U.S. patent application number 13/534068 was filed with the patent office on 2012-11-15 for extendable and/or expandable foam panel constructions.
This patent application is currently assigned to NOMACO INC.. Invention is credited to Randal L. Henderson, Ivan I. Sobran.
Application Number | 20120284928 13/534068 |
Document ID | / |
Family ID | 47140825 |
Filed Date | 2012-11-15 |
United States Patent
Application |
20120284928 |
Kind Code |
A1 |
Henderson; Randal L. ; et
al. |
November 15, 2012 |
EXTENDABLE AND/OR EXPANDABLE FOAM PANEL CONSTRUCTIONS
Abstract
By forming a plurality of separate, spaced, expansion zones in
preselected areas of a foamed plastic product having a desired size
and shape, a new foam plastic product is achieved which is capable
of being expanded or extended in at least one direction during its
use in order to accommodate dimensional changes or requirements. By
forming the expansion zones in a precisely desired pattern which
extends over a substantial portion of the foam plastic product, the
resulting product is capable of being expanded, extended, or
adjusted in at least one of its dimensions. In this way, the
resulting product is quickly and easily expanded or extended in one
direction to fit any desired application surface with ease and
simplicity.
Inventors: |
Henderson; Randal L.;
(Zebulon, NC) ; Sobran; Ivan I.; (Raleigh,
NC) |
Assignee: |
NOMACO INC.
Zebulon
NC
|
Family ID: |
47140825 |
Appl. No.: |
13/534068 |
Filed: |
June 27, 2012 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12386584 |
Apr 21, 2009 |
|
|
|
13534068 |
|
|
|
|
Current U.S.
Class: |
5/717 |
Current CPC
Class: |
A47C 27/053
20130101 |
Class at
Publication: |
5/717 |
International
Class: |
A47C 23/04 20060101
A47C023/04 |
Claims
1. A mattress, comprising: an innerspring having a perimeter; one
or more foam panels adjacent to at least a portion of the perimeter
of the innerspring, each of the one or more foam panels comprising:
an elongated member disposed along a longitudinal axis; and at
least one expansion zone integrally formed in the one or more foam
panels; wherein the at least one expansion zone is configured to
expand in the direction of the longitudinal axis of the at least
one foam panel to allow a length of the foam panel to be expanded
up to an expansion distance of the at least one expansion zone and
contracted.
2. The mattress of claim 1, further comprising one or more channels
disposed through the elongated member.
3. The mattress of claim 1, wherein the at least one expansion zone
is comprised of a plurality of expansion zones integrally formed in
the foam panel and forming a plurality of openings in the foam
panel.
4. The mattress of claim 1, wherein the plurality of expansion
zones are comprised of a plurality of apertures.
5. The mattress of claim 4, wherein a first aperture among the
plurality of apertures is disposed on a top edge of the foam panel,
and a second aperture among the plurality of apertures is disposed
on a bottom edge of the foam panel.
6. The mattress of claim 4, wherein the plurality of apertures form
apertures along length axes of the elongated member between a top
edge and a bottom edge of the foam panel.
7. The mattress of claim 4, wherein the plurality of apertures are
disposed along the longitudinal axis of the foam panel.
8. The mattress of claim 4, wherein the plurality of apertures are
disposed along a plurality of longitudinal axes of the foam
panel.
9. The mattress of claim 4, wherein the plurality of apertures are
comprised of a plurality of cuts.
10. The mattress of claim 4, wherein the plurality of apertures are
comprised of a plurality of slits.
11. The mattress of claim 1, wherein the at least one expansion
zone is comprised of a plurality of expansion zones.
12. The mattress of claim 11, wherein each of the one or more foam
panels further comprises at least one interconnected lattice of
foam disposed between adjacent expansion zones among the plurality
of expansion zones.
13. The mattress of claim 1, wherein the one or more foam panels
each comprises a substantially flat planar body including a top
surface and a bottom surface, and defined by a top edge, a bottom
edge, a first side edge, and a second side edge.
14. The mattress of claim 3, wherein the plurality of expansion
zones comprises a first expansion zone adjacent to a second
expansion zone, each of the plurality of expansion zones extending
from one edge to an opposite edge of the planar body.
15. The mattress of claim 14, wherein the first expansion zone
comprises a first portion of the plurality of apertures in a first
pattern of apertures, the first portion separately expandable and
contractible in a direction orthogonal to a first geometric line,
at least a portion of each of the first portion disposed within the
first geometric line when the first portion is fully contracted,
the first geometric line extending from the one edge to the
opposite edge of the planar body.
16. The mattress of claim 15, wherein the second expansion zone
comprises a second portion of the plurality of apertures in a
second pattern of apertures, the second portion separately
expandable and contractible in a direction orthogonal to a second
geometric line, at least a portion of each of the second portion
disposed within the second geometric line when the second portion
is fully contracted, the second geometric line extending from the
one edge to the opposite edge of the planar body.
17. The mattress of claim 16, wherein the first pattern of
apertures comprises a different aperture shape than the second
pattern of apertures, and the first geometric line and the second
geometric line are parallel to each other and parallel to the top
surface.
18. The mattress of claim 4, wherein the plurality of apertures is
further defined as being formed in a planar body in juxtaposed,
spaced, adjacent relationship to each other, effectively forming at
least one expansion zone which enables the foam member to be
expandable and contractible in the expansion zone.
