U.S. patent application number 10/710981 was filed with the patent office on 2006-02-16 for collapsible mattress border construction and method.
Invention is credited to Ian Craig Barkhouse.
Application Number | 20060031995 10/710981 |
Document ID | / |
Family ID | 35798533 |
Filed Date | 2006-02-16 |
United States Patent
Application |
20060031995 |
Kind Code |
A1 |
Barkhouse; Ian Craig |
February 16, 2006 |
COLLAPSIBLE MATTRESS BORDER CONSTRUCTION AND METHOD
Abstract
A collapsible mattress border assembly incorporates a series of
side rails and end rails pivotably joined together. The pivoting
joints may be hinges, such as formed by tapes, and certain ends of
the rails may be mitered. The collapsible mattress border assembly
is collapsed for shipping, and thereafter opened to form a frame or
border defining a central opening to accommodate a mattress
core.
Inventors: |
Barkhouse; Ian Craig;
(Linwood, PA) |
Correspondence
Address: |
CONNOLLY BOVE LODGE & HUTZ, LLP
P O BOX 2207
WILMINGTON
DE
19899
US
|
Family ID: |
35798533 |
Appl. No.: |
10/710981 |
Filed: |
August 16, 2004 |
Current U.S.
Class: |
5/690 ; 5/722;
5/739 |
Current CPC
Class: |
A47C 27/20 20130101;
A47C 27/15 20130101 |
Class at
Publication: |
005/690 ;
005/739; 005/722 |
International
Class: |
A47C 27/15 20060101
A47C027/15 |
Claims
1. a border assembly for a mattress or bedding material, said
assembly comprising: a first side rail, a first end rail pivotably
attached to said first side rail, a second side rail pivotably
attached to said first end rail, and a second end rail pivotably
attached to said second side rail and said first side rail, wherein
said side rails and said end rails form a collapsible border
assembly.
2. The border assembly according to claim 1, wherein said first and
second side rails and said first and second end rails comprise
polyurethane foam.
3. The border assembly according to claim 2, wherein pivotable
attachment between the first end rail and first side rail is by a
hinge.
4. The border assembly according to claim 2, wherein pivotable
attachment between the second side rail and the first end rail is
by a hinge.
5. The border assembly according to claim 3, wherein said hinge is
formed from a material selected from the group consisting of
adhesive tape, plastic, and polyurethane foam.
6. The border assembly according to claim 2, wherein pivotable
attachment between the first end rail and first side rail is by a
hinge formed by retaining a portion of foam material between said
first end rail and said first side rail when cutting a mitered end
wall in each of said rails.
7. A border assembly for a mattress or other bedding material, said
assembly comprising: a first foam side rail having a top wall, a
bottom wall, an outer side wall, an inner side wall, a mitered end
wall, and a square end wall; a first foam end rail having a top
wall, a bottom wall, an outer side wall, an inner side wall, a
square end wall, and a mitered end wall, wherein said mitered end
wall of said first foam end rail is pivotably attached to said
mitered end wall of said first foam side rail, thereby forming a
mitered corner joint; a second foam side rail having a top wall, a
bottom wall, an outer side wall, an inner side wall, a mitered end
wall, and a square end wall, wherein said square end wall is
pivotably attached to a portion of said inner side wall of said
first end rail, thereby forming a joint; and a second foam end rail
having a top wall, a bottom wall, an outer side wall, an inner side
wall, a square end wall, and a mitered end wall, wherein said
mitered end wall of said second foam end rail is pivotably attached
to said mitered end wall of said second foam side rail, thereby
forming a mitered joint, and said square end wall of said second
side rail is pivotably attached to a portion of said inner side
wall of said second end rail, thereby forming a joint.
8. The border assembly according to claim 7, wherein said first and
second foam side rails and said first and second foam end rails
comprise polyurethane foam
9. The border assembly according to claim 7, wherein pivotable
attachment between the first end rail and first side rail is by a
hinge.
10. The border assembly according to claim 7, wherein pivotable
attachment between the second side rail and the first end rail is
by a hinge.
11. The border assembly according to claim 9, wherein said hinge is
formed from a material selected from the group consisting of tape,
plastic, and polyurethane foam.
