U.S. patent application number 12/715018 was filed with the patent office on 2011-09-01 for size convertible mattress.
This patent application is currently assigned to Foamex Innovations Operating Company. Invention is credited to Lauren C. Gatto, Eric Holzer, Nicole Meluskey, Geoffrey R. Quinter.
Application Number | 20110209288 12/715018 |
Document ID | / |
Family ID | 44455303 |
Filed Date | 2011-09-01 |
United States Patent
Application |
20110209288 |
Kind Code |
A1 |
Quinter; Geoffrey R. ; et
al. |
September 1, 2011 |
SIZE CONVERTIBLE MATTRESS
Abstract
A mattress converts from a crib mattress with side walls and end
walls surrounding an infant sleeping surface on a central mattress
section therebetween to a twin mattress with a substantially planar
sleeping surface to support a reclining child or adult. The end
walls and side walls are tethered or hingedly connected to the
central mattress section and are moveable from an upright position
(crib mattress) to an open position (twin mattress). Sidewall
extensions are hingedly connected to the side walls and are
pivotably moveable from a first position above the side walls to a
second position axially aligned with the side walls when the side
walls are in the open position.
Inventors: |
Quinter; Geoffrey R.;
(Earlville, PA) ; Holzer; Eric; (Coopersburg,
PA) ; Meluskey; Nicole; (Center Valley, PA) ;
Gatto; Lauren C.; (Bethlehem, PA) |
Assignee: |
Foamex Innovations Operating
Company
Media
PA
|
Family ID: |
44455303 |
Appl. No.: |
12/715018 |
Filed: |
March 1, 2010 |
Current U.S.
Class: |
5/694 ;
5/722 |
Current CPC
Class: |
A47D 15/001
20130101 |
Class at
Publication: |
5/694 ;
5/722 |
International
Class: |
A47C 27/15 20060101
A47C027/15; A47C 27/14 20060101 A47C027/14 |
Claims
1. A mattress, comprising: a central mattress section defining a
top surface and having first and second ends and left and right
sides; a first end wall hingedly connected to said central mattress
section at or near said first end, said first end wall pivotably
moveable from an upright position to an open position; a second end
wall hingedly connected to said central mattress section at or near
said second end, said second end wall pivotably moveable from an
upright position to an open position; a first side wall hingedly
connected to said central mattress section at or near said left
side, said first side wall pivotably moveable from an upright
position to an open position; a second side wall hingedly connected
to said central mattress section at or near said right side, said
second side wall pivotably moveable from an upright position to an
open position; a first sidewall extension having a length and
defining a lengthwise axis, said first sidewall extension being
hingedly connected to an end of the first side wall and pivotably
moveable from a first position to a second position in which the
lengthwise axis is generally aligned with a lengthwise axis of the
first side wall; and a second sidewall extension having a length
and defining a lengthwise axis, said second sidewall extension
being hingedly connected to an end of the second side wall and
pivotably moveable from a first position to a second position in
which the lengthwise axis is generally aligned with a lengthwise
axis of the second side wall; wherein the first end wall is not
hingedly connected to the first side wall, the first sidewall
extension, the second side wall or the second sidewall extension,
and wherein the second end wall is not hingedly connected to the
first side wall, the first sidewall extension, the second side wall
or the second sidewall extension.
2. The mattress of claim 1, further comprising a third sidewall
extension having a length and defining a lengthwise axis, said
third sidewall extension being hingedly connected to an opposite
end of the first side wall and pivotably moveable from a first
position to a second position in which the lengthwise axis is
generally aligned with the lengthwise axis of the first side
wall.
3. The mattress of claim 2, further comprising a fourth sidewall
extension having a length and defining a lengthwise axis, said
fourth sidewall extension being hingedly connected to an opposite
end of the second side wall and pivotably moveable from a first
position over the second side wall to a second position in which
the lengthwise axis is generally aligned with the lengthwise axis
of the second side wall.
4. The mattress of claim 1, wherein when the first and second end
walls are in the upright position, the first and second side walls
are in the upright position, the top surface of the central
mattress section defines a body-supporting surface enclosed within
the first and second end walls and the first and second side
walls.
5. The mattress of claim 1, wherein when the first and second end
walls are in the open position, the first and second side walls are
in the open position, and first and second sidewall extensions are
in the second position, a substantially planar body-supporting
surface is formed that includes the central mattress section, the
first and second end walls and the first and second side walls.
6. The mattress of claim 5, wherein the substantially planar
body-supporting surface further comprises the first and second
sidewall extensions.
7. The mattress of claim 1, wherein the lengthwise axis of the
first sidewall extension is parallel or substantially parallel to
the lengthwise axis of the first side wall when the first sidewall
extension is in the first position.
8. The mattress of claim 1, wherein the lengthwise axis of the
second sidewall extension is parallel or substantially parallel to
the lengthwise axis of the second side wall when the second
sidewall extension in is the first position.
9. The mattress of claim 1, wherein the central mattress section,
first end wall, second end wall, first side wall, second side wall,
first sidewall extension and second sidewall extension are formed
of one or more materials selected from the group consisting of:
polyurethane foam, viscoelastic foam, and latex foam.