19. The mattress of claim 4, wherein the plurality of apertures are
further defined as being formed in a planar body in juxtaposed,
spaced, adjacent relationship to each other substantially
throughout the entire planar body.
20. The mattress of claim 4, wherein the plurality of apertures are
further defined as comprising a shape or configuration comprising
at least one selected from the group consisting of circles, slits,
half moon shapes, quarter moon shapes, triangles, trapezoids,
rectangles, ovals, and ellipses.
21. The mattress of claim 13, wherein the planar body is a product
of any desired width produced by employing continuous roll forming.
Description
RELATED APPLICATIONS
[0001] This application is related to U.S. Provisional Patent
Application Ser. No. 61/125,986, filed Apr. 29, 2008 entitled
"EXTENDABLE AND/OR EXPANDABLE FOAM PANEL CONSTRUCTIONS."
TECHNICAL FIELD
[0002] This invention relates to enlarged, foam panel constructions
and, more particularly, to enlarged foam constructions which are
capable of being expanded or extended in at least one dimension
whenever desired.
BACKGROUND ART
[0003] Throughout the years, an ever increasing variety of products
and product areas have benefitted from the use of foam plastic
materials. In this regard, product manufacturers, suppliers, and/or
shippers have found that foam plastic products, materials, and
profiles can be employed for improving the quality of the product
being produced, as well as for substantially improving packing
materials and product safety panels which are commonly used in
product protection during shipment. Furthermore, due to the unique
nature of foam plastic products and the ability of these products
to be formed in various sizes, shapes, and configurations, these
products have enjoyed increased acceptance and use.
[0004] As the abilities, capabilities, and versatility of foam
plastic material became known to individuals and corporate
entities, the popularity of foam plastic products substantially
increased, along with the wide variety of product areas and
purposes for which foam plastic products were employed. In this
regard, foam plastic material has been used for protecting small
fragile products such as those made from glass, as well as
protecting large products made from metal or similar materials,
such as refrigerators, stoves, and the like. In these large
products, foam plastic panels are often employed to peripherally
surround the product and protect the outer surfaces of the
product.
[0005] In addition, foam plastic materials have also been employed
in numerous other products as an integral components of the
product. In this area, furniture, bedding, and mattresses have
employed foam plastic materials as an integral component
incorporated into the product structure itself. In this instance,
foam plastic materials have proven to be effective in providing
support and integrity to the product as a replacement for
components which are more expensive and more difficult to
employ.
[0006] In spite of the fact that foam plastic products have gained
wide acceptance and use in a wide variety of applications,
industries, and product areas, it has been recognized that the use
of foam plastic products in many areas can be improved due to
inherent physical characteristics of the foam plastic materials. In
this regard, one of the principal difficulties encountered with the
use of foam plastic materials is the difficulty in controlling the
dimensions of the foam plastic material during production, in order
to assure that precisely desired dimensions are attained. This
problem has been found in the use of foam plastic panels for
protecting large products, as well as in the use of foam plastic
panels in furniture products, bedding, and mattresses.
[0007] In using large foam plastic panels for these products, the
overall size and shape of the foam plastic product is critical in
being used on a particular previously manufactured surface.
However, during the production of the foam plastic panels,
controlling a precise dimensional size has been found to be
particularly difficult. As a result, foam plastic panels are often
constructed in sizes larger than required, and then cut or trimmed
to the dimension needed for a particular application. Although
effective, this process is more expensive, since material is cut
and thrown away, as well as being time-consuming and labor
intensive.
[0008] Therefore, it is a principal object of the present invention
to provide foam plastic products which are capable of being
constructed in a manner which enables the product to possess an
expandable or variable capability enabling the size or shape of the
product to be flexible in at least one direction.
[0009] Another object of the present invention is to provide foam
plastic products having the characteristic features described above
which is capable of being produced with substantially no increase
in manufacturing costs.
[0010] A further object of the present invention is to provide foam
plastic products having the characteristic features described above
wherein the resulting product is capable of being expanded to a
desired dimension and automatically locked in that dimension.
[0011] Other and more specific objects will in part be obvious and
will in part appear hereinafter.
SUMMARY OF THE INVENTION
[0012] By employing the present invention, all of the difficulties
and drawbacks found in prior art constructions have been overcome
and a new, unique, foam plastic product is achieved which is
capable of being expanded or extended in at least one direction
during its use in order to accommodate dimensional changes or
requirements. In this way, foam plastic products of any size or
configuration are capable of being employed for a wide variety of
alternate purposes or applications due to the capability of the
product to be expanded in at least one dimension. As a result, foam
plastic products incorporating this construction achieve greater
versatility and benefit in numerous industries, applications, and
product areas, while also providing ease of use, speed and
convenience during the installation process.
[0013] In accordance with the present invention, the desired foam
plastic product is first produced using conventional manufacturing
techniques with the overall configuration, size, and shape desired
for the product. Thereafter, the foam plastic product is processed
using a desired manufacturing method wherein a plurality of
separate, spaced, expansion zones are formed in preselected areas
of the product.
