U.S. patent application number 10/686019 was filed with the patent office on 2005-01-06 for tray support for a mattress.
Invention is credited to Gladney, Richard F..
Application Number | 20050000026 10/686019 |
Document ID | / |
Family ID | 32108011 |
Filed Date | 2005-01-06 |
United States Patent
Application |
20050000026 |
Kind Code |
A1 |
Gladney, Richard F. |
January 6, 2005 |
Tray support for a mattress
Abstract
A mattress core support system in the form of a padded tray with
a rigid bottom surface. The tray is comprised of four foam sides,
providing edge support for persons sitting on the edge of the
mattress, and containing therein a mattress core. The system is
compatible with (and sized for) all standard mattress cores, e.g.,
coil spring, foam, foam/coil composite, and all known sizes. The
mattress avoids the need for flipping and the associated increased
cost of a two-sided mattress by including as its bottom member a
rigid platform.
Inventors: |
Gladney, Richard F.;
(Fairburn, GA) |
Correspondence
Address: |
ROPES & GRAY LLP
ONE INTERNATIONAL PLACE
BOSTON
MA
02110-2624
US
|
Family ID: |
32108011 |
Appl. No.: |
10/686019 |
Filed: |
October 15, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60419026 |
Oct 15, 2002 |
|
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Current U.S.
Class: |
5/717 ; 5/690;
5/739 |
Current CPC
Class: |
A47C 23/007 20130101;
A47C 27/15 20130101; A47C 19/021 20130101; A47C 23/00 20130101 |
Class at
Publication: |
005/717 ;
005/690; 005/739 |
International
Class: |
A47C 023/04; A47C
027/14 |
Claims
What is claimed is:
1. A mattress, comprising, a substantially rigid base platform, a
perimeter sidewall joined to the base platform and defining an
interior cavity, an innercore disposed within the cavity, and an
upholstery layer disposed over a top surface of the innercore.
2. A mattress according to claim 1, wherein the substantially rigid
base platform comprises a layer of high density foam.
3. A mattress according to claim 1, wherein the substantially rigid
base platform comprises a plurality of layers of foam to provide
composite high density layer.
4. A mattress according to claim 1, wherein the substantially rigid
base platform is sufficiently rigid to provide a support surface
that may be seated on to a bed frame, for providing a bed.
5. A mattress according to claim 1, wherein the substantially rigid
base platform comprises a wood, cardboard, plastic or foam member
selected to provide support to the innercore.
6. A mattress according to claim 1, wherein the innercore comprises
a plurality of spring coils.
7. A mattress according to claim 1, wherein the innercore is
selected from the group of open coil innercores, fabric encased
spring coil innercores, and springs in foam innercore.
8. A mattress according to claim 1, wherein the innercore comprises
a block of resilient foam.
9. A mattress according to claim 1, wherein the innercore comprises
a layer of latex.
10. A mattress according to claim 1, further comprising a layer of
upholstery over disposed over the innercore and the perimeter
wall.
11. A mattress according to claim 1, further comprising a layer of
plain sheeting disposed over an exterior face of the substantially
rigid base platform to provide a non-upholstered non-sleeping
surface.
12. A mattress according to claim 1, wherein the perimeter sidewall
comprises at least two rigid foam sidewalls.
13. A mattress according to claim 1, wherein the perimeter sidewall
comprises at least four rigid foam sidewalls.
14. A mattress according to claim 1, wherein the perimeter sidewall
is joined by an adhesive joint to the substantially rigid base
platform.
15. A mattress according to claim 14, wherein the adhesive joint
includes glue, tape, adhesive patches.
16. A mattress according to claim 1, wherein the perimeter sidewall
is joined by a mechanical fastener to the rigid base platform.
17. A mattress according to claim 1, further comprising a wire for
securing the innercore against the substantially rigid base
platform.
18. A mattress according to claim 1, wherein a layer of upholstery
is disposed over the innercore and attached to or adjacent the
sidewall for securing the innercore within the cavity.
19. A mattress according to claim 1, wherein the sidewall includes
a joint for allowing the mattress to pivot between a reclined and
an inclined position.