12. A method of preparing a collapsible border assembly for
pre-assembly into a mattress construction, comprising: forming a
mitered end wall on a first side rail by cutting said end wall at
an angle of between about 30 to 60 degrees; forming a mitered end
wall on a first end rail by cutting said end wall at an angle of
about 30 to 60 degrees; forming a mitered end wall on a second side
rail by cut-ting said end wall at an angle of about 30 to 60
degrees; forming a mitered end wall on a second end rail by cutting
said end wall at an angle of about 30 to 60 degrees; pivotably
attaching said first side rail to said first end rail at said
respective mitered end walls, thereby forming a mitered corner
joint; pivotably attaching said mitered end wall of said second end
rail to said mitered end wall of said second side rail, thereby
forming a mitered corner joint; pivotably attaching an end wall of
the second side rail to a portion of an inner side wall of said
first end rail, thereby forming a joint; and pivotably attaching an
end wall of the first side rail to a portion of an inner side wall
of said second end rail, thereby forming a joint, wherein the first
end rail, first side rail, second end rail and second side rail
together form the collapsible border assembly.
13. The method of claim 12, further comprising the step of:
collapsing said collapsible border assembly by straightening the
mitered corner joints and bending the joints to place said side
rails substantially in contact with said end rails.
14. The method of claim 12, wherein the mitered end walls are each
formed at an angle of about 45 degrees.
15. A mattress assembly kit having component parts capable of being
assembled at the mattress manufacturer's site, the kit comprising
the combination of: a mattress core section; a collapsible border
assembly having first and second side rails pivotably attached to
first and second end rails, wherein said first and second side and
end rails define a center opening to accommodate the mattress core
section; a top sheet for attaching to top walls of said first and
second side rails and said first and second end rails; and a bottom
sheet for attaching to bottom walls of said first and second side
rails and said first and second end rails.
16. A mattress comprising the border assembly of claim 1.
17. A mattress comprising the mattress assembly kit of claim
15.
18. A method of making a mattress that incorporates a mattress
border assembly, comprising: expanding said collapsible border
assembly having first side rails and second side rails pivotably
attached to first end rails and second end rails, wherein said side
rails and end rails define a center opening; inserting a mattress
core into said center opening, whereby said collapsible border
assembly forms a perimeter frame around said mattress core;
attaching a top sheet onto top walls of said side rails and end
rails; attaching a bottom sheet onto bottom walls of said side
rails and end rails; encasing said mattress core, said collapsible
border assembly, and said top and bottom sheets with a fabric or
casing.
Description
BACKGROUND OF THE TECHNOLOGY
[0001] 1. Field of Technology
[0002] The invention relates to a mattress border construction
formed of pre-assembled components. More specifically, the
invention relates to a collapsible border construction for better
packing and shipping efficiency when collapsed and for quicker
assembly of a mattress core expanded.
[0003] 2. Description of the Related Technology
[0004] Companies have searched for the perfect combination of
mattress components that result in a quality night's sleep.
Typically, sleeping mattresses are formed with a mattress central
portion or mattress core surrounded by a mattress border
construction. The mattress central portion may comprise a series of
coil springs connected together and encased in a quilted fabric or
casing. Alternatively, the mattress central portion may comprise
polyurethane or latex foam layers or synthetic or natural fibers,
optionally in combination with springs, and encased in quilted
fabric. The central portion might also constitute an air mattress
or water mattress or other body-supporting mattress structure.
[0005] Mattress border constructions stabilize the edge or border
portion of the mattress. These borders are more firm or rigid than
the mattress central portion and prevent the mattress from buckling
when a person sits on the mattress edge. Generally, the company
that manufactures the borders is not the same company that
manufactures or assembles the mattress. Therefore, the borders
usually are shipped to a mattress manufacturer for final attachment
to the mattress center portion, whereby the attachment is usually
done manually using various methods.
[0006] Mattress border constructions of various types have been
disclosed in the prior art. U.S. Pat. No. 5,537,699 of Bonaddio et.
al. discloses a mattress border construction formed with a foam
rail sleeve surrounding a plurality of springs arranged in a row.