[0014] By forming the expansion zones in a precisely desired
pattern which extends over a substantial portion of the foam
plastic product, the resulting product is capable of being
expanded, extended, or adjusted in at least one of its dimensions.
As a result, without degradation of the integrity of the foam
plastic product, the resulting product is quickly and easily
expanded or extended in one direction to fit any desired
application surface with ease and simplicity, without requiring any
trimming, cutting, or laborious procedures for achieving a desired
dimension.
[0015] Typically, each expansion zone is formed by cutting through
the foam product in a predetermined length and pattern relative to
adjacent cuts. In this way, predefined areas or cut-out zones are
created whenever the foam product is moved in a particular
direction.
[0016] Although the present invention can be implemented in a wide
variety of forms and employed in numerous products and
applications, one example of a product which is capable of
experiencing substantial improvement in production and manufacture
due to the application of the present invention is found in inner
spring mattresses. In the production of inner spring mattresses,
large foam panels are employed for improving support and longevity
of the product. Typically, these large foam panels are placed on
the surface of the inner spring assembly, positioned between the
inner spring surface and the textile material cover which
peripherally surrounds and defines the mattress assembly. In this
regard, these large foam panels have been employed and have
provided substantially improved mattress products.
[0017] Although the prior art foam panels have been successful in
improving inner spring mattress assemblies, the construction of
these enlarged, extruded foam panels are difficult to manufacture
with accurate and repeatable dimensional tolerances. As a result,
production difficulties and product installation problems presently
exist.
[0018] By employing the present invention, all of these prior art
difficulties are virtually eliminated and enlarged, extruded, foam
panels are capable of being constructed having adjustable or
variable dimensions, thereby enabling these panels to be employed
as the top supporting panel or surface of a mattress, and placed on
the surface of the inner spring and easily secured to the
terminating edges of the inner spring assembly. Furthermore, using
the enlarged extruded foam panels of the present invention, the
panels are merely extended in one dimension in order to assure that
the panels extend from one edge of the inner spring to the other
edge, completely covering the desired surface and establishing the
support for the mattress assembly.
[0019] In order to achieve this unique and previously unattainable
goal, the enlarged extruded foam panels of the present invention
are produced in the generally conventional manner and then exposed
to a subsequent manufacturing operation which forms a plurality of
zones in the foam panels, which enable the panel to expand and
contract in at least one dimension. In this regard, it has
typically been found that the expansion zones are formed in
enlarged sections, extending from the top edge to the bottom edge
of the foam panels. In addition, the width of each expansion zone
can be varied and any desired number of expansion zones can be
formed at spaced intervals to each other.
[0020] Once the expansion zone formation process has been
completed, the resulting foam panel construction is capable of
being expanded, extended, and contracted in at least one dimension.
In particular, when a plurality of expansion zones are formed in
the large foam panel extending from the top edge to the bottom edge
of the panel, the side edges of the resulting panel are capable of
being extended and contracted relative to each other.
[0021] As is fully detailed herein, the formation of numerous,
separate, and independent expansion zones in spaced relationship to
each other creates an elongated, expansion zone bearing section in
the panel which is able to be extended and contracted in one
dimension due to the ability of each expansion zone to have its
size or shape easily increased or decreased. In this way, the
enlarged foam panels of the present invention are positioned on the
inner spring surface and easily adjusted in one dimension, such as
its width, in order to completely extend from one side edge of the
inner spring assembly to the other side edge thereof quickly and
easily, while also being secured in the desired position. As a
result, prior art problems and difficulties are completely
eliminated.
[0022] In forming the expansion zones of the present invention in
the foam panels, each expansion zone can be formed with any desired
shape or configuration. In general, the only requirement is that
each expansion zone is separate and independent from each adjacent
expansion zone, thereby creating an interconnected lattice of foam
material which peripherally surrounds the expansion zones and
enables the resulting panel structure to be extendable in at least
one dimension.
[0023] In one embodiment, the interconnected lattice of foam
material which peripherally surrounds the expansion zones is formed
with an inherent spring force which attempts to maintain each
expansion zone in a substantially closed configuration. As a
result, the resulting foam panel is normally maintained in a
compact configuration, requiring the application of force to extend
the foam panel in the desired direction.
[0024] When the extending force is applied, the foam panel extends
or expands in the desired direction into an overall dimension
sought by the user. Furthermore, the increase in the dimension of
the foam panel causes each expansion zone to be enlarged as the
dimension is increased. However, if the extending force is removed,
the foam panel will return to its substantially original
configuration due to the inherent spring force of the
interconnected lattice of foam material.
[0025] In an alternate embodiment, the interconnected lattice of
foam material is constructed with a particular configuration which
enables the lattice of foam material to move between two specific
alternate positions. In a first position, the lattice of foam
material provides a spring force which attempts to return the foam
panel to its original position. However, in a second position, the
lattice of foam material becomes locked or substantially rigid in
the second position, resulting in a foam panel which is maintained
in a substantially stable overall expanded dimension.
[0026] This embodiment has been found to be particularly applicable
for use on products or applications where the foam panels
peripherally surround and protect a product being transported, and
are not typically secured to the product along the edges of the
panel. As a result, by achieving a foam panel which is fixed in its
overall dimension, the panels are quickly and easily placed in
position and maintained where desired, protecting a particular
surface of the product.