20. A bed comprising a mattress having a substantially rigid base
platform, a perimeter sidewall joined to the base platform and
defining an interior cavity, and an innercore disposed within the
cavity, and a platform having a flat surface for receiving the
mattress and raising the platform off the ground.
Description
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application Ser. Nos. 60/419026, filed 15 Oct. 2002 and naming
Richard F. Gladney as inventor, the contents of which are hereby
incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to bedding products, specifically
mattresses and mattress foundations.
[0004] 2. Description of the Related Art
[0005] Conventional mattress systems typically consist of a
foundation or box spring and a mattress. The mattress assembly
typically consists of a core, various layers of padding above and
below the core, and a cover enveloping the assembly. Additional
features or embellishments, such as support bolsters around the
perimeter of the core or toppers are also well-known.
[0006] The mattress core may comprise a plurality of coil springs,
either individually pocketed or un-pocketed, or one or more layers
(or regions) of different foam materials.
[0007] Present mattress systems have a number of drawbacks.
Firstly, the need for a separate foundation is costly and presents
logistical issues in terms of stocking foundations that match
mattresses. Mismatched sets must typically be sold at a discount.
Secondly, the complexity of assembling and covering a complete
mattress core and padding assembly results in higher than desirable
manufacturing costs and demand for skilled labor.
[0008] What is needed is a mattress system that eliminates the need
for a separate foundation piece and is simple to manufacture.
SUMMARY
[0009] Presently disclosed is a mattress core support system in the
form of a padded tray with a rigid bottom surface. The tray is
comprised of four foam sides, providing edge support for persons
sitting on the edge of the mattress, and containing therein a
mattress core. The system is compatible with (and sized for) all
standard mattress cores, e.g., coil spring, foam, foam/coil
composite, and all known sizes. The mattress avoids the need for
flipping and the associated increased cost of a two-sided mattress
by including as its bottom member a rigid platform.
[0010] In an exemplary embodiment, the present mattress thus
consists of a rigid base platform with four vertical side walls
mounted thereon. A standard mattress core may be placed within the
confines of the walls and on the platform. The entire assembly may
then be topped with a conventional layer of padding and closed by a
cover. In an exemplary embodiment, a cover envelopes the entire
assembly. In an alternate embodiment, the sides of the vertical
walls and the bottom surface of the platform may be pre-finished
according to conventional means and the cover attached to the side
panels only. This latter attachment may be made by conventional
means, as by a zipper, Velcro, or stitching, and with or without
additional decoration (such as rope welting) or embellishment (such
as a mattress topper).
[0011] More particularly, the invention provides a mattress having
a substantially rigid base platform, a parameter sidewall joined to
the base platform and defining and interior cavity, an innercore
disposed within the cavity and an upholstery layer disposed over a
top surface over the innercore.
[0012] In certain optional embodiments the mattress has a
substantial rigid base platform that comprises a layer of high
density foam or may comprise of plurality layers of foam which
provide a composite high density layer to form the base platform.
The substantially rigid base platform may be sufficiently rigid to
provide a support surface that may be fitted directly onto a bed
frame to provide a mattress and bed combination. In certain
embodiments, the substantially rigid base platform comprises a
wood, cardboard, fiber board, plastic, or foam member that selected
to provide support to the innercore. The material selected can
depend upon the application at hand, but is typically selected for
the purpose of providing sufficient structural support to allow the
mattress to be seated directly on top of a bed frame, a platform,
or directly to furniture legs, all of which can act as a stand for
lifting the mattress into a position so that it is off the floor
and more comfortable for the user.
[0013] In certain embodiments the innercore comprises a plurality
of spring coils, and the spring coils may be an open coil
structure, a fabric encased spring coil structure, or springs
disposed in a foam block. Optionally, the innercore may comprise a
block of resilient foam, including polyurethane or latex, and may
also in some embodiments comprise a waterbed innercore.
[0014] The layer of upholstery may optionally be disposed over the
innercore and the parameter wall. In further embodiments, a layer
of plain sheeting may be disposed over an exterior face of the
substantially rigid base platform to provide a non-upholstered,
non-sleeping surface.
