U.S. patent application number 14/792690 was filed with the patent office on 2016-03-03 for breathable and light weight mattress.
The applicant listed for this patent is Goodbaby Child Product Co. ,Ltd.. Invention is credited to Sagi Yaacoby.
Application Number | 20160058203 14/792690 |
Document ID | / |
Family ID | 55400449 |
Filed Date | 2016-03-03 |
United States Patent
Application |
20160058203 |
Kind Code |
A1 |
Yaacoby; Sagi |
March 3, 2016 |
Breathable And Light Weight Mattress
Abstract
The problems of the prior art are addressed by a novel mattress
for an infant play yard, crib, or bed. In one embodiment, a
mattress for a play yard, crib, or bed, comprises a plurality of
panels. Each panel can comprise a structural layer having a first
surface area. The structural layer can comprise a plurality of
structural components and a plurality of non-structural components.
A supporting surface can be positioned above the structural layer
and be in contact with and occupy a second surface area larger than
the first surface area. A cushioning layer is supported by the
supporting layer. The plurality of panels can be connected to one
another to allow for folding and transport of the mattress. In
certain embodiments, the structural components comprise ribs and
the non-structural components comprise openings between the ribs.
The panels may be formed of plastic, metal, wood, or other suitable
materials.
Inventors: |
Yaacoby; Sagi; (Brookline,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Goodbaby Child Product Co. ,Ltd. |
Kunshan City |
|
CN |
|
|
Family ID: |
55400449 |
Appl. No.: |
14/792690 |
Filed: |
July 7, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62042872 |
Aug 28, 2014 |
|
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|
Current U.S.
Class: |
5/722 ;
5/690 |
Current CPC
Class: |
A47D 15/003
20130101 |
International
Class: |
A47D 15/00 20060101
A47D015/00 |
Claims
1. A mattress for a play yard, crib, or bed, comprising: a
plurality of panels, wherein each panel of the plurality of panels
comprises: a structural layer comprising a plurality of structural
components and a plurality of non-structural components, each of
the plurality of structural components and plurality of
non-structural components having a width; a supporting surface
positioned above the structural layer, the supporting surface in
contact with the plurality of structural components and further
comprising openings having a width smaller than the width of the
non-structural components, the openings positioned over and in
communication with the non-structural components; and a cushioning
layer supported by the supporting surface; wherein the plurality of
panels are connected to one another to allow for folding of the
mattress.
2. The mattress of claim 1, wherein the plurality of structural
components comprise ribs, and the plurality of non-structural
components comprise open spaces between the ribs.
3. The mattress of claim 1, wherein the plurality of structural
components and the supporting surface are adhered together.
4. The mattress of claim 1, wherein the openings are in
communication with the plurality of non-structural components of
the structural layer.
5. The mattress of claim 4, wherein the cushioning layer further
comprises a plurality of openings, each of the plurality of
openings in communication with one of the openings in the
supporting surface.
6. The mattress of claim 1, wherein the supporting surface
comprises a planar surface.
7. The mattress of claim 1, wherein the cushioning layer comprises
a foam material.
8. The mattress of claim 1, further comprising an outer layer
enveloping each panel.
9. The mattress of claim 8, wherein the outer layer comprises
mesh.
10. The mattress of claim 1, wherein the structural layer,
supporting surface, and cushioning layer each have a length and
width that is substantially the same.
11. The mattress of claim 1, wherein the plurality of structural
components comprise a wall thickness of the panel surrounding the
plurality of non-structural components.
12. A mattress for a play yard, crib, or bed, comprising: a
plurality of panels, wherein each panel of the plurality of panels
comprises: a rigid layer having a first contact surface area, the
rigid layer comprising a plurality of ribs and openings between the
ribs; a cushioning layer supported by the rigid layer, the
cushioning layer configured to prevent an infant or child from
substantially contacting the rigid layer; wherein the plurality of
panels are hingedly connected to one another to allow for folding
of the mattress.