[0027] In an alternate use of this embodiment of the present
invention, the panel of foam material can be moved between its
compact position and its extended position whenever desired. As a
result, the foam panel can be used for various activities or
recreational purposes, such as a pool float, with the panel being
expanded for use, and contracted into a compact position for
storage. In this way, a substantially increased benefit is provided
to the consumer.
[0028] In producing the enlarged foam panels of the present
invention, several alternative construction methods can be employed
for forming the foam panel as well as the plurality of expansion
zones in the panel member. Although any effective method can be
employed, it has been found that the following methods are
exemplary of the production systems that can be used to achieve the
expandable or extendable foam panel of the present invention.
[0029] In this regard, the formation processes for creating the
foam panel member preferably comprises one or more selected from
the group consisting of extrusion injection molding, rotational
molding, compression molding, expansion molding, and casting. In
addition, the formation process for achieving the desired expansion
zones in the foam panel preferably comprise one or more selected
from the group consisting of water jet cutting, rotary die cutting,
punch press cutting and laser cutting.
[0030] In order to fully understand the construction of the
extendable foam panels of the present invention, one of the
preferred manufacturing methods is further detailed herein. In this
regard, the enlarged foam panel is produced in the normal manner
well known in the industry. Once the foam panel has been produced,
the foam panel is passed through a cutting die which forms the
plurality of expansion zones in the panel member. Typically, these
expansion zones are most easily created by forming slots or slits
in the foam panel, extending from the top surface to the bottom
surface thereof. Furthermore, as detailed above, the expansion
zones are formed in the panel in predefined, desired sections of
the panel, with each section preferably extending from one edge to
the opposed edge thereof.
[0031] In a typical construction using this embodiment of the
forming process, the cutting die comprises either a rolling cutting
die or a flat cutting die which enables the enlarged foam panel to
be continuously passed therethrough. In using a rolling cutting
die, which has been found to be most efficient in a continuous
production operation, a pair of die members are cooperatively
associated with each other and constructed with a spaced zone
therebetween through which the enlarged foam panel is capable of
passing.
[0032] With at least one of the cooperating die members
incorporating raised cutting elements, the desired slots or slits
are formed in the foam panel as the panel passes between the
cooperating rolling dies, with the area adjacent to the slots or
slits being left intact. In this way, the expansion zones are
easily formed along with the interconnected lattice of foam
material surrounding the expansion zones.
[0033] Furthermore, using this production process, the desired
expansion zones are quickly and easily formed in the enlarged foam
panel in the precisely desired areas. Furthermore, once the
elongated length of the foam panel has passed between the rolling
dies, the resulting product is fully produced and ready for
packaging and distribution to the user.
[0034] As is evident from this disclosure, as well as in the
detailed discussion contained below, any desired configuration,
shape, or orientation can be employed for forming slots, slits, and
resulting expansion zones in the panel members. In one embodiment,
the slot, slits and resulting expansion zones can be found randomly
while in another alternate embodiment, the slots, slits and
resulting expansion zones are formed in a cooperating pattern.
However, regardless of the particular configuration employed, the
slots, slits, and/or expansion zones are preferably staggered
relative to each other in the desired direction in order to produce
an integrated lattice of foam material peripherally surrounding the
separate and independent expansion zones. In this way, the desired
flexibility and expansion capabilities are most effectively
achieved.
[0035] It has also been found that longitudinally extending,
staggered straight slits/slots and/or longitudinally extending,
staggered, arcuately curved slits/slots produce the most effective
expansion zones and are easily manufactured in a controlled
process. Furthermore, in the preferred embodiment, a first row of
longitudinally extending staggered, slits/slots are offset relative
to the second row of longitudinally extending, staggered
slots/slits. If desired, further offset orientations can be
employed for one or more additional rows. However, by employing at
least two offset rows of slots/slits, a highly effective product is
produced with an integrated lattice of foam peripherally
surrounding each resulting expansion zone and providing the desired
continuous spring force.
[0036] Finally, using an alternative construction process of the
present invention, a greatly enlarged panel member can be achieved
without required large, costly equipment to be employed. In this
alternate method, foam panel members are constructed in the manner
detailed above and then welded to each other along an adjacent side
edge. If two panels are welded together, this resulting product is
double the size or area of the original panel. Furthermore, by
repeating this process, panels of any size or shape can be
economically produced.
[0037] The invention accordingly comprises the several steps and
the relation of one or more of such steps with respect to each of
the others, as well as the article produced which possesses the
features, properties, and relation of elements, which are
exemplified in the following detailed disclosure, with the scope of
the invention being indicated in the claims.