The foam rail sleeve defines a core into which a row of coil
springs is inserted. The foam is slit on the side wall to
facilitate insertion of the row of springs and then sealed with an
adhesive. Several of these foam rail sleeves surround a mattress
center portion, thereby forming a periphery, and are attached to
the mattress center portion with adhesive. It has been found,
however, that the adhesive can be difficult to apply, and can
create more need for substantial clean up of applicators and
surrounding surfaces. Furthermore, liquid adhesives and hot melt
adhesives cannot be pre-applied before the mattress border
construction is delivered to the mattress manufacturer.
[0007] U.S. Pat. No. 5,701,623 of May shows a composite mattress
topper surrounded by border sections of latex foam. The border
sections have square ends or alternatively angled ends similar to a
picture frame. The border sections are attached to the core section
with an adhesive that cannot be pre-applied before the border
sections are shipped. Thus, this technology does not reduce the
overall cost of assembly.
[0008] To avoid the use of liquid adhesives, U.S. Pub. No. US
2003/0000021 A1 shows a mattress border assembly containing
double-sided high strength adhesive tape attached to portions of
the foam rails. The double-sided adhesive tape contains a release
layer on one side to prevent premature adhesion during packing and
shipping. This technology allows the mattress manufacturer to
attach the border sections to one another and to the mattress core
without the use of messy liquid adhesives. Furthermore, multiple
foam rails may be stacked one atop another in a standard shipping
container, and assembled on site at the mattress manufacturer.
Shipping multiple borders in an unassembled state is cheaper than
shipping a series of assembled borders.
[0009] Another technology that avoids the use of liquid adhesives
is disclosed in U.S. Pat. No. 4,970,743 of Wride et. al. The
mattress border consists of foam perimeter sections that have an
interlocking design with a tongue and groove type arrangement,
where the tongue and groove extends the entire length of the
perimeter sections. Securing means, such as tape or hook and loop
fasteners, are stretched across the tongue and groove joints to
provide extra support. Furthermore, the patent discloses the use of
extra support tapes to prevent bowing of the sidewalls upon
application of transverse pressure.
[0010] A consequence of the pre-applied adhesive coated rails is
the need to manually attach each rail to the mattress core, thus,
not significantly reducing the assembly cost. The same drawback is
noticed with the interlocking rails because each rail must be
manually inserted into the adjoining rail then the entire assembly
reinforced with tape. To overcome this manual assembly step, some
manufacturers use a unitary border assembly as seen in U.S. Pat.
No. 5,259,079 of Visser et. al., which shows the use of a tray to
hold the mattress core. The tray can accommodate both a liquid
filled and non-liquid filled mattress core either separately or in
combination. During mattress assembly, the manufacturer places the
desired mattress core or mattress core combination inside the tray
without the use of adhesives.
[0011] Similarly, U.S. Pat. No. 4,389,743 of Callaway shows the use
of a one piece rigid outer perimeter border with an opening at one
end. The opening allows the mattress manufacturer to easily insert
a mattress core in a "cassette-like" manner. The outer end of the
mattress core contains the remaining end of the perimeter border.
Both these technologies allow for easy assembly in the mattress
manufacturing plant, thus, reducing the overall assembly cost. The
draw back, however, is that these technologies are costly to ship
to the mattress manufacturers because of the large dead volume
provided by the center opening or tray. This dead volume requires
that the packer use a container with an interior volume much large
than the volume of several stacked mattress borders, which
increases packing and shipping costs.
SUMMARY OF THE INVENTION
[0012] None of the described mattress border assemblies have the
desired characteristics of easy assembly and compact design for
increased packing and shipping efficiency. What is needed,
therefore, is a mattress border assembly that collapses into a
compact shape for efficient packing and shipping and easily expands
into a unitary border assembly for a mattress construction.
[0013] The present border assembly overcomes this problem by
providing a series of foam rails that are connected to one another
in a manner that allows each foam rail to pivot away from its
adjacent rail. The configuration allows (1) the packer to
efficiently collapse the border assembly into a shipment-ready
size, and (2) the assembler to easily expand the border assembly
into a unitary perimeter frame for attachment to a mattress
core.
[0014] In a first aspect, a collapsible border assembly according
to the invention has two foam side rails and two foam end rails.
Preferably, each foam rail has a generally flat or square end wall
and an angled or mitered end wall, where the miter preferably is at
about 30 to 60 degrees, most preferably about 45 degrees. Upon
assembly, the mitered end walls of the two side rails abut the
mitered end walls of the two end rails, and the square end walls of
the two side rails abut inner side walls of the two end rails.