13. The mattress of claim 12, wherein the cushioning layer further
comprises openings in communication with the openings between the
plurality of ribs.
14. The mattress of claim 12, wherein the plurality of ribs further
comprises a design.
15. The mattress of claim 14, wherein the design is selected from
the group consisting of hexagons, triangles, circles, squares,
cross-hatch, and herringbone patterns.
16. The mattress of claim 14, wherein the design is a repeated
design.
17. The mattress of claim 12, further comprising a supporting layer
positioned above the ribs, the supporting layer in contact with the
ribs and having a second contact surface area larger than the first
contact surface area; wherein the supporting layer supports the
cushioning layer.
18. The mattress of claim 12, further comprising an open space in
the interior at least one of the plurality of ribs.
19. The mattress of claim 12, wherein the plurality of structural
components comprise a material selected from the group consisting
of machined aluminum and molded plastic.
20. A panel for a play yard, crib, or bed, comprising: a structural
layer having a first contact surface area, the structural layer
comprising a plurality of structural components and a plurality of
openings; a supporting layer positioned above the structural layer,
the supporting layer in contact with the first contact surface area
and occupying a second contact surface area larger than the first
contact surface area, the supporting layer further comprising
openings in fluid communication with the openings in the structural
layer; a cushioning layer supported by the supporting layer, the
cushioning layer in contact with the second contact surface area
and having openings in fluid communication with the openings in the
supporting layer; and a mesh layer surrounding the structural
layer, supporting layer, and cushioning layer; wherein the
structural layer, supporting layer, and mesh layer each have a
length and width that is substantially the same.
Description
[0001] The present application claims priority to U.S. Provisional
Patent Application Ser. No. 62/042,872 for "Breathable and Light
Weight Mattress", filed Aug. 28, 2014, the disclosure of which is
incorporated herein by reference.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to a mattress for a play
yard, crib, or bed. In particular, the present disclosure relates
to a mattress having a rigid substructure that is breathable,
light-weight, and foldable.
BACKGROUND
[0003] Play yards are well known in the art. Play yards are
structures designed to provide a safe environment for infants and
children. Conventional play yards are designed to fold into a
compact, generally rectangular structure. When erected, the play
yard should be stable, and provide support to keep the structure
standing upright. For maximum convenience, a foldable play yard
should be readily collapsible to a storage position without the
disassembly of any parts. When stored, the play yard should be
easily transportable from one location to another.
[0004] Play yards typically include a mattress that may be removed
and placed within an opened play yard. Play yard mattresses are
designed to safely support a child or infant placed therein. Play
yard mattresses are typically composed of a plurality of panels
made from medium-density fiberboard (MDF), particle board, or other
similar materials. The panels are connected at hinge points so that
they may be folded over one another for ease of transportation. The
panels may also be folded into a square tube, or wrapped around a
folded play yard. To use, the panels are unfolded to form a
rectangular mattress, which is then placed within an opened play
yard to create a safe surface for play for an infant or child.
[0005] There are a number of issues with conventional play yard
mattresses. Mattresses may be heavy or cumbersome, thus affecting
the portability of the play yard. Infants may also expel bodily
fluids onto a mattress, which may collect around the infant and
lead to the mattress becoming unsanitary or unsafe. The mattress
may retain odors or become stained, which may be minimized, but not
eliminated, by the usage of a mattress sheet. Cleaning these
mattresses may be cumbersome and sometimes ineffective, as
bacteria, germs, and other matter may become embedded within the
mattress. Further, rebreathing carbon dioxide is a contributing
cause of Sudden Infant Death Syndrome (SIDS) and asphyxiation.
Conventional crib mattresses, bedding, and materials may lead to
rebreathing of carbon dioxide, and therefore may be a contributing
environmental cause of SIDS and other ventilation concerns.