THE DRAWINGS
[0038] For a fuller understanding of the nature and objects of the
invention, reference should be had to the following detailed
description taken in connection with the accompanying drawings, in
which:
[0039] FIG. 1 is a top plan view of one embodiment of the readily
extendable/expandable foam panel construction of the present
invention;
[0040] FIG. 2 is a top plan view of an alternate embodiment of the
readily extendable/expandable foam panel construction of the
present invention;
[0041] FIG. 3 is a top plan view of a further alternate embodiment
of the readily extendable/expandable foam panel construction of the
present invention;
[0042] FIG. 4 is a perspective view of one embodiment of the
readily extendable/expandable foam panel construction of the
present invention forming an integral component of a mattress
construction;
[0043] FIG. 5 is a perspective view of an alternate embodiment of
the readily extendable/expandable foam panel construction of the
present invention configured for use in an alternate mattress
construction;
[0044] FIG. 6, which comprises FIGS. 6A, 6B, and 6C are all
perspective views of an alternate embodiment of the readily
extendable/expandable foam panel construction of the present
invention, depicting the foam panel in two alternate configurations
between a collapsed position and a fully extended position;
[0045] FIG. 7, which comprises FIGS. 7A, 7, 7C, and 7D, are
perspective views of fragmentary portions of the readily
extendable/expandable foam panel construction of the present
invention depicting alternate configurations of the panel
construction during its movement between a fully compact, collapsed
position into a fully extended position;
[0046] FIG. 8, which comprises FIGS. 8A, 8B, and 8C are perspective
views of various alternate constructions and configurations of a
further alternate embodiment of the present invention.
[0047] FIG. 9 which comprises FIGS. 9A and 9B are perspective views
of an elongated foam profile extrusion and cross-sectional panels
cut therefrom depicting the foam panel construction of the present
invention in both its fully collapsed position and its fully
extended position;
[0048] FIG. 10 which comprises FIGS. 10A and 10B are perspective
view of a further alternate embodiment of the foam panels of FIG.
12 shown in a collapsed, fully extended position; and
[0049] FIG. 11 which comprises FIGS. 11A and 11B are perspective
views of an alternate embodiment of the foam panel construction of
the present invention shown in a collapsed, fully extended
position.
DETAILED DISCLOSURE
[0050] By referring to FIGS. 1-11, along with the following
detailed description, the preferred construction of several
alternate embodiments of the readily extendable/expandable foam
panel construction of the present invention can best be understood.
In this disclosure, although several alternate constructions and
embodiment details are provided, further alternate configurations
and constructions can be implemented without departing from the
scope of the present invention. Consequently, it is to be
understood that the following detailed disclosure is provided for
exemplary purposes only and is not intended as a limitation of the
present invention.
[0051] In FIGS. 1-3, three alternate configurations of readily
extendable/expandable foam panel 20 of the present invention are
shown. In each of these embodiments, readily extendable/expandable
foam panel 20 comprises foam panel member 21 and a plurality of
expansion zones or cutout zones 22 formed therein. As shown, each
expansion zone 22 extends through foam panel 21, from the top
surface thereof to the bottom surface.
[0052] In the constructions depicted, each foam panel member 21
comprises a generally rectangular shape defined by top edge 24,
bottom edge 25, and side edges 26 and 27. In addition, for purposes
of illustration, expansion zones 22 are depicted comprising
substantially identical shapes in each of the alternate
embodiments. In this regard, each expansion zone 22 comprises a
substantially crescent or half moon shape. Although this shape is
depicted in the Figures, this shape is provided for exemplary
purposes only and, as fully detailed above, expansion zones 22 may
comprise any desired size or shape.
[0053] As stated above, the only requirement is that each expansion
zone 22 comprises a separate and independent zone positioned in
spaced relationship to adjacent zones 22. Finally, when expansion
zones 22 are formed in foam panel member 21, a fully interconnected
lattice 23 of foam material is formed between expansion zones 22 in
peripherally surrounding cooperating relationship therewith.
[0054] In the embodiments depicted in FIGS. 1 and 2, substantially
the entire available surface of foam panel 21 comprises expansion
zones 22. In FIGS. 1 and 2, side edges 26 and 27 do not incorporate
expansion zones 22, while the embodiment in FIG. 1 also
incorporates a plurality of additional longitudinally extending
sections which are devoid of expansion zones 22. In addition, as
clearly shown in FIGS. 1 and 2, expansion zones 22 are formed in
foam panel member 21 extending completely from top edge 24 to
bottom edge 25, regardless of the areas which are devoid of
expansion zones 22.
[0055] In the embodiment depicted in FIG. 3, expansion zones 22 are
formed in sections 31 and 32 of foam panel member 21, while the
remainder of foam panel member is devoid of expansion zones 22. In
addition, the cutout zones or expansion zones 22 formed in sections
31 and 32 extend from top edge 24 to bottom edge 25 directly
adjacent side edges 26 and 27.
[0056] As is evident to one having ordinary skill in the art, any
desired pattern of expansion zones 22 can be formed in foam panel
21 in order to achieve a desired readily extendable configuration.
By incorporating expansion zones 22 which substantially cover foam
panel 21 in its entirety, the expandability or extendibility of
foam panel 20 is optimized. By employing a limited number of
sections of expansion zones 22, as depicted in FIG. 3, the overall
dimensional extendibility of foam panel 20 is more limited.
[0057] Regardless of the configuration employed, readily
extendable/expandable foam panel 20 is capable of being
dimensionally changed quickly and easily in order to accommodate
any desired overall linear distance or dimension. In this regard,
by applying a force to side edges 26 and 27 in an attempt to cause
edges 26 and 27 to be spaced apart from each other, a user is able
to quickly and easily increase the overall width of foam panel 20
to any desired dimension. As a result, by employing the present
invention, foam panels are quickly and easily extended or expanded
to accommodate any desired dimension for use with the particular
product.