10. The mattress of claim 1, wherein at least the central mattress
section is formed as a composite of two or more foams of varying
support characteristic or resiliency.
11. The mattress of claim 1, wherein connections between the
central mattress section and the first and second side walls
comprise hinges formed of a material selected from the group
consisting of: fabrics, films, laminates and elastics.
12. The mattress of claim 1, wherein the connections between the
central mattress section and the first and second end walls
comprise hinges formed of a material selected from the group
consisting of: fabrics, films, laminates and elastics.
13. The mattress of claim 1, wherein the connections between the
first and second sidewall extensions and the first side wall and
the second side wall are hinges formed of a material selected from
the group consisting of: fabrics, films, laminates and
elastics.
14. The mattress of claim 1, further comprising releasable
fasteners applied to the top surface of the central mattress
section and to surfaces of the first and second end walls to join
the first and second end walls to the central mattress section in
the upright position.
15. The mattress of claim 1, further comprising releasable
fasteners applied to the top surface of the central mattress
section and to surfaces of the first and second side walls to join
the first and second side walls to the central mattress section in
the upright position.
16. The mattress of claim 1, further comprising releasable
fasteners applied to lengthwise surfaces of the first and second
sidewall extensions and to lengthwise surfaces of the first and
second side walls to join the first sidewall extension to the first
side wall and to join the second sidewall extension to the second
side wall.
17. The mattress of claim 1, further comprising releasable
fasteners applied to end surfaces of the central mattress section
and to surfaces of the first and second end walls to join the first
and second end walls to the central mattress section in the open
position.
18. The mattress of claim 1, further comprising releasable
fasteners applied to side surfaces of the central mattress section
and to surfaces of the first and second side walls to join the
first and second side walls to the central mattress section in the
open position.
19. The mattress of claim 1, further comprising releasable
fasteners applied to lengthwise surfaces of the first and second
sidewall extensions and to side surfaces of the first end wall to
join the first and second sidewall extensions to the first end wall
when the first end wall is in the open position and the first and
second sidewall extensions are in the second position.
20. The mattress of claim 5, further comprising a cover extending
substantially over at least the substantially planar
body-supporting surface.
21. The mattress of claim 1, further comprising a cover extending
substantially over at least the central mattress section.
22. The mattress of claim 1, wherein at least one of the sidewall
extensions defines a void therein to receive an accessory or
toy.
23. A mattress, comprising: a central mattress section defining a
top surface and having first and second ends and left and right
sides; a first end wall tethered to said central mattress section
at or near said first end, said first end wall moveable from an
upright position to an open position; a second end wall tethered to
said central mattress section at or near said second end, said
second end wall moveable from an upright position to an open
position; a first side wall tethered to said central mattress
section at or near said left side, said first side wall moveable
from an upright position to an open position; a second side wall
tethered to said central mattress section at or near said right
side, said second side wall moveable from an upright position to an
open position; a first sidewall extension having a length and
defining a lengthwise axis, said first sidewall extension being
connected to an end of the first side wall and pivotably moveable
from a first position to a second position in which the lengthwise
axis is generally aligned with a lengthwise axis of the first side
wall; and a second sidewall extension having a length and defining
a lengthwise axis, said second sidewall extension being connected
to an end of the second side wall and pivotably moveable from a
first position to a second position in which the lengthwise axis is
generally aligned with a lengthwise axis of the second side wall;
wherein at least one of the first end wall or the second end wall
is not hingedly connected to the first side wall, the first
sidewall extension, the second side wall or the second sidewall
extension.
24. The mattress of claim 23, wherein when the first and second end
walls are in the upright position, the first and second side walls
are in the upright position, the top surface of the central
mattress section defines a body-supporting surface enclosed within
the first and second end walls and the first and second side
walls.
25. The mattress of claim 23, wherein when the first and second end
walls are in the open position, the first and second side walls are
in the open position, and first and second sidewall extensions are
in the second position, a substantially planar body-supporting
surface is formed that includes the central mattress section, the
first and second end walls and the first and second side walls.
26. The mattress of claim 25, wherein the substantially planar
body-supporting surface further comprises the first and second
sidewall extensions.
27. The mattress of claim 23, wherein the lengthwise axis of the
first sidewall extension is parallel or substantially parallel to
the lengthwise axis of the first side wall when the first sidewall
extension is in the first position.
28. The mattress of claim 23, wherein the lengthwise axis of the
second sidewall extension is parallel or substantially parallel to
the lengthwise axis of the second side wall when the second
sidewall extension in is the first position.
29. The mattress of claim 23, wherein the central mattress section,
first end wall, second end wall, first side wall, second side wall,
first sidewall extension and second sidewall extension are formed
of one or more materials selected from the group consisting of:
polyurethane foam, viscoelastic foam, and latex foam.
30. The mattress of claim 23, wherein at least the central mattress
section is formed as a composite of two or more foams of varying
support characteristic or resiliency.
31. The mattress of claim 23, wherein connections between the
central mattress section and the first and second side walls
comprise tethers formed of a material selected from the group
consisting of: fabrics, films, laminates and elastics.
