U.S. patent application number 11/890715 was filed with the patent office on 2009-02-12 for knockdown modular mattress.
Invention is credited to Neil Grigg.
Application Number | 20090038080 11/890715 |
Document ID | / |
Family ID | 40345110 |
Filed Date | 2009-02-12 |
United States Patent
Application |
20090038080 |
Kind Code |
A1 |
Grigg; Neil |
February 12, 2009 |
Knockdown modular mattress
Abstract
The field of the present invention pertains to knockdown
mattresses. More particularly, the present invention relates to
mattresses that can be assembled and disassembled by the end user.
The present invention when assembled or reassembled presents a
visual impression to the end user looks like a conventional
"factory assembled" mattress. The invention further provides for a
modular mattress assembly kit that can be shipped by express
delivery services while taking up far less volume than a
conventional mattress.
Inventors: |
Grigg; Neil; (High Point,
NC) |
Correspondence
Address: |
BRIAN D. VOYCE
8401 STERLING BRIDGE ROAD
CHAPEL HILL
NC
27516
US
|
Family ID: |
40345110 |
Appl. No.: |
11/890715 |
Filed: |
August 7, 2007 |
Current U.S.
Class: |
5/720 ; 5/690;
5/716; 5/738 |
Current CPC
Class: |
A47C 27/001 20130101;
A47C 31/105 20130101; A47C 27/06 20130101; A47C 27/05 20130101 |
Class at
Publication: |
5/720 ; 5/690;
5/716; 5/738 |
International
Class: |
A47C 27/00 20060101
A47C027/00 |
Claims
1. A modular mattress comprising: a) a peripheral support module
having exterior lateral edges extending the depth of the mattress
that define the outer dimensions of the modular mattress, said
peripheral support module being comprised of a supportive and
compressible foam; b) at least two mattress chambers disposed
within the interior of the peripheral support module, each chamber
defining interior chamber walls on the peripheral support module;
c) a plurality of internal support modules, each such internal
support module being sized and dimensioned to fit in a snug
relationship with the interior walls of a respective chamber, and
each such internal support module being disposed within such
respective chamber; and d) a cover completely enveloping the
peripheral support module, said cover having a top panel, a lateral
skirt, a bottom panel, and a closure means, the cover being sized
and dimensioned to permit the top panel, the lateral skirt, and the
bottom panel to apply tension to the combination of the peripheral
support module and the internal support modules within the
respective chambers such that when the closure means is in a closed
position, the tension holds the peripheral support module and the
internal support modules in a relatively fixed position with
respect to each other, distributes any mattress load amongst the
combination of the peripheral support module and the internal
support modules, and maintains the cover in a taught state without
a mattress load.
2. An unassembled modular mattress kit comprising: a) a peripheral
support module having exterior lateral edges extending the depth of
the mattress that define the outer dimensions of the modular
mattress, such peripheral support module being comprised of a
supportive and compressible foam; and having at least two mattress
chambers disposed within the interior of the peripheral support
module, thereby defining interior chamber walls on the peripheral
support module, said peripheral support module being compressed
into a volume less than half the volume of the peripheral support
module in an uncompressed state; b) a plurality of internal support
modules, each being sized and dimensioned to fit in a snug
relationship with the interior walls of a respective chamber, said
internal support modules being compressed into a volume less than
half the volume of the internal support modules in an uncompressed
state; and c) a cover for completely enveloping the peripheral
support module, said cover having a top panel, a lateral skirt, a
bottom panel, and a closure means, the cover being sized and
dimensioned to permit the top panel, the lateral skirt, and the
bottom panel to apply tension to the combination of the peripheral
support module and the internal support modules within the
respective chambers such that when the closure means is in a closed
position, the tension holds the peripheral support module and the
internal support modules in a relatively fixed position with
respect to each other, distributes any mattress load amongst the
combination of the peripheral support module and the internal
support modules, and maintains the cover in a taught state without
a mattress load.