[0015] In certain embodiments, the parameter sidewall comprises at
least two rigid foam sidewalls and in other embodiments it
comprises at least four rigid foam sidewalls. The parameter
sidewall may be joined to the substantially rigid base platform by
an adhesive joint or by a mechanical joint. Adhesive joints may
include glue, tape, and adhesive patches. Mechanical fasteners may
include straps, hook and loop fasteners, bolts, hog rings, and
other similar devices. Optionally a wire, such as a boarder wire or
a helical wire, may be provided for securing the innercore against
the substantially rigid base platform. In such embodiments, the
wire may be hog ringed, or otherwise pinned to or adjacent the
substantially rigid base platform. In other particular embodiments,
the mattress may include a pivot located in the sidewalls for the
purpose of allowing the mattress to pivot between a reclined and an
inclined position.
[0016] In other aspects it will be understood that the systems
herein include a bed assembly that comprises a mattress as
described above as well as a platform assembly that provides some
type of flat surface for supporting the mattress.
[0017] Still further features may be added and modifications made
as the application requires. For example, in certain embodiments,
the mattresses described herein include a layer of a fire resistant
or a retardant material that, may in certain optional embodiments,
lie beneath a layer of upholstery and provide a barrier that
reduces or prevents inflammation of the interior materials of the
mattress. In still other embodiments, the mattresses described
herein may be two-sided mattresses and may come in any suitable
shape and size, including California King, king, Olympic Queen,
queen, and twin. It will further be understood that the assemblies
described herein may be employed in other applications, including
futons, couches, or any other type of seating furniture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The present disclosure may be better understood and its
numerous features and advantages made apparent to those skilled in
the art by referencing the accompanying drawings.
[0019] FIG. 1 depicts a portion of a foam tray assembly, according
to one embodiment of the present invention.
[0020] FIG. 2 depicts a foam tray assembly with a spring coil core
in place, according to one embodiment of the present invention.
[0021] FIG. 3 depicts an exploded view of the mattress 10 depicted
in FIG. 1;
[0022] FIG. 4 depicts a process of applying an upholstery layer
over a top surface of the mattress; and
[0023] FIG. 5 depicts the mattress assembly 10 of FIG. 1 atop of a
frame support.
The use of the same reference symbols in different drawings
indicates similar or identical items.
DETAILED DESCRIPTION
[0024] The embodiments illustrated herein are merely provided for
the purpose of describing the invention, and the invention is not
to be limited to the embodiments presented. It will apparent to
those of ordinary skill in the art that various modifications,
additions and subtractions can be made to the mattresses, processes
and beds described herein without departing from the scope of the
invention.
[0025] FIG. 1 shows a corner portion of a tray support constructed
according to one embodiment of the present invention. Rigid
platform 10 forms a base on which side walls 20 (two of four shown)
are mounted. The well or cavity defined by the attachment of the
walls 20 to platform 10 provides a space in which a conventional
mattress core can be inserted without further attachment to the
rest of the tray structure. The conventionally separate foundation
or box spring piece may be entirely eliminated as platform 10
provides sufficient mechanical support for the mattress
assembly.
[0026] Side walls 20 are constructed from a dense natural and/or
synthetic foam material of the type commonly used in the bedding
arts. The foam may be (but is not limited to) latex, polyurethane,
or other foam products commonly known and used in the bedding and
seating arts and having a suitable density. A typical density is
about, but not limited to 1.0 to 3.0 and more typically 1.5 to 1.9,
and 20 to 60 ILD, and more typically 20 to 35. One example of such
a foam is the high density polyurethane foam, such as manufactured
by Foamex Corporation in Linwood, Ill. Alternatively, any foam
having a high indent load deflection (ILD) would be satisfactory
for use as rails, headers and footers, as well as optionally the
base platform 60. Although a specific foam composition is
described, those skilled in the art will realize that foam
compositions other than one having this specific density and ILD
can be used. For example, foams of various types, densities, and
ILDs may be desirable in order to provide a range of comfort
parameters to the buyer.
