for a conventional mattress and which also
allows selectivity in the characteristics of the central
portion.
[0010] It is also an object of the present invention to provide a
method for making such a mattress topper, which affords selectivity
in the respective characteristics between the central portion of
the topper and a peripheral portion.
[0011] It is a further object of the present invention to provide
such a method and mattress topper for use with a conventional
mattress of uniform compressibility, which allow customization of
that conventional mattress to provide a selected combination of
densities and compressibility characteristics.
[0012] It is a further object to provide such a method and mattress
topper which reduce the overall cost of inventory and/or
manufacture.
[0013] The above objects are achieved in accordance with the
present invention in a mattress topper having a tray formed by a
bottom topper sheet of compressible material, with four side rails
of compressible material affixed at the periphery of one of the
large faces thereof, to form a rectangular frame with a central
rectangular recess therein. The rails preferably are formed of
material with a relatively high density, so as to provide edge
support when the tray is placed on a conventional mattress.
[0014] The recess can be filled with multiple layers or sheets of
different materials, having respectively different densities,
compressibility characteristics (ILD=internal load deflection),
etc., so that by appropriately selecting these inserts, the overall
characteristics of the topper can be selected. In general,
characteristics will be selected to produce a desired firmness or
feel. Since the tray with the inserts is used on a conventional
mattress this allows the conventional mattress to be converted or
customized as desired.
[0015] In the inventive method, a foam topper tray of the type
described above is first produced, and multiple inserts of
respectively different types are made available. Depending on the
overall characteristics of the completed product that are desired,
inserts are selected and placed in the recess in the tray to create
a mattress topper with customized characteristics.
[0016] The inventive method and topper reduce costs by allowing
layers of reduced size to be used, improving the ease of
manufacture, reducing overall manufacturing costs and allowing
fewer material SKUs (shop keeping units) to be kept in
inventory.
[0017] The topper tray is manufacturable with different dimensions,
the dimensions being selected to match the dimensions of various
types of commercially available mattresses, such as king size,
queen size, twin size, etc. These dimensions are standard size in
the industry and are well known to those of ordinary skill in the
art.
DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of a topper tray constructed in
accordance with the principles of the present invention.
[0019] FIG. 2 is an exploded view showing the components of the
topper tray and a number of inserts used in accordance with the
inventive topper tray and method.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] As shown in FIG. 1, a topper tray 1 has a bottom topper
sheet 2 with a top surface, and four rails 3 disposed at the
periphery of the top surface of the topper sheet 2. The topper
sheet 2 and the rails 3 can be composed of foam material or
polyester densified fiber (PDF). Combinations of foam and PDF can
be used. The foam material used for the rails 3 is preferably of a
relatively high density, so as to afford a higher resistance to
compression at the edge regions. When the topper tray 1 is placed
on a conventional mattress, therefore, the topper tray 1 will
provide support at the edges thereof for a person sitting on the
edge of the mattress.
[0021] The topper sheet 2 may be formed of the same higher density
material as the rails 3, however, this is not necessary to produce
the desired edge support and therefore preferably the topper sheet
2 will be formed of a compressible material of lower density than
the rails 3. Since lower density material is, in general, less
expensive than a higher density material, this will reduce the
overall cost.
[0022] The rails 3 are attached to the top surface of the topper
sheet 2 in a suitable manner, such as by adhesive or double-sided
tape, and also are suitably attached to each other at their
respective ends. Preferably the topper sheet 2 is a 1/2 inch 1.2#
topper. The rails 3 preferably are composed of VPF-1.65# 50 ILD
foam grade. The rails 3 preferably have a cross-section of
approximately 21/2 inches by 21/2 inches.
[0023] The outer dimensions of the topper tray 1 are matched to
those of standard-size mattresses which are commercially available,
since the topper tray 1 is intended to be placed on top of such a
conventional mattress. The topper tray 1 thus will be available in
different sizes, respectively corresponding to these conventionally
sized mattresses. Examples of such conventional sizes are twin
(371/2".times.74") twin XL (371/2".times.79"), full
(521/2".times.34"), full XL (521/2".times.79"), queen
(591/2".times.79"), king (751/2".times.79") and cal king
(711/2".times.83").
[0024] As shown in FIG. 2, multiple inserts 4, 5 and 6 (or more or
fewer) are disposed in the central recess in the topper tray 1
formed by the rails 3. The dimensions of the inserts 4, 5 and 6
will thus be equal to the dimensions of the topper sheet 2, less
the widths of the rails 3. The inserts 4, 5 and 6 will be adhered
to each other, such as by spot gluing double-sided tape, etc., but
will not be adhered to the rails of the topper tray 1. The inserts
thus will be fitted into the recess formed by the rails 3 in the
topper tray 1 without any direct attachment to the rails. The
bottommost insert 4 may be attached to the topper sheet 2, but this
is not always necessary.
[0025] The inserts 4, 5 and 6 are suitable selected to provide the
combination of the topper tray 1 with the inserts with desired
characteristics as to compressibility, density, water permeability,
etc.
[0026] Examples of suitable inserts for the inserts 4, 5 and 6 are
11/2".times.1/2" CV, 2".times.1" CV, 11/2".times.3/4" XL 21 ILD CV,
1" latex, 2" visco, 1" XL 21 ILD, 7/8".times.3/8" convoluted foam,
or 1" visco.
[0027] One or more of the inserts 4, 5, 6 may be zoned, i.e., it
can have regions thereof, such as a head region or torso region, of
different firmness than other regions thereof.
[0028] The inserts 4, 5 and 6 are combined to have a height or
thickness approximating the height of the rails 3. Preferably all
of the combinations will have a natural crown of 1/2" or more.
[0029] Although modifications and changes may be suggested by those
skilled in the art, it is the intention of the inventors to embody
within the patent warranted hereon all changes and modifications as
reasonably and properly come within the scope of their contribution
to the art.
* * * * *