32. The mattress of claim 23, wherein the connections between the
central mattress section and the first and second end walls
comprise tethers formed of a material selected from the group
consisting of: fabrics, films, laminates and elastics.
33. The mattress of claim 23, wherein the connections between the
first and second sidewall extensions and the first side wall and
the second side wall are hinges formed of a material selected from
the group consisting of: fabrics, films, laminates, and
elastics.
34. The mattress of claim 23, further comprising releasable
fasteners applied to the top surface of the central mattress
section and to surfaces of the first and second side walls to join
the first and second side walls to the central mattress section in
the upright position.
35. The mattress of claim 23, further comprising releasable
fasteners applied to lengthwise surfaces of the first and second
sidewall extensions and to lengthwise surfaces of the first and
second side walls to join the first sidewall extension to the first
side wall and to join the second sidewall extension to the second
side wall.
36. The mattress of claim 23, further comprising releasable
fasteners applied to surfaces of the first and second side walls
and to the first and second end walls to join the first end wall to
the first side wall and to join the second end wall to the second
side wall.
37. The mattress of claim 23, further comprising releasable
fasteners applied to end surfaces of the central mattress section
and to surfaces of the first and second end walls to join the first
and second end walls to the central mattress section in the open
position.
38. The mattress of claim 23, further comprising releasable
fasteners applied to side surfaces of the central mattress section
and to surfaces of the first and second side walls to join the
first and second side walls to the central mattress section in the
open position.
39. The mattress of claim 1, further comprising releasable
fasteners applied to lengthwise surfaces of the first and second
sidewall extensions and to side surfaces of the first end wall to
join the first and second sidewall extensions to the first end wall
when the first end wall is in the open position and the first and
second sidewall extensions are in the second position.
40. The mattress of claim 23, further comprising a cover extending
substantially over at least the substantially planar
body-supporting surface.
41. The mattress of claim 23, further comprising a cover extending
substantially over at least the central mattress section.
42. The mattress of claim 23, wherein at least one of the sidewall
extensions defines a void therein to receive an accessory or toy.
Description
FIELD OF THE INVENTION
[0001] This invention relates to bedding mattresses convertible
from a first size suitable for use in an infant's crib to a second
size suitable for use with a twin bed. The bedding mattress has
sections that are hingedly connected so that they may be pivotably
moved from a first position forming a mattress combined with
sidewalls or bumpers for use in an infant's crib to a second
position forming a twin-size mattress.
BACKGROUND
[0002] Infants generally sleep in cribs, with structure surrounding
the sleeping surface to prevent the infant from rolling or falling
off the sleeping surface. Frequently, the structure surrounding the
sleeping surface comprises bars or poles or solid sidewalls.
Various forms of cushioning material, usually called crib bumpers,
may be installed to surround the sleeping surface and cover at
least a portion of the bars or poles to protect the infant from
bumping his or her head, and from poking arms or legs outside of
the crib. See, e.g., U.S. Pat. No. 6,957,464.
[0003] Toddlers and younger children usually begin to sleep on
regular bedding mattresses, frequently twin-sized mattresses. The
twin-sized mattresses do not fit within the crib structure. Some
infant cribs are designed to be converted from a crib to a child's
twin-sized bed. See, e.g., U.S. Pat. Nos. 5,754,993; 5,715,551;
4,525,883 and 4,361,919.
[0004] While the infant crib may be convertible to a twin-sized bed
frame, parents still must purchase a twin-sized mattress to be used
with the converted bed frame. Parents prefer multi-use childrens'
products, but the convertible cribs offered today do not come with
convertible mattresses.
[0005] One convertible infant mattress is shown in U.S. Pat. Nos.
5,937,465 and 5,822,817. The mattress system defines a sleeping
recess between upstanding walls in a configuration for use in a
crib. The mattress system includes a separable accessory panel that
is removed when the mattress system is installed in a crib. The
accessory panel can be inserted into the recess, and the mattress
system can then be inverted to provide a larger sleeping surface
for a child as opposed to an infant. However, this mattress system
with the accessory panel inserted still has the periphery
dimensions of a crib mattress, and does not convert in size to that
of a twin-size mattress.
[0006] A mattress that can be used in a crib for infants and
converted to a twin-sized mattress for use on a standard bedding
frame for toddlers and children continues to be sought. Moreover,
crib mattresses that have upstanding sidewalls to serve as crib
bumpers are desired by parents.