[0027] The size of the siderails can vary according to the
application, but each rail typically measures 3-10 inches (7.5-25
cm) in thickness. The depicted side rails are equal in length and
width, and their length is chosen to correspond to the length of
the size of mattress desired. For a regular king size or Queen size
mattress, the length of rails should be about 78.5 inches (200 cm),
although the length can vary to accommodate the width of the header
or footer, it the header or footer is to extend across the full
width of the base platform 60. Similarly, the header/footer piece
typically has a thickness of about 3-10 inches (7.7-25 cm), and the
width is chosen to correspond to the width of the size of mattress
desired. In the case of a regular king size mattress the width
would be about 74.5 inches (190 cm), and for a queen size mattress,
the width would be about 58.5 inches (149 cm), depending on how the
foam rails are arranged to form the perimeter sidewall.
[0028] Side walls 20 are mounted or attached to platform 10 by
conventional means, such as (but not limited to) gluing, stapling,
heat fusion or welding, or stitching.
[0029] Platform 10 may consist of another panel of rigid foam, or
it may comprise a wooden, cardboard, or plastic structure selected
to provide support to the mattress core. Depending on the mattress
core selected and its inherent stiffness, stiffer or more compliant
base platforms 10 may be chosen. The relatively rigid layer may
have a high density polyurethane foam layer (20-170 ILD), or
several foam layers (20-170 ILD each), that alone or in
combination, provide a density and rigidity suitable for the
application. Such a choice, as well as the choice of the means and
methods for attaching side walls 20 to platform 10, are well within
the skill of an ordinary practitioner.
[0030] FIG. 2 shows an exemplary embodiment of a tray support with
a coil spring mattress core 40 in place. Note that, for clarity,
top padding layers 50 and the cover have been removed. One of
ordinary skill in the art will recognize that various combinations
of top padding, covers, and toppers are compatible with the system
disclosed herein. Accordingly, the invention is not limited to any
means of finishing the mattress and includes all such means and
materials within its scope.
[0031] Conventional coil spring core 40 may be comprised of
conventional helical or semi-helical springs known and used in the
art today. The springs may also be encased in a fabric material,
either individually in pockets, in groups, or in strings joined by
fabric, all of which are well-known in the bedding art. For many
years, one form of spring assembly construction has been known as
Marshall construction. In Marshall construction, individual wire
coils are each encapsulated in fabric pockets and attached together
in strings which are arranged to form a closely packed array of
coils in the general size of the mattress. Examples of such
construction are disclosed in U.S. Pat. No. 685,160, U.S. Pat. No.
4,234,983, U.S. Pat. No. 4,234,984, U.S. Pat. No. 4,439,977, U.S.
Pat. No. 4,451,946, U.S. Pat. No. 4,523,344, U.S. Pat. No.
4,578,834, U.S. Pat. No. 5,016,305 and U.S. Pat. No. 5,621,935, the
disclosures of which are incorporated herein by reference in their
entireties.
[0032] A foam core module may also be substituted for coil spring
mattress core 40. The foam core module is, in some embodiments, a
monolithic block of a single type of resilient foam selected from
foams having a range of densities (themselves well-known in the
art) for supporting one or more occupants during sleep. In one
embodiment, foam core is made of any industry-standard natural
and/or synthetic foams, such as (but not limited to) latex,
polyurethane, or other foam products commonly known and used in the
bedding and seating arts having a density of 1.5 to 1.9 and 20 to
35 ILD. Although a specific foam composition is described, those
skilled in the art will realize that foam compositions other than
one having this specific density and ILD can be used. For example,
foams of various types, densities, and ILDs may be desirable in
order to provide a range of comfort parameters to the buyer.
[0033] In an alternative embodiment, the foam core may comprise one
or more horizontal layers of multiple types of foams arranged in a
sandwich arrangement. This sandwich of different foams, laminated
together, may be substituted for a homogeneous foam block of a
single density and/or ILD.