[0006] Currently, some of these issues are addressed in a variety
of ways, with varying degrees of success. In some cases, the
solutions to these issues are expensive, thereby raising the price
of the play yard mattress. It would be beneficial if these issues
could be addressed in a safe, convenient and cost effective
manner.
SUMMARY
[0007] The problems of the prior art are addressed by a novel panel
for a mattress. The panel may be used in mattresses for a play
yard, crib, bed, or other furniture designed to accommodate an
infant or child. In one embodiment, the problems of excess weight
and lack of breathability are solved by a play yard mattress
composed of a plurality of panels having structural components and
non-structural components. The plurality of panels are connected to
one another to allow for folding, thus creating a foldable play
yard mattress. The combination provides sufficient structural
support for the panel, yet results in a light-weight structure.
Further, the non-structural components may increase breathability
of both the panel and mattress.
[0008] An object of the invention is to provide a light weight and
breathable mattress for use by an infant or child. To achieve this
object, embodiments of the disclosure may comprise a mattress
having a rigid substructure with perforations, covered by a soft
fabric.
[0009] In some embodiments, the structural and non-structural
components may comprise a design, which further may comprise a
repeated pattern. The design may be any design, such as hexagons,
triangles, circles, squares, cross-hatch, or herringbone patterns.
The structural components may comprise ribs surrounding the
non-structural components, and the non-structural components may be
open spaces between the ribs. Alternately, the non-structural
components may comprise areas of the panel having a thinner wall
thickness than the structural components.
[0010] In some embodiments, the panels are formed of molded
plastic. The panels may be formed using suitable plastic molding
techniques, which may include gas assist injection molding, blow
molding, and rotational molding. In other embodiments, the panels
may be formed of metal, such as machined aluminum, or even
wood.
[0011] In some embodiments, the panels are connected to one another
using a hinge, such as a living hinge or metal hinge. The panels
may also be covered in fabric and soft material, such as batting,
foam, or rubber, thus making the contact surface of the panel soft
and walkable. In a further embodiment, the fabric and soft material
may be replaced in the event of stains or retained odors. The
plurality of panels may comprise four, five, or any number of
panels.
[0012] In some embodiments, each panel may be formed from an upper
and a lower panel, each having an edge, structural components, and
non-structural components. The panels are stacked on top of one
another such that the edges of each panel are in contact, thus
forming an interior space between the panels. In other embodiments,
the structural components of the upper and lower panels are in
contact. The panels may be connected using heat welding, screws,
snaps, or a living hinge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a better understanding of the present disclosure,
reference is made to the accompanying drawings, which are
incorporated herein by reference and in which:
[0014] FIGS. 1A-D are top views of several embodiments of panels
according to embodiments of the disclosure,
[0015] FIG. 2A is a cross-sectional view along the line A-A' in
FIG. 1A, and FIG. 2B is a cross-sectional view along the line B-B'
in FIG. 1A;
[0016] FIG. 3 is a cross-sectional view of a compound panel formed
from an upper panel and a lower panel according to an embodiment of
the disclosure;
[0017] FIGS. 4A-B are cross-sectional views of embodiments of
panels according to the disclosure comprising ribs having interior
spaces;
[0018] FIGS. 5A-D are top, bottom, perspective, and zoomed
perspective views of a panel comprising a supporting surface for
accommodating a foam backing or other material according to the
disclosure;
[0019] FIGS. 6A-D are top, bottom, perspective, and zoomed
perspective views of another embodiment of a panel comprising
another embodiment of a supporting surface for accommodating a foam
backing or other material according to the disclosure;
[0020] FIGS. 7A-B are top perspective and bottom perspective views,
respectively, of the panel of FIGS. 6A-D and further comprising a
foam backing adhered to the supporting surface;
[0021] FIG. 8A is a cross sectional view along line C-C' of the
panel of the embodiment of the panel of FIG. 7A, and FIGS. 8B-E are
cross-sectional views of additional embodiments of panels
comprising embodiments of supporting surfaces according to the
disclosure;
[0022] FIG. 9 is a top view of a plurality of panels, such as the
panel of FIG. 1A, hingedly attached to form the rigid substructure
of a play yard mattress according to one embodiment of the
disclosure;
[0023] FIGS. 10A-B are perspective views of the top and bottom,
respectively, of an unfolded or opened play yard mattress
comprising multiple panels of FIG. 8B, and FIGS. 10C-D are
perspective and top views of the play yard mattress of FIGS. 10A-B
in a folded or closed configuration; and
[0024] FIG. 11 is a perspective view of a play yard illustrating
two positions for placement of a mattress.