SUMMARY OF THE INVENTION
[0007] In one embodiment, a crib mattress that is convertible to a
twin-sized bedding mattress has a central mattress section defining
a top surface and first and second ends and left and right sides. A
first end wall is hingedly connected to the central mattress
section at the first end, and the first end wall is pivotably
moveable from an upright position to an open position. A second end
wall is hingedly connected to the central mattress section at the
second end, and the second end wall is pivotably moveable from an
upright position to an open position. A first side wall is hingedly
connected to the central mattress section at the left side, and the
first side wall is pivotably moveable from an upright position to
an open position. A second side wall is hingedly connected to the
central mattress section at the right side, and the second side
wall is pivotably moveable from an upright position to an open
position. Each side wall may have one or more sidewall extensions
hingedly connected to an end of the side wall and pivotably
moveable from a first position to a second position. In the first
position, the lengthwise axis of a respective sidewall extension is
parallel or substantially parallel to the lengthwise axis of the
respective side wall to which it is connected. In the second
position, the lengthwise axis of a respective sidewall extension is
generally aligned with the lengthwise axis of the respective side
wall to which it is connected. When the first and second end walls
are in the open position, the first and second side walls are in
the open position, and sidewall extensions are in the second
position, a substantially planar body-supporting surface is formed
that includes the central mattress section, the first and second
end walls, the first and second side walls, and, preferably, the
sidewall extensions.
[0008] In a second embodiment, a crib mattress that is convertible
to a twin-sized bedding mattress has a central mattress section
defining a top surface and first and second ends and left and right
sides. A first end wall is tethered to the central mattress section
at the first end, and the first end wall is separable from the
central mattress section and moveable from an upright position to
an open position. A second end wall is tethered to the central
mattress section at the second end, and the second end wall is
separable from the central mattress section and moveable from an
upright position to an open position. A first side wall is tethered
to the central mattress section at the left side, and the first
side wall is moveable from an upright position to an open position.
A second side wall is tethered to the central mattress section at
the right side, and the second side wall is moveable from an
upright position to an open position. Each side wall may have one
or more sidewall extensions hingedly connected to an end of the
side wall and pivotably moveable from a first position to a second
position. In the first position, the lengthwise axis of a
respective sidewall extension is parallel or substantially parallel
to the lengthwise axis of the respective side wall to which it is
connected. In the second position, the lengthwise axis of a
respective sidewall extension is generally aligned with the
lengthwise axis of the respective side wall to which it is
connected. When the first and second end walls are in the open
position, the first and second side walls are in the open position,
and sidewall extensions are in the second position, a substantially
planar body-supporting surface is formed that includes the central
mattress section, the first and second end walls, the first and
second side walls, and, preferably, the sidewall extensions.
[0009] The sidewall extensions may define one or more voids therein
to receive an accessory or toy when the mattress is in the crib
configuration.
[0010] The central mattress section, first end wall, second end
wall, first side wall, second side wall, and the sidewall
extensions preferably are formed of foam, such as polyurethane
foam, viscoelastic foam, and/or latex foam. The mattress components
may be formed of multiple layers of foams of varying resiliency or
support characteristic. For example, the body-contacting surfaces
in the twin bed configuration may be of a more resilient or softer
foam. Such more resilient or softer foam may be co-molded or bonded
to a firmer foam for greater support.
[0011] The hinge connections between the mattress components may be
formed of sheet-like materials, such as fabrics, films, laminates
and elastics. The tethers between mattress components in the second
embodiment may be formed of sheet-like materials, such as fabrics,
films, laminates and elastics.
[0012] To enhance stability of the mattress in the upright
configuration suitable for a crib mattress, releasable fasteners
may be applied to end surfaces of the central mattress section and
to surfaces of the first and second end walls to join the first and
second end walls to the central mattress section in the upright
position. Similarly, releasable fasteners may be applied to the top
surface of the central mattress section and to surfaces of the
first and second side walls to join the first and second side walls
to the central mattress section in the upright position.
Preferably, releasable fasteners may be applied to end surfaces of
the side walls and to surfaces of the end walls to join the side
walls to the end walls in the upright position. Preferably,
releasable fasteners may be applied to lengthwise surfaces of the
sidewall extensions and to lengthwise surfaces of the first and
second side walls to join the sidewall extensions to the respective
side walls.
[0013] To enhance stability of the mattresses in the open
configuration suitable for a twin mattress, releasable fasteners
may be applied to end surfaces of the central mattress section and
to surfaces of the first and second end walls to join the first and
second end walls to the central mattress section in the open
position. Similarly, releasable fasteners may be applied to side
surfaces of the central mattress section and to surfaces of the
first and second side walls to join the first and second side walls
to the central mattress section in the open position. Preferably,
releasable fasteners may be applied to lengthwise surfaces of the
sidewall extensions and to side surfaces of the first end wall to
join the sidewall extensions to the first end wall when the first
end wall is in the open position and the sidewall extensions are in
the second position.
[0014] A cover may extend substantially over at least the
substantially planar body-supporting surface. A cover may extend
substantially over at least the central mattress section. A cover
may extend over the entirety of the size convertible mattress.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention will be described in the following
detailed description with reference to the following drawings in
which:
[0016] FIG. 1 is a perspective view of a crib configuration for a
size-convertible mattress of one embodiment according to the
invention;
[0017] FIG. 2 is a perspective view of the size-convertible
mattress of FIG. 1 in which end walls and side walls are partially
disassembled from the crib configuration;
[0018] FIG. 3 is a perspective view of the size-convertible
mattress of FIG. 1 in which the end walls, side walls and sidewall
extensions are in open position for a twin bed configuration;
[0019] FIG. 4 is a perspective view of the size-convertible
mattress of FIG. 1 in its twin bed configuration;
[0020] FIG. 5 is a longitudinal section taken along line 5-5 in
FIG. 1;
[0021] FIG. 6 is a transverse section taken along line 6-6 in FIG.