[0034] In a further embodiment, the foam core may comprise one or
more vertical regions of different foam compositions (including
vertical regions having multiple horizontal layers), where the
different foams are arranged to provide different amounts of
support (also referred to as "firmness" in the art) in different
regions of the sleeping surface.
[0035] Accordingly, the invention is not limited to any particular
type of foam density or ILD or even to a homogenous density/ILD
throughout the foam core. Furthermore, the invention is not limited
to any particular type of core.
[0036] The mattress may then be finished as is customary for a
one-sided mattress, The innercore is typically covered with padding
layers on the top and bottom surfaces, and the whole assembly is
encased within a ticking, often quilted, that is sewn closed around
its periphery to a border or boxing. After assembly the mattress
can be covered by any other decorative covering or pillow-top.
[0037] In an exemplary embodiment, a conventional mattress cover
envelopes the entire assembly. In an alternate embodiment, the
sides of the vertical walls and the bottom surface of the platform
may be pre-finished according to conventional means and the cover
attached to the side panels only. This latter attachment may be
made by conventional means, as by a zipper, Velcro, or stitching,
and with or without additional decoration (such as rope welting) or
embellishment (such as a mattress topper).
[0038] In summary, FIG. 2 illustrates a mattress support comprising
a wall member and a platform member, wherein said wall member is
attached to the top surface of said platform member to define a
well disposed to receive a mattress core. Said wall member may
comprise one or more segments each attached to said platform. Said
wall member segments may also be attached to each other. Said
mattress support may also comprise a top padding member attached to
said wall member and a cover enveloping said top padding member,
said wall member, and said platform member and secured thereto.
[0039] FIG. 3 depicts an exploded view of one mattress according to
the invention. Specifically, FIG. 3 depicts a mattress assembly
that includes a substantially rigid base platform 60, foam
side-rails 62, a foam header/footer-piece 64, adhesive tape strips
68 and adhesive patches or dots 70. Not shown is the innercore
assembly 40 shown in FIG. 2.
[0040] In one process for assembling the mattress depicted in FIG.
3, the rigid base platform 60 has adhesive patches or dots 70
disposed around its parameter edge. The adhesive strips 70 or dots
70 may be commercially available adhesive products of the type sold
by the 3M Corporation of Minneapolis, Minn. For example, a
double-sided adhesive tape, such as 9692, 9695 or 6035, all of
which are manufactured by 3M may be suitable. In the process
depicted in FIG. 3, the adhesive patches 70 are shown as squares of
adhesive material laid on the base platform or deck 60. To this
end, the adhesive material is cut into square sections of the
appropriate size and applied individually to the upper surface of
the base platform 60. However, the shape and size of the patches 70
may vary according to the application and different shapes and
sizes may be employed. It has been found to be advantageous to
employ discrete patches of adhesive material as it facilitates the
assembly process. In one practice the adhesive patches 70 are
provided as a stack of square patches, each having individual
backing and each capable of being peeled off the stack and applied
to the base platform 60. During the assembly process, individual
squares of adhesive material are peeled off the stack and applied
to the base platform 60, or optionally to the side rails or
header/footer, or both. Once the adhesive bonds to the base
platform, the backing material may be peeled away leaving the
adhesive material as the depicted patch 70 which is ready to join
to the foam side rail or the header/footer pieces. Further and
optionally, the interior cavity formed by the perimeter sidewall
may have adhesive material joined thereto for the purpose of
securing the innercore unit to the interior of the tray
support.
[0041] Although the depicted adhesive material is preferred, in
other embodiments other type of fast-setting adhesive, suitable for
reliably and securely fastening together pieces of foam material
may be employed. Moreover, other fastening techniques, such as
spray glue, mechanical fasteners, stitching or hook and loop
fasteners, may be employed as well. The adhesive tape has a width
that is equal to or less than the width of the rails 62, 64, and is
provided as individual strips having lengths that are complementary
to the length of each of the rails. In one practice, the adhesive
dots are applied by contacting the adhesive face of the patch
against the base platform 60 and peeling the backing material away
from the adhesive material leaving the adhesive material 70 fixed
to the base platform 60. Once the adhesive patches 70 are in place
along the portion of the perimeter where the header/footer-piece 64
or a side-rail 62 will go, the foam header/footer 64 or side-rail
70 may be seated over the adhesive patches and pressure applied to
the side-rail or header/footer piece 64 so that it contacts the
adhesive patches 70. An adhesive joint forms between the base
platform 60 and the side-rail 62 or header/footer 64.