DETAILED DESCRIPTION
[0025] FIG. 1 shows a front view of a single panel 100 of a
mattress for a play yard, crib, or bed according to one embodiment
of the instant disclosure. In this embodiment, the panel 100 is
formed from molded plastic; however, a variety of materials may be
used. For example, panels within the scope of the disclosure may be
formed from plastic, metal, cardboard, rubber, wood, and the like.
The panels may be molded, machined, or cast. As will be discussed
in further detail below, the panel 100 may be combined with several
similar panels according to the disclosure in order to form a
mattress. In particular, the panel 100 serves as a rigid, yet
light-weight substructure for the mattress, thus providing
stability for the mattress. However, the panel 100 also allows for
ventilation and transmission of fluids and gases, and certain
embodiments further comprise soft surfaces for placing an infant or
child thereon.
[0026] The panel 100 has an edge 102 forming its perimeter. The
edge 102 may comprise the same material as the panel, or
alternately may be composed of a different material. In certain
embodiments, the edge 102 may be omitted. The panel 100 further
comprises a plurality of structural components 106 and a plurality
of non-structural components 108. The structural components 106 are
configured to provide support, strength, and stability for the
panel 100, whereas the non-structural components 108 are configured
to reduce the weight of the panel 100. Further, as shown in this
embodiment, the structural components 106 and non-structural
components 108 may be arranged to comprise a pattern 104.
[0027] As shown in this embodiment, the pattern 104 can comprise a
repeated hexagonal design. However, the hexagonal design is only
exemplary, and it should be understood that other patterns or
shapes may be used, such as triangles, circles, squares,
cross-hatch, or herring-bone patterns. The pattern 104 may be
repeating or non-repeating. Further, the pattern 104 may comprise
any shape, design, or figure, and not just geometric shapes. In
certain embodiments, the pattern 104 may comprise multiple shapes
or patterns. The use of a pattern 104 is helpful in providing a
design for the structural components 106; however, certain
embodiments may also lack the use of a pattern 104 according to the
disclosure.
[0028] The structural components 106 can comprise ribs surrounding
the edges of each shape in the pattern 104, which as shown in this
embodiment comprises a hexagonal design. However, in certain
embodiments the structural components 106 can comprise other
various internal features of the panel 100. In particular, the
structural components 106 may be configured to provide support,
strength, or stability for the panel 100. Preferably, the
structural components 106 should comprise non-deformable or
non-elastomeric materials, and thus be able to rely on their own
tensile properties for support, as opposed to requiring another
component or set of components to provide structural support for
the panel 100. The structural components 106 should also preferably
be able to maintain these properties when the weight of an infant
or child is placed on the panel 100, such that the panel 100 may be
used as a component of or as a mattress for a play yard, crib, or
other enclosure.
[0029] As shown in this embodiment, the non-structural components
108 can comprise the width or distance between the structural
components 106. For example, the non-structural components 108 can
comprise a plurality of openings or cutouts in the panel, such as
the hollow or open centers of each shape in the pattern 104.
Accordingly, the non-structural components 108 create a channel
between the top and bottom of the panel 100. The non-structural
components 108 provide the benefits of reducing the weight of the
panel 100, reducing material usage, and also allowing ventilation
and drainage of gas and fluid when the panel 100 is used as part of
a mattress for a play yard, crib, or other enclosure. Preferably,
the non-structural components 108 are configured to provide these
benefits without affecting the structural integrity of the panel
100.