1;
[0022] FIG. 7 is a partial perspective view of a crib configuration
for a size-convertible mattress of a second embodiment according to
the invention;
[0023] FIG. 8 is a perspective view of the size-convertible
mattress of FIG. 7 in which end walls and side walls are partially
disassembled from the crib configuration; and
[0024] FIG. 9 is a partial perspective view of the size-convertible
mattress of FIG. 7 in its twin bed configuration.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring to FIG. 1, one embodiment of a size-convertible
mattress is shown in a crib configuration 10. The mattress in the
crib configuration 10 has a central mattress section 12 surrounded
by upstanding end walls 14, 16 and side walls 20, 22. The central
mattress section 12 is of a size having a generally planar sleeping
surface to accommodate an infant or small child. The upstanding end
walls 14, 16 and side walls 20, 22 serve as bolster cushions or
protective barriers between the spindles or poles or side walls of
the crib furniture and the sleeping surface of the central mattress
section 12. In its crib configuration 10 the mattress may have
outer periphery dimensions comparable to a standard crib mattress,
such as about 27 inches by 52 inches (69 cm by 131 cm).
[0026] The size-convertible mattress may be converted from its crib
configuration 10 (FIG. 1) to a twin mattress configuration 70 (FIG.
4) upon rotating the end walls 14, 16 and side walls 20, 22 in a
manner as described herein. In the crib configuration 10 (FIG. 1),
the side walls 20, 22 are removably joined to the planar top
surface of the central mattress section 12 with fasteners 50, such
as hook and loop strips (sometimes referred to as Velcro.RTM.
fasteners). In the crib configuration 10 (FIG. 1), the end walls
14, 16 are removably joined to end portions of the side walls 20,
22 and sidewall extensions 24, 26, 28, 30 with fasteners 50, such
as hook and loop strips. FIG. 6 illustrates the connections with
fasteners 50 that hold the second end wall 16 to the ends of the
first side wall 20 and second sidewall extension 26.
[0027] The first and second end walls 14, 16 have hinges 40 formed
at their bottom corners. For example, a first portion of a hinge 40
is joined or attached to an inner surface of the first end wall 14,
and a second portion of a hinge 40 is joined or attached to a top
planar surface of the central mattress section 12. See FIG. 5.
Hinges 40 may be formed of a resilient material that may be
repeatedly bent back and forth as desired for converting the
mattress from a crib configuration 10 to a twin mattress
configuration 70. The hinges preferably are adhesively attached or
flame laminated to surfaces of the mattress components. The hinges
may be joined to the surfaces of the components forming the
mattress with adhesive, or by flame lamination or by stitching or
by other known attachment means. In flame lamination, foam surfaces
may be heated to softening and the hinge material may be applied to
the softened surface portion(s). Upon cooling, a bond between hinge
material and foam material is formed. Possible materials to form
the hinges include fabrics, such as nylons, rip-stop nylon, and
CORDURA nylon. The fabrics may be woven, and may be coated with
moisture-resistant barrier-coatings.
[0028] In the first mattress embodiment (FIG. 1), the end walls may
have dimensions of about 12 inches in height, 27 inches in length
and 6 inches in width. The side walls may have dimensions of about
6 inches in height, 51 inches in length and 6 inches in width. The
sidewall extensions may have dimension of about 6 inches in height,
20 inches in length and 6 inches in width.
[0029] As shown in FIG. 2, the first end wall 14 may be rotated
about its hinge 40 and folded down in the direction of arrow 34 so
as to lay flat. Compare FIGS. 3 and 4 with FIG. 2. Upon rotating
the first end wall 14, the fasteners 50 holding the first end wall
to end surfaces of the first and second side walls 20, 22 and first
and third sidewall extensions 24, 28 are separated from one
another. When fully opened, the inner side surface of the first end
wall 14 forms a plane or substantially forms a plane with the
planar top surface of the central mattress section 12 (See FIGS. 3
and 4).
[0030] Similarly, the second end wall 16 may be rotated about its
hinge 40 and folded down in the direction of arrow 34 so as to lay
flat. Compare FIG. 2 with FIGS. 3 and 4. Upon rotating the second
end wall 16, the fasteners 50 holding the second end wall to end
surfaces of the first and second side walls 20, 22 and second and
fourth sidewall extensions 26, 30 are separated from one another.
When fully opened, the inner side surface of the second end wall 16
forms a plane or substantially forms a plane with the planar top
surface of the central mattress section 12 (See FIG. 4).
[0031] Still referring to FIG. 2, the first side wall 20 may be
rotated about its hinge 42 in the direction of arrow 36 and folded
down so as to lay flat. Compare FIG. 2 with FIGS. 3 and 4. Upon
rotating the first side wall 20, the fasteners 50 holding one
lengthwise side surface of the first side wall 20 to the top planar
surface of the central mattress section 12 are separated from one
another. In addition, the second side wall 22 may be rotated about
its hinge 42 in the direction of arrow 36 and folded down so as to
lay flat. Upon rotating the second side wall 22, the fasteners 50
holding one lengthwise side surface of the second side wall 22 to
the top planar surface of the central mattress section 12 are
separated from one another.