[0042] In sequence, the separate side-rails 62 and
header/footer-pieces may be joined to the adhesive patches 70 and
once in position an adhesive tape strip, such as the depicted
strips 68, may be attached around the exterior edges and ends of
the side-rails header/footer pieces to more securely hold the
sidewall parameter in place and together. Once the parameter
sidewall is formed, the inner spring assembly, whether it is foam
or spring or a combination of the two, may be placed inside the
cavity formed interior to the side-rails and header and
footer-pieces. The foam encased mattress may be made in any size,
including standard bedding sizes, such as king size, California
king size, queen, size, twin size, etc. according to the method of
the invention, by shaping the major component parts as appropriate.
Desired firmness of the mattress 10 may be selected by choosing any
desired firmness of the innerspring core or unit.
[0043] As shown in FIG. 4, a subsequent step may occur wherein an
upholstery layer 72 is disposed over the assembled innercore and
parameter sidewall. In one practice, the upholstery layer 72 is
stitched to upholstery material stapled or otherwise joined to the
exterior surface of the parameter sidewall. In this way, the
upholstery layer, as well as any intermediate padding, acts to hold
the innercore within the cavity defined by the parameter sidewall.
Thus, in this embodiment, no extra adhesive, such as spray glue or
mechanical fasteners, such as hog rings, need to be employed to
keep the innercore in place. However, in optional embodiments,
particularly when an open coiled spring assembly is employed or a
pocketed coil spring assembly is employed, a wire extending about a
parameter of the innercore may be employed for holding or securing
the innercore against the base platform. The wire may be a border
wire, a helical wire, or any other type of suitable wire,
including, but not limited to, portions of the helical wire springs
that may be exposed other otherwise available for this purpose. The
wire assembly may extend around a portion of the parameter of the
innercore or may extend transversely through the innercore. Either
way, the wire may be secured to or adjacent the base platform 60
for the purpose of securing the innercore against the rigid base
platform 60. Examples of certain types of border wires are known in
the art and described for example in U.S. Patent entitled Bed
Having Reduced Sagging, naming Richard F. Gladney as inventor. In
other embodiments, the innercore 40 may be secured within the
cavity defined by the parameter sidewall as the application demands
or permits.
[0044] Turning to FIG. 5, the bed and frame assembly of the
invention are depicted wherein the mattress depicted in FIG. 1 and
described above is laid directly upon a bed frame 78 and no
intermediate box-spring or foundation is employed. In this
preferred embodiment, the tray support provides a sufficiently
rigid base 60 that it can be placed directly over a platform or,
depending on the rigidity of the construction, directly on to a bed
frame. To this end, exterior surface of the platform base 60
provides a non-sleeping surface which comprises the substantially
rigid layer of material covered by a thin layer of a non-woven
sheeting. Optionally, a rigid border may be provided around the
peripheral edge of the lower non-sleeping surface to provide
additional support as well as to provide a suppor structure that
can rest in the bed frame or optionally, to which furniture legs
may be direclty attached for the purpose to raising the mattress
off the bedroom floor.
ALTERNATE EMBODIMENTS
[0045] The order in which the steps of the present method are
performed is purely illustrative in nature. In fact, the steps can
be performed in any order or in parallel, unless otherwise
indicated by the present disclosure.
[0046] While particular embodiments of the present invention have
been shown and described, it will be apparent to those skilled in
the art that changes and modifications may be made without
departing from this invention in its broader aspect. For example,
the mattress may include a fire resistant fabric beneath the
quilting layer to provide fire resistant properties. Further, the
mattress may be adjustable for allowing a user to include the
mattress for supporting a seated position. Therefore, the appended
claims are to encompass within their scope all such changes and
modifications as fall within the true spirit of this invention.
* * * * *