[0030] In certain embodiments, the non-structural components 108
may simply be thinner portions of the panel 100, rather than hollow
segments, openings, a width, or volume between the structural
components 106. For example, the panel may be formed such that the
wall thickness of the non-structural components is thinner than
that of the structural components. Alternately, the pattern may
comprise various combinations of both open and thinned
non-structural components 108. Certain embodiments can taper
between the structural and non-structural components. Various
configurations and combinations of structural components and
non-structural components are within the scope of the present
disclosure.
[0031] As previously noted, panels 100 according to the disclosure
may comprise a variety of materials. For example, suitable plastic
materials include polypropylene, reinforced polypropylene, nylon,
reinforced nylon, polyvinyl chloride, plastic blends (including
blends comprising glass fibers and carbon fibers), and the like.
Panels formed of metal may comprise aluminum, titanium, and the
like. Still further embodiments may employ wood, cardboard, and
other materials. Various embodiments and material usage are
considered to be within the scope of the disclosure.
[0032] To achieve an optimal balance between weight and stability,
a ratio between the panel surface area comprising the structural
components 106 and the panel surface area comprising non-structural
components 108 may be varied. Increasing the surface area of the
panel occupied by the structural components 106 will increase
stability of the panel 100, at the expense of increased weight. In
contrast, increasing the surface area of panel occupied by the
non-structural components 108 will decrease weight, yet also
decrease stability. For example, one may vary both the dimensions
of each shape in the pattern 104, the size of the ribs surrounding
or forming the shape, and the spacing between the ribs or size of
the openings or non-structural components 108. Increasing the
average size of the shape in the pattern 104 leads to a larger open
surface area, thus decreasing the overall weight of the panel.
However, this also results in decreased stability and increased
flexion, which can be undesirable when the panel is used to support
an infant or child. These effects may be countered by increasing
the width of the ribs forming each shape, which reduces the
cumulative open surface area of the panel, thus increasing
stability. In certain embodiments, these effects may also be
moderated by choosing lighter or stronger materials for the
structural components 106.
[0033] FIGS. 1B-1C illustrate further variations of panels 120, 140
according to embodiments of the disclosure. Similar to the panel
100, the panels 120, 140 comprise edges 122, 142; patterns 124,
144; structural components 126, 146; and non-structural components
128, 148, respectively. The panel 120 in FIG. 1B features a pattern
124 having repeated hexagons of a larger width than those in the
panel 100 of FIG. 1A. As discussed above, this property leads to a
larger percentage of the surface area of the panel 120 devoted to
non-structural components 128. The increased open surface area of
the panel results in a panel having both decreased weight and
decreased stability. If the resulting decrease in stability is
unacceptable, this effect may be compensated by increasing the
percentage of the panel 120 devoted to structural components 126 by
increasing the size of the ribs forming or surrounding each shape
in the pattern 124, 144, by using a stronger material for the
structural components 126, 146, or a combination of approaches.
[0034] Similarly, the panel 140 in FIG. 1C features a pattern 144
having smaller hexagons than the panel 100 of FIG. 1A, thus
decreasing the surface area devoted to non-structural components
148 and increasing the surface area devoted to structural
components 146. This increases both stability and weight. If the
increase in weight is unacceptable, this effect may be compensated
by decreasing the width of the ribs surrounding and forming each
hexagon, by using a weaker material, or by using a combination of
approaches. Accordingly, the ratio between structural and
non-structural components may be varied until an acceptable balance
between weight and stability is achieved. In certain embodiments,
the percentage of surface area of the panel devoted to the openings
or non-structural components 128 is greater than that devoted to
the structural components 126. This feature is particularly useful
to aid in both ventilation of air and drainage of liquids.