3. A method of assembling a knockdown mattress comprising: a)
selecting the following elements: i) a peripheral support module
having exterior lateral edges extending the depth of the mattress
that define the outer dimensions of the modular mattress, such
peripheral support module being comprised of a supportive and
compressible foam; and having at least two mattress chambers
disposed within the interior of the peripheral support module,
thereby defining interior chamber walls on the peripheral support
module, said peripheral support module being compressed into a
volume less than half the volume of the peripheral support module
in an uncompressed state; ii) a plurality of internal support
modules, each being sized and dimensioned to fit in a snug
relationship with the interior walls of a respective chamber, said
internal support modules being compressed into a volume less than
half the volume of the internal support modules in an uncompressed
state; and iii) a cover for completely enveloping the peripheral
support module, said cover having a top panel, a lateral skirt, a
bottom panel, and a closure means, the cover being sized and
dimensioned to permit the top panel, the lateral skirt, and the
bottom panel to apply tension to the combination of the peripheral
support module and the internal support modules within the
respective chambers such that when the closure means is in a closed
position, the tension holds the peripheral support module and the
internal support modules in a relatively fixed position with
respect to each other, distributes any mattress load amongst the
combination of the peripheral support module and the internal
support modules, and maintains the cover in a taught state without
a mattress load; b) decompressing the peripheral support module and
the internal support modules to an uncompressed state; c) inserting
each support module into its respective chamber in the peripheral
support module; d) placing the cover about the combination; and e)
moving the cover closure means into a closed position
Description
BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The field of the present invention pertains to mattresses.
More particularly, the present invention relates to knockdown
mattresses that can be assembled and disassembled by the end user.
The present invention when assembled or reassembled presents a
visual impression to the end user looks like a conventional
"factory assembled" mattress. The invention further provides for a
modular mattress assembly kit that can be shipped by express
delivery services while taking up far less volume than a
conventional mattress.
[0003] (2) Description of the Related Art, Including Information
Disclosed Under 37 CFR 1.97 & 1.98
[0004] The prior art has looked at forms of modular mattress
construction in the past. However, the prior art has failed to
disclose a combination of elements that can not only be assembled
and reassembled by an end user, but also can provide the desired
quality look of a conventional factory assembled mattress.
[0005] For example, U.S. Pat. No. 3,950,800 to Garshfield discloses
a modular mattress structure having insulators, stuffing pad, and a
cover having an inner flange that holds the components in
place.
[0006] A customized modular mattress bedding is also shown in U.S.
Pat. No. 5,745,940 to Roberts et alia. Layers of foam are into a
support module according to the end users desire for support.
[0007] Another approach to a modular mattress having a removable
liquid filled insert is seen in U.S. Pat. Nos. 6,192,538 and
6,481,033 to Fogel. At least two support modules are positioned
side by side, with a depression in the top of the support module. A
comfort cushion is disposed atop each module, lying in the
depression. The walls of the support modules are wrapped in a
non-woven material that is adhesively bonded thereto, this material
providing the dimensional stability for the mattress.
[0008] None of the above systems have been accepted commercially.
They all lack an acceptable finished mattress look to the end user.
Furthermore, none of these systems provide for a system in which
the mattress can be broken down and shipped by the end user in half
the volume or less of the assembled mattress.
BRIEF SUMMARY OF THE INVENTION
[0009] The field of the present invention pertains to mattresses.
More particularly, the present invention relates to mattresses that
can be assembled and disassembled by the end user. The present
invention, when assembled or reassembled, presents a visual
impression to the end user looks like a conventional "factory
assembled" mattress. The invention further provides for a modular
mattress assembly kit that can be shipped by express delivery
services while taking up far less volume than a conventional
mattress.
[0010] The present invention comprises a modular mattress (10). As
seen in FIGUREs, the combination of elements for this mattress
includes the following: a peripheral support module (20), at least
two mattress chambers (30), a plurality of internal support modules
(40), and a mattress cover (50).