[0058] In FIG. 4, a typical mattress assembly 35 is depicted which
incorporates the present invention. As shown, mattress assembly 35
comprises a support base 36 on which inner spring assembly 37 is
positioned. As shown, inner spring assembly 37 comprises a
plurality of helically coiled springs mounted in side to side,
adjacent relationship with each other. In this embodiment, mattress
assembly 35 is completed by placing extendable/expandable foam
panel 20 on the top surface of spring assembly 37. Once this
assembly is completed, the entire mattress is finalized by securing
any desired additional components thereto and then peripherally
surrounding the assembly with a cover of textile material to form
the desired product.
[0059] As is evident from FIG. 4, the ease of constructing mattress
assembly 35 using the present invention is readily achieved. As
shown therein, extendable/expandable foam panel 20 is positioned on
the top surface of spring assembly 37 for providing the top
supporting surface of the finally constructed mattress. In
completing the secure affixation of extendable/expandable foam
panel 20 with spring assembly 37, any dimensional variations
between the surface area defined by spring assembly 37 and
extendable/expandable foam panel 20 are easily accommodated.
[0060] In this regard, once extendable/expandable foam panel 20 is
placed on the top surface of spring assembly 37, side edge 26 of
foam panel 20 is merely pulled to be coextensive with the
terminating edge of spring assembly 37. Once in the desired
position, a portion of edge 26 is affixed to the edge of spring
assembly 37 by employing a fastener or clip 38. This process is
repeated along the entire length of edge 26 until the entire edge
is affixed to spring assembly 37. Thereafter, a similar process is
employed with edge 27 in order to completely secure foam panel 20
to spring assembly 37.
[0061] As is evident from the foregoing detailed discussion by
employing extendable/expandable foam panel 20 of the present
invention foam panel 20 is quickly and easily securely affixed to
spring assembly 37 with assurance that the entire top surface of
spring assembly 37 is completely covered by foam panel 20. In
addition, the complete coverage of spring assembly 37 is achieved
with ease and simplicity in both the installation and manufacture
of foam panel 20.
[0062] In FIG. 4, mattress assembly 35 is depicted incorporating
the components detailed above. In addition to these components,
namely foam panel 20, spring assembly 37, and support base 36,
mattress assembly 35 also incorporates side edge guard/support
number 39. In order to provide a final construction which achieves
inherent strength and rigidity along the side edge of the mattress,
for reducing buckling over long-term use and providing support for
individuals when sitting on the edge of the mattress, most
higher-quality mattress assemblies incorporate a side edge
guard/support member 39. As depicted, side edge guard/support
member 39 is mounted about spring assembly 37, peripherally
surrounding the side edges thereof and being securely affixed
thereto. In this way, the desired beneficial results are
achieved.
[0063] In FIG. 5, an alternate embodiment of extendable/expandable
foam panel 20 is depicted. In this embodiment, foam panel 20 is
constructed in a manner similar to the embodiment detailed above
and shown in FIG. 1. However, in this embodiment, side panels 40
and 41 are formed as an integral component of foam panel 20. By
employing this embodiment of the present invention, side edge
guard/support members 39 are not required and the material and
labor needed to affix side edge guard/support members 39 to
mattress assembly 35 is completely eliminated.
[0064] By employing the embodiment of the present invention
depicted in FIG. 5, side panels 40 and 41 are automatically
installed at the precisely desired location along the
longitudinally extending side edges of spring assembly 37. In this
way, by securely affixing expandable/extendable foam panel 20 to
spring assembly 37, side panels 40 and 41 are automatically mounted
in the precisely desired position, providing inherent support,
rigidity, and longevity to the resulting product.
[0065] By referring to FIGS. 6-8, along with the following detailed
discussion, further alternate embodiments of the present invention
can best be understood. As is fully detailed below, in these
embodiments of the present invention, expandable/extendable foam
panel 20 is constructed in a manner which enables the foam panel to
become locked in its opening position after it has been fully
extended.
[0066] In this way, the panel members manufactured in accordance
with this embodiment of the present invention achieve a fixed
dimension when fully opened and extended, while also possessing a
smaller, second dimension when compacted into its original
position. By employing this embodiment of the present invention,
the resulting foam panel can be opened to its fully extended
position and then placed in cooperating association with a desired
surface, without requiring affixation of the foam panel to the
product in order to maintain the foam panel in the expanded
configuration.
[0067] In FIG. 6, one configuration of extendable/expandable foam
panel 20 of this embodiment of the present invention is depicted.
In this embodiment, readily extendable/expandable foam panel 20
comprises foam panel member 21 and a plurality of expansion zones
22 formed therein. As shown, each cut of zone 22 extends through
foam panel 21 from the top surface thereof to the bottom
surface.
[0068] In this embodiment, each expansion zone 22 comprises a
unique configuration which has been specially designed to achieve a
uniquely configured lattice 23 of foam material which peripherally
surrounds and defines each expansion zone 22. In this regard,
lattice 23 of foam material is configured to enable panel member 21
to be extended or expanded in one direction in a manner which
causes each cut of zone to become enlarged.
[0069] In this regard, this embodiment of the present invention
operates in a manner similar to the embodiment detailed above.