[0035] In these embodiments, the structural components 106, 126,
146 of panels 100, 120, 140 are approximately 8-10 mm tall. Each
panel can be approximately 670 mm (26.4'') in length long and 240
mm (9.44'') in width. These particular dimensions are useful for
connecting multiple panels together to form a mattress. However, in
certain embodiments, various other dimensions and shapes may be
used to accommodate a variety of play yards or other structures.
For example, in certain embodiments a panel according to the
disclosure may be circular, elliptical, triangular, rectangular,
star-shaped, heart-shaped, and the like. In certain embodiments,
the width of the structural components can be 1.8-2.0 mm and the
width of the non-structural components can be about 25 mm. Further,
in certain embodiments, panels can have a width that is greater
than or equal to its length.
[0036] The panel 100 and structural components 106 may be formed
using a variety of methods. For example, in certain embodiments a
panel can comprise plastic, which may be formed using gas assist
injection molding. In this case, the interior of the ribs may be
cleared out in the gassed area, leaving an interior space. Gas
assist injection molding may also be used to finely tune the wall
thickness of the panel and rib size. Other suitable methods for
molding may be used, such as blow molding and rotational molding.
As previously noted, suitable plastic materials for molding include
polyethylene, polypropylene, polycarbonate, nylon, and reinforced
composites of these materials, for example.
[0037] As previously noted, in certain embodiments, panels
according to the disclosure may also comprise other materials, such
as metal, wood, and the like. FIG. 1D illustrates another
embodiment of a panel 160 according to an embodiment of the
disclosure. In this embodiment, the panel 160 comprises an aluminum
sheet comprising an edge 162, a pattern 104, structural components
166, and non-structural components 168. As shown in this
embodiment, the non-structural components 168 can comprise the
perforations or holes formed in the aluminum, and the structural
components 166 comprise the portions of the panel 160 which have
not been perforated. In various embodiments, the size, number,
arrangement, and shape of the perforations can be varied to achieve
a desired ratio of stability and weight. In certain embodiments,
aluminum may be preferred over plastic materials as it is a light
weight and strong material. However, in certain embodiments plastic
may be preferred, as it may take advantage of specialized molding
techniques which may be used to include other features, as will be
discussed in additional detail below.
[0038] FIG. 2A is a cross-sectional view along the line A-A' of
FIG. 1A and illustrates the structure of the structural components
106 and non-structural components 108 in the panel 100. As
previously noted, in this embodiment, the structural components 106
comprise ribs surrounding the edges of the non-structural
components 108. As shown in this embodiment, the ribs can have a
thickness (i.e., the height between the top and bottom of the panel
100) that tapers from a maximum thickness 210 to a minimum
thickness 205.
[0039] FIG. 2B illustrates a cross-sectional view along lines B-B'
of the panel 160 of FIG. 1D. As previously noted with respect to
FIG. 1D, the panel 160 lacks ribs and a raised edge. In this
embodiment, the structural components 166 comprise the wall
thickness 215 (i.e., height) of the panel 160 between the
non-structural components 168. For example, the non-structural
components 168 of FIG. 2B may simply be openings, cutouts,
perforations, or other features punched or machined into the panel
160, thus leaving the wall thickness of the panel 160 remaining as
the structural components 106.
[0040] FIG. 3 illustrates another embodiment of a panel 300
according to the disclosure. As shown in this embodiment, the panel
300 can comprise multiple panels, such as an upper panel 310 and a
lower panel 320, which may be stacked together or otherwise
combined to form a combined panel 300. Similar to the panel 100,
the panels 310, 320 further comprise structural components 306 and
non-structural components 308. The panels are stacked such that an
upper panel edge 302 on the upper panel 310 is in contact with a
lower panel edge 303 on the lower panel 320, thus forming an
interior space 330 between the two panels 310, 320. Further, as
shown in this embodiment, the combination of the non-structural
components 308 and interior space 330 creates a channel providing
fluid communication between the top and bottom of the panel
300.