[0011] The peripheral support module has exterior lateral edges
(22) and (24) extending the depth of the mattress that define the
outer dimensions of the modular mattress. The peripheral support
module can be comprised of a supportive and compressible foam. The
dimensions of this module should extend inward a sufficient
distance to enable a typical user to sit on the edge of the
assembled mattress and provide support such that the mattress
perimeter maintains firmer support than that support provided by
the internal modular support component. Thus, edge stability of the
mattress is maintained when the user is in a seated position atop
the mattress. Additionally, such a combination of support permits
the user to occupy the full width of the mattress when in a
reclining position.
[0012] The mattress chambers (30) are openings disposed within the
interior of the peripheral support module. Each chamber defines
interior chamber walls (32) on the peripheral support module. Each
chamber can be filled with an internal support module (40). These
modules can be constructed out of various conventional mattress
support structures such as spring sets, foam blocks, fluid
bladders, laminated combinations, or the like. Each internal
support module is sized and dimensioned to fit in a snug
relationship with the interior walls (32) of its respective
chamber. The snugness is defined by a combination of the degree of
the stiffness of the peripheral module. Thus, the support module
may displace outwardly the interior walls of the chamber.
[0013] A mattress cover (50) completely envelops the combination of
the peripheral support module and the accompanying internal support
modules. The cover has a top panel (52), a lateral skirt (54), a
bottom panel (56), and a closure means (58). The cover is sized and
dimensioned to permit the combination of the top panel, the lateral
skirt, and the bottom panel to apply tension to the combination of
the peripheral support module and the internal support modules
within the respective chambers. The tension created by the cover,
once the closure means is closed, holds the peripheral support
module and the internal support modules in a relatively fixed
position with respect to each other, distributes any mattress load
amongst the combination of the peripheral support module and the
internal support modules, and maintains the cover in a taught state
throughout its panels and skirt, even without a mattress load. By
"relatively fixed", the present invention refers to the fact that
the internal support module will not shift vertically or
horizontally in a chafing fashion with respect to the peripheral
support module either when conventional mattress loads are applied
or in a resting non-loaded position.
[0014] The present invention also comprises an unassembled modular
mattress kit. Using the above elements, one can have the internal
support modules separate from the peripheral support module. Each
internal support module is configured so as to be able to be
compressed to less than half the volume in the uncompressed state.
Likewise, the peripheral support module is configured so as to be
able to be compressed to less than half the volume in the
uncompressed state. Each internal support module can have a binding
means attached that secures the support module in a compressed
state for ease of handling. Likewise, the peripheral support module
can have a binding means attached that secures the support module
in a compressed state for ease of handling. Optionally, at least
part of the cover can be attached to the peripheral support module.
Such a kit enables one to ship a knock down mattress through
conventional express delivery services.
[0015] The present invention also comprises a method for assembling
a knockdown mattress from the above mattress kit. The steps of this
method include first selecting a combination of elements as
described above. Second, one decompresses the peripheral support
module and the internal support modules. Then one inserts each
support module into its respective chamber in the peripheral
support module. One places the cover about the combination and
moves the closure means into a closed position.
[0016] An object of the invention is to provide a knockdown
mattress that has the look and comfort of a quality, fixed assembly
mattress while having the assembly/disassembly functionality of a
knockdown mattress.
[0017] A second object of the invention is to provide a knockdown
mattress that can be assembled without any tools.
[0018] A third object of the invention is to provide a knockdown
mattress that can be disassembled into a package that can be
shipped through conventional ground delivery services, such as
FedEx Ground or United Parcel Service.
[0019] A fourth object of the invention is to provide a knockdown
mattress in which the modular components do not shift in use and
are not detectable from the exterior.
[0020] A fifth object of the invention is to provide the ability of
either designing or converting a mattress on a customized basis to
satisfy individual comfort requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective view of a preferred embodiment of
the present invention showing the claimed elements with the top
mattress cover in an open position.
[0022] FIG. 2 is a side cutaway view of a preferred embodiment of
the present invention showing the claimed elements in an open
position.