[0032] When in the crib configuration 10, the first and second
sidewall extensions 24, 26 are held in contact with a side surface
of the first side wall 20 with fasteners 50 (such as hook and loop
fasteners). The longitudinal axes of the first and second sidewall
extensions 24, 26 are generally in parallel with the longitudinal
axis of the first side wall 20. Once the first side wall 20 is in
its open position, fasteners 50 may be released and first and
second sidewall extensions 24, 26 may be rotated in the direction
of arrows 38 (FIG. 3) about hinges 44 to open positions in which
the first and second sidewall extensions are axially aligned with
the first side wall 20. Alternatively, the first and second
sidewall extensions 24, 26, may be rotated when the first side wall
20 is in its upright position, but after the first and second end
walls 14, 16 have been rotated to their open positions. See FIGS. 3
and 4. Similarly, the third and fourth sidewall extensions 28, may
be rotated about hinges 44 to open positions in which the third and
fourth sidewall extensions 28, 30 are axially aligned with the
second side wall 22.
[0033] In the twin mattress configuration (FIG. 4), the first and
second end walls 14, 16 are unfolded down and aligned with surfaces
generally planar with the generally planar top surface of the
central mattress section 12. In addition, the first and second side
walls 20, 22 are unfolded down and aligned with surfaces generally
planar with the generally planar top surface of the central
mattress section 12. Moreover, the first, second, third and fourth
sidewall extensions 24, 26, 28, 30 are unfolded down and axially
aligned with the first and second side walls 20, 22. As so rotated
and unfolded, the central mattress section 12, first and second end
walls 14, 16, first and second side walls 20, 22 and first, second,
third and fourth sidewall extensions 24, 26, 28, 30 together form a
generally planar surface of a size of a twin bed mattress
configuration 70 (FIG. 4). Fasteners 50 (not shown) may be provided
at facing surfaces to hold the various components together in the
twin bed mattress configuration (FIG. 4).
[0034] In the twin bed mattress configuration 70, the mattress may
have an outer periphery dimension comparable to a standard twin
mattress, such as about 39 inches by 75 inches (99 cm by 191 cm).
The twin bed mattress configuration 70 preferably has a thickness
in the range of 6 to 18 inches (15 cm to 46 cm), more preferably
about 6 inches (15 cm). The size convertible mattress may be
encased in a removable cover (not shown), such as canvas, cotton
sheeting, flannel or other suitable fabric, when in the twin bed
mattress configuration 70 or the crib configuration 10.
[0035] The size-convertible mattress may be folded back from the
twin mattress configuration 70 (FIG. 4) to the crib mattress
configuration 10 (FIG. 1) by releasing any fasteners between
components and rotating the components about hinges 44, 42, 40 in
the reverse direction from that shown to unfold the components from
the crib configuration 10. The components may be re-fastened
together in the crib configuration 10.
[0036] The mattress components are formed of one or more resilient
materials suitable for holding a reclining infant, child or adult.
In a preferred embodiment, the resilient material is a cellular
polymer, such as polyurethane foam or latex foam. Cellular
polyurethane structures (e.g., foams) typically are prepared by
generating a gas during polymerization of a liquid reaction mixture
generally comprised of a polyester or polyether polyol, an
isocyanate, one or more surfactants, one or more catalysts and one
or more blowing agents. The gas causes foaming of the reaction
mixture to form the cellular structure. The surfactant(s) stabilize
the structure and/or assist in cell opening. Polyurethane foams
with varying density and hardness may be formed. Hardness is
typically measured as IFD ("indentation force deflection") or CFD
("compression force deflection"). Specifically, IFD.sub.25 is the
force required to compress the foam to 25% of its original
thickness or height, and IFD.sub.65 is the force required to
compress the foam to 65% of its original thickness or height.
Tensile strength, tear strength, compression set, air permeability,
fatigue resistance, support factor, and energy absorbing
characteristics may also be varied, as can many other properties.
Specific foam characteristics depend upon the selection of the
starting materials, the foaming process and conditions, and
sometimes on the subsequent processing.
[0037] Viscoelastic polyurethane foams are characterized by high
vibration damping, body conformance and slow recovery from
compression. Most viscoelastic foams have densities in the range of
from about 2.0 to 6.0 pounds per cubic foot (32 to 96 kg/m.sup.3),
but higher densities are sometimes desired (e.g., 8.0 pounds per
cubic foot (128 kg/m.sup.3) and higher). Viscoelastic foams have
gained popularity for bedding applications because such foams are
advertised as reducing pressure points, which are believed to cause
tossing and turning during sleep.