[0041] In certain embodiments, the structural components 306 of the
upper and lower panels 310, 320 may first be aligned prior to
stacking. In certain embodiments, the edges of the panels 310, 320
may be connected by a living hinge, welded, heat-sealed, screwed,
or snapped together. In this way, the combined panel 300 has a
thickness 340 (i.e., height) that is larger than the thickness of a
single panel, yet the combined panel 300 can still be strong,
breathable, and light weight. In certain embodiments, the ribs or
structural components 306 of the two panels may also be connected.
In other embodiments, the panels 310, 320 may be releasably
attached for ease of assembly and disassembly.
[0042] In certain embodiments, structural components may further
comprise a hollow or open interior. FIGS. 4A-B illustrate
cross-sectional views of embodiments of panels 400, 405 according
to the disclosure comprising structural components 406 and
non-structural components 408, of which the structural components
406 further comprise interior spaces 412. FIG. 4A illustrates the
panel 400 as comprising two sections 401, 402 that combine together
to form the structural components 406 (i.e., as shown in this
embodiment, ribs). Further, in this embodiment, the combination of
the two sections 401, 402 leaves an interior space 412 within the
rib itself, thus resulting in a rib that is thicker, yet having
reduced weight due to an air pocket formed within the interior
space 412.
[0043] In certain embodiments, an interior space 412 may be formed
in structural components 406 through means other than stacking two
separate sections. FIG. 4B illustrates a cross-sectional view of
the panel 405 that has been formed using a gas-assist or blow
molding technique. Accordingly, in this embodiment, the interior
space 412 has been formed directly within the structural component
406 itself during fabrication, as opposed to by joining two
separate sections together. In certain embodiments, this may be
preferable as it helps to ensure integrity of the structural
component 406 and thus prevent breaching of the interior space
412.
[0044] Further, the use of an interior space 412 may be
particularly advantageous in embodiments of panels that require a
wider rib, such as for attachment to another surface or foam
backing, for example. Accordingly, in this embodiment, the
structural components 406 can provide a contact surface area which
may be used for attachment or support of a foam panel or other soft
material.
[0045] As previously noted, panels according to the disclosure may
serve as a mattress or a component of a mattress for a play yard,
crib, or other enclosure. The mattress should preferably provide a
soft and walkable surface for a caregiver to place a child or
infant. In certain embodiments, panels according to embodiments of
the disclosure may be covered in covered in fabric and soft
material, thus making the contact surface of the panel soft and
walkable. The soft material may comprise foam, breathable foam,
three-dimensional mesh, spacer mesh, batting, rubber, or any other
suitable material. A combination of soft materials may be used,
e.g., a foam backing and a sheet or mattress cover. Further, the
fabric and soft material may be removable such that if the
materials begin to retain odor, or become stained, torn, or frayed,
they may simply be removed for washing or replacement. However, in
other embodiments, the fabric and soft material may not be
replaceable to minimize the number of seams and/or failure points
for the fabric, and depending on other considerations regarding
longevity and intended use.
[0046] FIGS. 5A-D illustrate another embodiment of a panel 500
according to the disclosure. Similar to previous embodiments of
panels disclosed herein, as shown in this embodiment, the panel 500
comprises an edge 502, a pattern 504, structural components 506,
and non-structural components 508. Further, the panel 500 comprises
a supporting surface 516 positioned above the structural components
506. The supporting surface 516 comprises a planar surface above
the structural components 506 that increases the available surface
area of the panel to support an additional cushioning layer, such
as a soft material configured to support an infant or child.
Suitable soft materials can comprise foam, mesh, padding, and the
like. Additionally, as shown in this embodiment, the supporting
surface 516 can comprise openings 518 or perforations positioned
above the non-structural components 508, thus creating a channel
between the top and bottom of the panel 500 and maintaining
breathability of the panel 500.