However, the unique aspect of this embodiment of the present
invention provides lattice 23 of foam material with a unique
configuration which causes the lattice to become rigid or fixed in
its configuration once panel member 21 has been opened to a
specific overall dimension. In this way, foam panel 20 is
effectively locked in its open position.
[0070] In achieving this configuration, lattice 23 of foam material
is constructed to possess a spring biasing force similar to the
spring forces possessed by foam panel 20 detailed above. However,
in this embodiment, lattice 23 is also constructed to automatically
shift from providing a flexible, spring biasing force to being
rigid, fixed, or locked in its open position, preventing foam panel
20 from automatically moving into a compact position.
[0071] Foam panels 20 manufactured in accordance with this
embodiment of the present invention are fully depicted in FIGS. 6
and 7. As shown therein, two alternate configurations for expansion
zones 22 are provided. However, in each of these alternate
embodiments, lattice 23 of foam material is constructed to become
fixed or rigid whenever panel 20 has been expanded beyond a
particular dimension. As a result, extendable/expandable foam
panels 20 are capable of being maintained in a fully compact
position, as shown in FIGS. 6A and 7A, and extended or expanded to
an open configuration, as shown in FIGS. 8B and 7D. However,
whenever foam panel 20 has been opened to its substantially full
extent, as depicted in FIG. 7C, lattice 23 of foam material becomes
rigid or fixed in its configuration, maintaining panels 20 in a
substantially rigid, open position.
[0072] In addition, as shown in FIG. 6C, foam panel 20 is
preferably constructed for simultaneously providing both a locked
and unlocked configuration. As depicted, the upper and lower
portions of panel 20 have lattice 23 in its fully extended and
locked position, while the middle portion of foam panel 20 is not
fully extended. As a result, the side edges of foam panel 20 become
arcuately curved.
[0073] Due to the ability of lattice 23 to become automatically
locked in its fully extended position, the configuration depicted
in FIG. 6C is maintained, until a force is applied to panel 20 to
return panel 20 into its compact position. As a result, the dual
locking, multi-purpose versatility nature of panel 20 is clearly
evident.
[0074] When panel 20 is in the configuration depicted in FIG. 6C,
lattice 23 of the foam material is effectively locked throughout
panel 20. In this regard, whenever the foam elements forming
lattice 23 are expanded sufficiently to cause the elements to pivot
beyond 180.degree., the elements become locked. However, the amount
of force required to reverse the locked configuration varies with
the position of lattice 23, with the most force being required when
the foam elements of lattice 23 are fully extended.
[0075] Although lattice 23 of foam material is constructed to
maintain panel 20 in a fixed, rigid, open position when panel 20 is
fully extended, lattice 23 of foam material is also configured to
be reversible. Consequently, whenever desired, the side edges above
foam panel member 21 can be advanced towards each other, causing
lattice 23 of foam material to return to its original position,
with expansion zones 22 returning to their substantially closed and
collapsed configuration. In this way, readily extendable/expandable
foam panel 20 of this embodiment of the present invention can be
employed for a wide variety of alternate applications in its fully
extended configuration, while also being quickly and easily
returned to its small, compact configuration for storage or
shipment.
[0076] This unique construction is fully depicted in FIG. 7,
wherein foam panel portion 20 is depicted in four alternate
extended positions in order to illustrate exactly how the "locking
segments" operate. Once the lockable expansion segments are created
in foam panel 20, regardless of the manufacturing process, these
segments are considered "at rest" (or in a relaxed state) as shown
in FIG. 7A. As the two ends of foam panel 20 are pulled apart in
opposite directions, the lockable expansion segments begin to
separate and open up. However, there is a spring force at work,
which attempts to pull the segments back to a closed position (see
FIG. 7B). As the two ends of the foam panel are pulled even further
apart, the lockable expansion segments reach a postion where they
have pivoted to a mid-way point and the spring force begins to
decrease as the foam segments now begin to compress against each
other with vertical force (see FIG. 7C). Now, as the expansion
segments pivot past the mid-way point, the vertical force of the
foam segments pressing against one another and begins to force the
segments into a subsequently open position (see FIG. 7D) and
completely removes the original spring force that was present in
FIG. 7B. The expansion segments are now "locked" into an open
configuration (see FIG. 7D).
[0077] Another unique aspect of this embodiment of the present
invention is the substantial expansion distance that can be
achieved using the present invention. As diagrammatically depicted
in FIG. 7, extendable/expandable foam panel 20 is capable of being
altered from a compact configuration (FIG. 7A) to an elongated,
substantially enlarged configuration (FIG. 7D). In addition, a
plurality of alternate expansion distances can be achieved between
the two extremes.
[0078] In this regard, it has been found that expansion distances
ranging between every one foot width of foam panel 20, panel 20 can
be expanded to a width ranging between about 2.25 and 2.8 feet in
width. As a result, one extendable/expandable foam panel 20 is
capable of being employed for use with a wide variety of various
products having different dimensions. Although the dimensions of
the product may vary, the capability of foam panel 20 of the
present invention to be adjusted to accommodate numerous alternate
dimensions enables a single foam panel to be used with a wide
variety of differently sized end products.