After assembly, the mitered end walls form a mitered corner joint
and the square end walls form a substantially square joint, whereby
the mitered corner joints are oppositely opposed from one another
when the mattress border is expanded. Each foam rail has an outer
side wall and an inner side wall for receiving hinges that connect
the four rails together. The hinges are located on the outer side
walls of the mitered joints and on the inner side walls at the
square joints, so that the side and end rails pivot at the hinges
on vertical axes defined by the hinges, where such axes are
perpendicular to the angle of rotation of the side and end rails
during collapsing and expanding of the border assembly.
[0015] Once assembled, the border assembly forms a perimeter frame
defining a center opening to accommodate the mattress core, such as
a spring support mattress, an air mattress, a water mattress or a
foam mattress, or any combination. During packing, the border
assembly may be collapsed upon itself to a compact size for
shipment by pivoting the mitered end walls of the side rails and
end rails away from each other, and opening the hinges associated
with such mitered end walls. In the collapsed position, the mitered
end walls are separated by about 90 degrees, and the planar or
square end walls are substantially released from the inner side
walls, thus closing the center opening. Once collapsed, the side
rails are in substantial contact with the end rails, with one side
rail and one end rail aligned end to end, and the other end rail
and the other side rail aligned end to end, and with each pair of
side/end rails substantially parallel to one another. The packer
may then stack several collapsed border assemblies into a shipping
container that has substantially the same interior volume as the
stack, thus, increasing packing and shipping efficiency and
reducing the overall mattress assembly cost.
[0016] Preferably, the hinge comprises a material that has a
flexible center portion that runs the vertical length of the hinge.
More preferably, the hinge comprises an adhesive tape, and most
preferably an acrylic adhesive tape. Alternatively, the hinge
comprises plastic or other rigid material that has a flexible
center portion that runs the vertical length of the hinge. Such
alternative hinges can be attached to the rails using conventional
adhesives. In yet another embodiment, a hinge may be formed by
cutting one block of rail material to form the mitered portion
between an end rail and a side rail, where the cut is made so as to
leave a portion of the rail material uncut thus pivotably joining
the newly formed end and side rail together at such uncut portion,
thus forming the hinge.
[0017] In an alternate aspect of the invention, the collapsible
border assembly surrounds a mattress core to form a mattress. Here,
the border assembly is expanded to form the perimeter frame with a
center opening for receiving the mattress core. The mattress core
is then inserted into the opening, whereby the mattress border
substantially surrounds the outer edges of the mattress core.
Furthermore, a first foam cover sheet or topper assembly can be
adhered to a top wall of both the side and end rails and a second
foam cover sheet or topper assembly can be adhered to a bottom wall
of the both the side and end rails. This forms a mattress
construction which can then be covered by fabric or a suitable
alternative casing.
[0018] A further aspect of the invention is a method of preparing a
collapsible mattress border assembly for shipment prior to assembly
into a mattress construction. With such method, one end wall of
each of a first and second foam side rail is mitered to about 30 to
about 60 degrees, preferably about 45 degrees. The same miter is
cut into one end wall of each of a first and second end rail. When
the mattress border is ready to be assembled, the mitered end wall
of the first foam side rail abuts the mitered end wall of the first
foam end rail to form a mitered corner joint. A hinge is then
attached to an outer side wall of both the first foam side and end
rail, substantially covering the mitered corner joint. The hinge
can be any device having a flexible vertical center portion that
allows the two mitered end walls to pivot away from each other,
more preferably rigid plastic, and most preferably adhesive
tape.
[0019] The second end wall of the first side rail abuts a portion
of an inner side wall of the first end rail to form a substantially
square joint. A hinge is then attached to an inner side wall of
both the second foam side rail and the first foam end rail,
substantially covering the square joint. The mitered end wall of
the second end rail then abuts the mitered end wall of the second
side rail to form a mitered corner joint. A hinge is then attached
to an outer side wall of both the second foam side and end rail,
substantially covering the mitered corner joint. At this stage, the
second end wall of the first side rail then abuts a portion of an
inner side wall of the second end rail, thereby forming a
substantially square joint and the collapsible border assembly. A
hinge can then be attached to an inner side wall of the first side
rail and an inner wall of the second end rail, substantially
covering the square joint.