DETAILED DESCRIPTION OF THE INVENTION
[0023] A preferred modular mattress embodiment is shown in the
FIGUREs. As seen in FIG. 1, the combination of elements for this
mattress includes the following: a peripheral support module (20),
at least two mattress chambers (30), a plurality of internal
support modules (40), and a mattress cover (50).
[0024] The peripheral support module can be constructed in several
ways. It can be molded as one piece. It can be fabricated by
cutting a single piece of foam. Or it can be made by gluing pieces
of foam that make up the individual lengths and widths of the
peripheral support module. The peripheral support module is
comprised of a supportive and compressible bedding foam such as
high density polyurethane. As shown in the FIGUREs, the perimeter
or bolster rails of the peripheral support module extend inward
about one foot, enabling a typical user to sit on the edge of the
assembled mattress. The bolster firmness is greater than that of
the internal support module. Preferably, a longitudinal bolster is
disposed down the middle of the mattress, separating and defining
two separate mattress chambers. Preferably, the peripheral support
module can have intermediate rails (26) that extend longitudinally
and transversely between the outer bolster rail, thereby creating
at least four mattress chambers.
[0025] Each chamber can be filled with an internal support module
(40). As shown in the FIGUREs, spring sets (42) are covered in a
conventional protective material. These spring sets are sized such
that they snugly fit within the chambers, displacing the interior
chamber walls from their original, preloaded position. Preferably,
there are no voids between the internal support module and the
interior chamber walls.
[0026] The mattress cover (50) comprises a fabric (including woven
or knitted fabrics) that completely envelops the combination of the
peripheral support module and the accompanying internal support
modules. The cover is made from conventional cloth materials used
on factory assembled, non-modular mattresses. The cover closure
means (58) comprises a zipper along the edge of the bottom panel
that can withstand the tension forces generated by the mattress
cover. The mattress cover is sized such that the interior volume of
the cover is less than the volume of the peripheral support module
in its uncompressed state. The tension provided by the mattress
cover is sufficient to provide dimensional integrity to the
mattress by keeping all of the mattress elements moving together in
response to load. There is no shifting of internal parts, one with
respect to another due to the tension supplied by the closed cover.
Fire resistance can be an important factor in a consumer selecting
a bed mattress. Therefore, the mattress cover can also comprise
fire-resistant material on the external surface.
[0027] In a preferred embodiment, the mattress can also comprise
additional support layers atop the internal support modules. Thus,
as seen in FIG. 2, one can place an upper mattress support layer
(60), such as a memory foam layer, above the internal support
modules and the peripheral support module.
[0028] The present invention also comprises an unassembled modular
mattress kit. The kit comprises an internal support module (40)
compressed along the axis of spring compression to less than half
the volume in the uncompressed state. Likewise, the peripheral
support module is configured compressed to less than half the
volume in the uncompressed state, being folded along either its
transverse axis, its longitudinal axis, or both axes. A preferred
embodiment with intermediate rails would have those rails moveable
so as to facilitate folding. The bottom panel of the mattress cover
(56) is attached to the peripheral support module, such as by
adhesive bonding. Such a kit enables one to ship the present
invention through conventional express delivery services.
[0029] Finally, the present invention also comprises a method of
assembling a knockdown mattress. First on selects the peripheral
support module, internal support modules, and the mattress cover
elements found in the mattress kit described above. One
decompresses the peripheral support module and the internal support
modules to an uncompressed state. Each support module is inserted
into its respective chamber in the peripheral support module. If
not already attached to the peripheral support module, then one
places the cover about the combination. Finally, one moves the
cover closure means into a closed position.
[0030] The ordinarily skilled artisan can appreciate that the
present invention can incorporate any number of the preferred
features described above.
[0031] All publications or unpublished patent applications
mentioned herein are hereby incorporated by reference thereto.
[0032] Other embodiments of the present invention are not presented
here which are obvious to those of ordinary skill in the art, now
or during the term of any patent issuing from this patent
specification, and thus, are within the spirit and scope of the
present invention.
* * * * *