[0038] Representative polyurethane foams suitable for mattresses
and cushions, such as bolsters and pillows, include foams offered
by FXI Foamex Innovations under brands REFLEX, REFLEX NATURAL,
AERUS and AERUS NATURAL. Such foams may have densities in the range
of about 1 to 10 pounds per cubic foot, preferably about 2 to 6
pounds per cubic foot, and IFD.sub.25 in the range of 7 to 70
pounds per square inch. Representative latex foams suitable for
mattresses and cushions, such as bolsters and pillows include latex
foams offered by FXI Foamex Innovations under brand NATURAL LATEX
FROM FXI. Such latex foams have densities in the range of about 1
pounds per cubic foot and up to about 30 pounds per cubic foot.
[0039] The central mattress section 12, first and second end walls
14, 16, first and second side walls 20, 22, and first, second,
third, fourth sidewall extensions 24, 26, 28, 30 are shown in FIGS.
1-6 as dual components. In this embodiment, when the mattress is in
the twin bed configuration (FIG. 4), the top layer 72 forming the
reclining surface of the mattress preferably comprises a resilient
cellular polymer, such as polyurethane foam, or a slow-recovery
foam, such as a viscoelastic foam, and the bottom layer 74 forming
the supporting surface of the mattress comprises a firm
polyurethane foam. For example, the top layer 72 may comprise an
ENERGIA polyurethane foam with a density of 3 to 4 pounds per cubic
foot, and the bottom layer 74 may comprise a REFLEX foam with a
density of 3 to 4 pounds per cubic foot. As another example, the
top layer 72 may comprise a polyurethane foam with a density of 4
pounds per cubic foot and an IFD.sub.25 in the range of 35 to 65
pounds per square inch, and bottom layer 74 may comprise a
viscoelastic foam with a density of 3.5 pounds per cubic foot and
an IFD.sub.25 of 12 pounds per square inch.
[0040] When the mattress is in the crib configuration 10 (FIG. 1),
preferably the firm layer 74 forms the body-supporting surface of
the central mattress section 12. When the mattress is in the twin
bed configuration 70 (FIG. 6), a user may position said mattress
with either the firm layer 74 or the softer top layer 72 as the
body-supporting surface.
[0041] To make a multi-layer configuration, the two different foam
layers 72, 74 are joined together, such as by co-molding, flame
lamination or adhesive bonding. Then, the components forming the
central mattress section 12, first and second end walls 14, 16,
first and second side walls 20, 22, and first, second, third,
fourth sidewall extensions 24, 26, 28, 30 are cut to desired size.
These components are then connected by various hinges 40, 42, 44 to
form the size-convertible mattress.
[0042] The sidewall extensions 24, 26, 28, 30 may be formed with
one or more voids 60 therein. Voids 60 are suitable for receiving
toys or accessories (not shown) when the size convertible mattress
is in its crib configuration 10 (FIG. 1). Such voids 60 do not
detract from body-supporting characteristics of the sidewall
extensions when the mattress is in its twin bed configuration 70
(FIG. 4).
[0043] Referring next to FIGS. 7-9, a second embodiment of a
size-convertible mattress according to the invention has a crib
configuration 110 in which a central mattress section 112 is
surrounded by upstanding end walls 114, 116 and side walls 120,
122. In its crib configuration 110 the mattress of this second
embodiment may have outer periphery dimensions comparable to a
standard crib mattress, such as about 27 inches by 52 inches (69 cm
by 131 cm).
[0044] In the second mattress embodiment (FIG. 7), the end walls
may have dimensions of about 18 inches in height, 27 inches in
length and 6 inches in width. The side walls may have dimensions of
about 6 inches in height, 51 inches in length and 6 inches in
width. The sidewall extensions may have dimension of about 6 inches
in height, 20 inches in length and 6 inches in width
[0045] The size convertible mattress of the second embodiment may
be converted from its crib configuration 110 to a twin mattress
configuration 170 (FIG. 9) upon separating the first and second end
walls 114, 116 and side walls 120, 122 and reattaching them to side
surfaces of the central mattress section 112 in a manner as
described herein. In the crib configuration 110 (FIG. 7), the side
walls 120, 122 are removably joined to the planar top surface of
the central mattress section 112 with fasteners 50, such as hook
and loop strips (sometimes referred to as Velcro.RTM. fasteners).
In the crib configuration 110 (FIG. 7), the end walls 114, 116 are
removably joined to end portions of the side walls 120, 122 and
sidewall extensions 124, 126, 128, 130 with fasteners 50, such as
hook and loop strips. Fastener connections are similar to those
used in the first embodiment described with reference to FIGS.
1-6.
[0046] The first and second end walls 114, 116 have tethers 100
formed at their bottom corners. For example, a first portion of a
tether 100 is joined or attached to an outer surface of the first
end wall 114, and a second portion of a tether 100 is joined or
attached to a bottom generally planar surface of the central
mattress section 112. See FIG. 7. Possible materials to form the
tethers 100 include fabrics, laminates and elastics. Woven nylon or
cotton that includes elastomeric stretch yarns is one example of a
fabric with stretch that may be used. Resilient rubber or latex
sheeting are examples elastics that may be used. The tether
material may be coated with moisture-resistant barrier-coatings.
The tethers 100 may be joined to the surfaces of the components
forming the mattress with adhesive, or by flame lamination or by
stitching or by other known attachment means.