[0020] Other aspects and advantages will be apparent from the
following description given hereinafter referring to the attached
drawings.
DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective view of a collapsed border assembly
showing the mitered corner joints and square joints and the hinges
covering said joints;
[0022] FIG. 2 is a cross-sectional view in front elevation taken
along line 2-2 of FIG. 1;
[0023] FIG. 3 is a top plan view showing multiple collapsible
border assemblies packed in a shipping carton;
[0024] FIG. 4 is an end cross sectional view in elevation taken
along line 4-4 of FIG. 3, showing multiple collapsible border
assemblies packed in a shipping carton;
[0025] FIG. 5 is an exploded perspective view of a border assembly
expanded to form a perimeter frame with a center opening for
receiving a mattress core;
[0026] FIG. 6 is a top plan view of an expanded mattress border
assembly according to the invention;
[0027] FIG. 7 is a right side elevational view of the expanded
mattress border assembly of FIG. 6;
[0028] FIG. 8. is an exploded perspective view of a mattress
incorporating a mattress border assembly and topper assemblies;
[0029] FIG. 9 is a top plan view of the mattress of FIG. 8,
partially broken away to show the mitered corner and square joints
and hinges covering said joints in the mattress border assembly;
and
[0030] FIG. 10 is a right side elevational view of the mattress of
FIG. 9.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0031] Referring first to FIGS. 1 and 2, a border assembly 10 in
the collapsed position has side rails 12, 12' and end rails 14, 14'
both formed of a resilient material such as, but not limited to,
polyurethane foam. Examples of polyurethane foams that could be
used for the rails have densities in the range of about 1.0 to
about 2.5 pounds per cubic foot (pcf), and firmnesses from about 40
to about 125 ILD.sub.25 (indentation load deflection or sometimes
also called IFD.sub.25--see ASTM 3574). Other resilient materials
besides polyurethane foam may be used.
[0032] Side rails 12, 12' and end rails 14, 14' have top walls 20,
bottom walls 22, end walls 24, mitered end walls 28, inner side
walls 30, and outer side walls 32. The side rails 12, 12' and end
rails 14, 14' may be comprised of polyurethane foam surrounding
springs or other firming central mattress structure, such as shown
in U.S. Pat. No. 5,537,699 of Bonaddio et. al., or latex core, or
fiber core, or water or air mattress, or a combination. In the
embodiment shown in FIGS. 1 and 2, hinges 34 are applied to each
joint formed by the abutment of the mitered end walls 28 of the
side rails 12, 12' to the mitered end walls 28 of the end rails 14,
14', and the abutment of the square end walls 24 of the side rails
12, 12' to a portion of the inner side walls 30 of the end rails
14, 14'. The abutment of the mitered end walls 28 forms mitered
corner joints 36, and the abutment of the square end walls 24 forms
substantially square joints 37, whereby the mitered corner joints
36 are oppositely opposed from one another when the mattress border
10 is expanded to an open position.
[0033] The hinges 34 can be made of a material with a flexible
center portion that runs the vertical length of the hinge, more
preferably rigid plastic with a vertical flexible center portion.
Most preferably, the hinges are formed from adhesive tape. Examples
of suitable tapes may have a woven or non-woven construction, such
as DUON.RTM. or TYPAR.RTM., and can range from 1.0 to 3.0
oz./square yard. A rigid plastic hinge can be attached using
conventional adhesive means such as glue or double sided adhesive
tape. Furthermore, a rigid plastic hinge provides the border
assembly 10 with extra torsional stability.
[0034] The hinges 34 are located on the outer side walls 32 of the
mitered end walls 28 and on the inner side walls 30 of the square
end walls 24. The vertical flexible center portion substantially
covers the mitered corner joints 36 and square joints 37. The
hinges 34 allow the side rails 12, 12' and end rails 14, 14' to
pivot on a vertical axis that is perpendicular to the angle of
rotation during collapsing and expanding of the border assembly 10.
FIG. 2 shows hinge 34 in a collapsed position attached to the inner
side walls 30.