[0079] In FIG. 8, several alternate views are provided of a further
alternate foam panel product which is capable of enjoying the
benefits achieved by extendable/expandable foam panel 20. In this
embodiment, a water toy or float construction 50 is attained
wherein extendable/expandable foam panel 20 incorporates
longitudinally extending, cylindrically shaped foam tubes 51 and 52
intergrally formed along the side edges of the panel 20. By
employing this construction, a float configuration is realized
which is capable of being quickly and easily converted from a small
compact configuration into an enlarged, fully extended, body
supporting configuration for use as a pool water float.
[0080] As shown in FIG. 8, extendable/expandable foam panel 20
incorporates a plurality of expansion zones 22 forming lattice 23
of foam material therebetween. As detailed above, the size and
shape of expansion zones 22 are configured to establish lattice 23
of foam material which enables foam panel 20 to possess two
separate and distinct properties or physical characteristics.
[0081] One of the properties possessed by foam panels 20 of this
embodiment of the present invention is a spring biasing force which
actively attempts to return foam panel 20 to its original compact
position during its initial stages of being extended or expanded.
However, whenever foam panel 20 has been extended or expanded to a
pre-defined dimension, the configuration of lattice 23 of foam
material created by expansion zones 22 causes foam panels 20 to
become locked, fixed, or rigid in its fully extended or expanded
position. In this way, the float construction 50, or any other
resulting product, maintains a specific dimension whenever panel 22
has been fully extended.
[0082] As a result, the float construction 50 can be used in the
desired manner with complete assurance that the overall width of
the product will be maintained throughout its use. Furthermore,
when use has been completed, float construction 50 is returned to
its original collapsed position by merely exerting a closing
pressure on the side edges of foam panel 20. In this way, expansion
zones 22 return from a fully open position to their collapsed,
closed configuration, enabling float construction 50 to be storable
in its small, compact configuration.
[0083] By referring to FIG. 9, along with the following detailed
discussion, an alternate method for manufacturing
extendable/expandable foam panels 20 can best be understood. In
this manufacturing method, an elongated foam profile 60 is extruded
using generally conventional foam profile extrusion equipment. In
addition, in this embodiment, cuts, slits, or open areas 61 are
formed in foam profile 60 as an integral part of the extrusion
process by forming the extrusion die in a desired manner. By
incorporating cuts, slits, or open areas 61 in foam profile 60, the
entire foam profile 60 is capable of being extended or expanded in
at least one direction, since cuts, slits, or open areas 61 create
or form the desired expansion zones whenever foam profile 60 is
extended or expanded.
[0084] If desired, elongated foam profile 60 can be employed in the
configuration achieved from the extrusion process. However, it has
been found that this manufacturing method can be most effectively
employed by forming a plurality of segments 65 from an elongated
foam profile 60. In this regard, segments 65 are quickly and easily
created by merely cutting elongated foam profile 60 perpendicularly
to the central axis thereof, effectively achieving a
cross-sectional segment 65 having a desired thickness.
[0085] As depicted in FIG. 9B, each cross-sectional segment 65 is
easily produced and is capable of being quickly and easily extended
or expanded by merely pulling the side edges thereof in opposite
directions. In this way, the overall width of section 65 is
extended or expanded, while cuts, slits, or open zones 61 formed
therein are converted into expansion zones 67, with lattice 68 of
foam material peripherally surrounding expansion zones 67. In the
configuration depicted in FIG. 9, cuts, slits, or open zones 61 are
constructed with the design detailed above which achieves expansion
zones 67 that are automatically converted from a construction
having an inherent spring biasing return force to a construction
which when fully extended becomes locked In its open position.
[0086] In FIG. 10, a further alternate embodiment of the present
invention is depicted. In this embodiment, elongated foam profiles
60 are constructed as detailed above and shown in FIG. 12, and then
subsequently welded in adjacent, side to side relationship with a
cooperating elongated foam profile 60. The resulting product is
depicted in FIG. 10, wherein three separate elongated foam profiles
60 have been welded to each other.
[0087] Thereafter, in an alternative embodiment of the present
invention, elongated sections of the resulting welded profile are
formed, effectively achieving an elongated foam cross-section
having three sections 65 welded to each other. In this way, a final
structure is realized which possesses any desired length. As a
result, an enlarged longitudinally extending product is achieved
having virtually any desired dimension which is able to be
manufactured both expeditiously and economically.
[0088] Finally, in FIG. 11, a further alternate embodiment of
expandable/extendable foam panel 20 is depicted. In this
embodiment, foam panel 20 is constructed with cuts, slits, and open
zones 70 formed in foam panel 20 extending both horizontally and
vertically. By employing this construction, foam panel 20 can be
extended or expanded in two mutually exclusive directions, depicted
in FIG. 11 as both horizontal expansion and vertical expansion.
Although FIG. 11 depicts cuts, slits, and open zones 70 being
formed perpendicular to each other, any desired angular
relationship can be employed without departing from the scope of
this invention.
[0089] It will thus be seen that the objects set forth above, among
those made apparent from the preceding description, are efficiently
obtained and, since certain changes may be made in the above
article without departing from the scope of the invention, all
matter contained in the above description or shown in the
accompanying drawings shall be interpreted as illustrative and not
in a limited sense.
[0090] It is also to be understood that the following claims are
intended to cover all of the generic and specific features of the
invention herein described, and all statements of the scope of the
invention which, as a matter of language, might be said to fall
therebetween.
* * * * *