[0047] As shown in FIG. 8, the second end wall 116 may separated
from the first and second side walls 120, 122 and second and fourth
sidewall extensions 126, 130 and turned 90 degrees (rotated) in the
direction of arrow 134 so as to lay flat. Upon rotating the second
end wall 116, the fasteners 50 holding the second end wall to end
surfaces of the first and second side walls 120, 122 and second and
fourth sidewall extensions 126, 130 are separated from one another.
When fully opened, the inner side surface of the second end wall
116 forms a plane or substantially forms a plane with the planar
top surface of the central mattress section 112 (See FIG. 9). The
tethers 100 hold the second end wall 116 in proximity to or
adjacent to the central mattress section 112 as the mattress is
being converted or reconfigured.
[0048] Similarly, the first end wall 114 may be separated from the
first and second side walls 120, 122 and first and third sidewall
extensions 124, 128 and turned 90 degrees (rotated) so as to lay
flat. Upon rotating the first end wall 114, the fasteners 50
holding the first end wall to end surfaces of the first and second
side walls 120, 122 and first and third sidewall extensions 124,
128 are separated from one another. When fully opened, the inner
side surface of the first end wall 114 forms a plane or
substantially forms a plane with the planar top surface of the
central mattress section 112. The tethers 100 hold the first end
wall 114 in proximity to or adjacent to the central mattress
section 112 as the mattress is being converted or reconfigured.
[0049] Still referring to FIG. 8, the first side wall 120 may be
separated from the central mattress section 112 and turned 90
degrees (rotated) in the direction of arrow 136 and folded down so
as to lay flat. Upon rotating the first side wall 120, the
fasteners 50 holding one lengthwise side surface of the first side
wall 120 to the top planar surface of the central mattress section
112 are separated from one another. In addition, the second side
wall 122 may be turned 90 degrees (rotated) in the direction of
arrow 136 and folded down so as to lay flat. Upon rotating the
second side wall 122, the fasteners 50 holding one lengthwise side
surface of the second side wall 122 to the top planar surface of
the central mattress section 112 are separated from one another.
The tethers 102 hold the first and second side walls 120, 122 in
proximity to or adjacent to the central mattress section 112 as the
mattress is being converted or reconfigured.
[0050] When the second embodiment of the mattress is in the crib
configuration 110, the first and second sidewall extensions 124,
126 are held in contact with a side surface of the first side wall
120 with fasteners 50 (such as hook and loop fasteners). The
longitudinal axes of the first and second sidewall extensions 124,
126 are generally in parallel with the longitudinal axis of the
first side wall 120. Once the first side wall 120 is in its open
position, fasteners 50 may be released and first and second
sidewall extensions 124, 126 may be rotated in the direction of
arrows 138 (FIG. 8) about hinges 144 to open positions in which the
first and second sidewall extensions 124, 126 are axially aligned
with the first side wall 120. Alternatively, the first and second
sidewall extensions 124, 126, may be rotated when the first side
wall 120 is in its upright position, but after the first and second
end walls 114, 116 have been rotated to their open positions. See
FIGS. 8 and 9. Similarly, the third and fourth sidewall extensions
128, 130 may be rotated about hinges 144 to open positions in which
the third and fourth sidewall extensions 128, 130 are axially
aligned with the second side wall 122.
[0051] In the twin mattress configuration (FIG. 9), the first and
second end walls 114, 116 are aligned with surfaces generally
planar with the generally planar top surface of the central
mattress section 112. In addition, the first and second side walls
120, 122 are aligned with surfaces generally planar with the
generally planar top surface of the central mattress section 112.
Moreover, the first, second, third and fourth sidewall extensions
124, 126, 128, 130 are unfolded down and axially aligned with the
first and second side walls 120, 122. As so rotated and unfolded,
the central mattress section 112, first and second end walls 114,
116, first and second side walls 120, 122 and first, second, third
and fourth sidewall extensions 124, 126, 128, 130 together form a
generally planar surface of a size of a twin bed mattress
configuration 170 (FIG. 9). Fasteners 50 (not shown) may be
provided at facing surfaces to hold the various components together
in the twin bed mattress configuration 170 (FIG. 9).
[0052] In the twin bed mattress configuration 170, the mattress may
have an outer periphery dimension comparable to a standard twin
mattress, such as about 39 inches by 75 inches (99 cm by 191 cm).
The twin bed mattress configuration 170 preferably has a thickness
in the range of 6 to 18 inches (15 cm to 46 cm), more preferably
about 6 inches (15 cm).
[0053] The size-convertible mattress may be folded back from the
twin mattress configuration 170 (FIG. 9) to the crib mattress
configuration 110 (FIG. 7) by releasing any fasteners between
components and reassembling the end walls 114, 116, side walls 120,
122 and sidewall extensions 124, 126, 128 and 130 in upright
configurations, such as by turning or rotating by 90 degrees. The
components may be re-fastened together in the crib configuration
110.
[0054] The invention has been illustrated by detailed description
and examples of the preferred embodiments. Various changes in form
and detail will be within the skill of persons skilled in the art.
Therefore, the invention must be measured by the claims and not by
the description of the examples or the preferred embodiments.
* * * * *