[0035] In the collapsed position (FIGS. 1 and 2), the border
assembly 10 is very compact, which is ideal for packing and
shipping efficiency. Here, the mitered end walls 28 are separated
by about a 90 degree angle, and the square end walls 24 of the side
rails 12, 12' are substantially released from the inner side walls
30 of the end rails 14, 14'. Hinges 36 are in a substantially open
position, and hinges 37 are closed or bent by about 180.degree..
Furthermore, once collapsed, the side rails 12, 12' are in
substantial contact with the end rails 14, 14'.
[0036] As shown in FIGS. 3 and 4, multiple collapsible border
assemblies 10 may be packed side by side and vertically stacked
into a shipping carton 38. The interior volume of the carton 38 is
substantially the same as the volume of the stack of border
assemblies, thus reducing packing and shipping costs.
Alternatively, multiple collapsible border assemblies may be
stacked together in collapsed configuration to form a bundle that
is then wrapped with a shrink wrap, a polyethylene sheet or other
sheet-like wrapping material (not shown) for shipment with or
without use of a shipping carton.
[0037] As shown in FIGS. 5 to 7, a mattress border assembly 10 in
the expanded or open position comprises a perimeter frame-like
structure formed from two side rails 12, 12' pivotably attached to
two end rails 14, 14'. The hinge 34 attached to the side rails 12,
12' to the end rails 14, 14' allows the two sets of rails to pivot
on a vertical axis where the angle of rotation is perpendicular to
the vertical axis. The expanded frame 10 forms a perimeter defining
a center opening 38 for receiving a mattress core 42. The mattress
core 42 can be inserted into the center opening 38 using
conventional methods. FIG. 6 shows a mattress 60 with a mattress
core 42 surrounded by the border assembly 10 according to another
embodiment of the invention.
[0038] FIG. 8 illustrates a further embodiment of a mattress 62
wherein a mattress core 42 is surrounded by a mattress border
assembly 10 and covered by a top foam cover sheet 50 and a bottom
foam cover sheet 54. The top foam cover sheet 50, which may also be
a topper assembly, may be adhered to the top walls 20 of the side
rails 12, 12' and end rails 14, 14' using an adhesive, such as a
spray adhesive, a hot melt adhesive or double sided adhesive tape.
Adhesives may be, for example, spray adhesives, such as Simalfa
#3091-250Y, or hot melt adhesives, such as Industrial Adhesives
#90-747C. An example of a suitable double-sided tape is 3M
#9695.
[0039] Similarly, the bottom cover sheet 54, which may also be a
topper assembly, may be adhered to the bottom walls 22 of the side
rails 12, 12' and end rails 14, 14' using an adhesive, such as a
hot melt adhesive or double sided adhesive tape. The mattress
assembly 62 so formed comprises a mattress border assembly 10
encasing a mattress core 42 as shown in FIGS. 9 and 10. The
mattress construction can then be completed in the customary
fashion, by encasing the assembly in a fabric or quilting or
ticking or casing to form the completed mattress.
[0040] In yet another embodiment, strips of double sided adhesive
tape may be applied to the top walls 20 and bottom walls 22 of both
the side rails 12, 12' and bottom rails 14, 14'. The exposed
surface of the adhesive tape is covered with a removable protective
liner to prevent premature adhesion during packing and shipping.
The adhesive tape allows for efficient attachment of the top foam
sheet 50 or topper assembly and bottom foam sheet 54 or topper
assembly. The tape should have a bonding strength in the range of 5
to 15 psi, preferably 10 psi. The tape preferably is coated with an
acrylic adhesive to a coating weight in the range of 30 to 34
grains per 24 square inches, preferably 32 grains per 24 square
inches. The bond must tack and set quickly, reaching about 90% of
its full bonding capability within about 10 minutes of adhering
parts together with the tape, and preferably reaches full bonding
capability within about 15 minutes.
[0041] Numerous characteristics and advantages have been set forth
in the foregoing description, together with detail of structure and
function. The novel features are pointed out in the appended
claims. The disclosure, however, is illustrative only, and changes
may be made in detail, especially in matters of size, shape, and
arrangement of parts, within the principle of the invention, to the
full extent indicated by the broad general meaning of the terms in
which the appended claims are expressed. Therefore, the invention
must be measured by the claims and not by the description of the
examples or the preferred embodiments.
* * * * *