[0047] In this embodiment, the panel 500 comprises injection molded
plastic. Accordingly, the panel 500, structural components 506, and
supporting surfaces 516 may be formed together as a single plastic
component. However, in certain embodiments, supporting surfaces 516
according to the disclosure may also be added later as a separate
component from the structural components 506. For example, the
supporting surface 516 may comprise a sheet of plastic or other
material that is adhered to the structural components 506; thus,
the openings 518 in the supporting surface 516 may comprise holes,
openings, or perforations punched into the supporting surface 516.
Preferably, the openings 518 should be positioned over the
non-structural components 508 to create a channel between the top
and bottom of the panel 500, thus ensuring breathability and the
ability to transfer gas, liquid, air, and other materials through
the panel 500.
[0048] A supporting surface 516 provides a variety of benefits for
a panel according to the disclosure. For example, as shown in this
embodiment, the supporting surface 516 provides additional
stability for the panel 500 by preventing twisting or torsion of
the structural components 506. Additionally, the supporting surface
516 provides additional strength to the panel 500, thus allowing
for the use of thinner structural components 506 or structural
components 506 comprising materials that would otherwise not be
practical or provide sufficient strength. Accordingly, while the
first contact surface area of the structural components 506 may be
insufficient to adhere to a cushioning layer, the provision of a
second, larger, contact surface area by the use of a supporting
layer or supporting surface 516 helps to attach the structural
components 508 to a cushioning layer or other soft material without
increasing the size of the structural components 506, thus helping
to keep the panel light weight.
[0049] FIGS. 6A-D illustrate another embodiment of a panel 600
comprising an edge 602, structural components 606, and
non-structural components 608, and a supporting surface 616
according to the disclosure. In contrast to the supporting surface
516 of the panel 500, as shown in this embodiment, the supporting
surface 616 can comprise openings 618 having substantially the same
shape (i.e., hexagonal) as the non-structural components 608. As
shown in this embodiment, the feature may help to facilitate
fabrication of the panel during fabrication, such as by injection
molding or other plastic fabrication techniques. Further, having
the openings substantially conform to the shape of the pattern 604
helps to maximize air flow and ventilation by maximizing the amount
of open area between the top and bottom of the panel 600.
[0050] While in these embodiments, the supporting surfaces 516, 616
comprise features that are positioned above the structural
components 506, 606, respectively, in certain embodiments
supporting surfaces according to the disclosure may extend
outwardly from structural components according to the disclosure.
For example, in certain embodiments, a supporting surface may
comprise protrusions that extend longitudinally from a structural
component or rib according to the disclosures. The protrusions may
have a surface along the same plane as the top of the structural
components. Accordingly, the protrusions would similarly provide a
larger surface area for attachment of an additional component as
compared to only the structural components. Various embodiments and
equivalents are considered to be within the scope of the
disclosure.
[0051] FIGS. 7A-B illustrate the panel 600 of FIGS. 6A-D, and
further comprising a cushioning layer, such as a foam backing 650
adhered to the supporting surface 616. As previously noted, the
supporting surface 616 facilitates attachment of the foam backing
650 by increasing the available surface area on the top of the
panel 600 (i.e., by reducing the amount of surface area on the top
of the panel occupied by the non-structural components) available
for attachment to the panel. The foam backing 650 allows for the
panel 600 to be used as a soft surface for a caregiver to safely
place a child or infant thereon. Ideally, the foam backing 650
should be chosen or configured such that the infant or child does
not sufficiently come into contact with the structural components
608. Though in this embodiment the foam backing 650 is only
attached to one side of the panel 600, in other embodiments foam
backing or other soft material may be attached on both sides.
Further, due to the non-structural components 608, the panel 600
will be breathable, promoting air flow and allowing for liquids
placed on the foam backing 650 to drain. Preferably, the foam
backing 650 will comprise a material that is gas and liquid
permeable and washable. Examples of suitable materials for use as a
foam backing 650 can comprise nylon foam, closed-cell or open-cell
foam, EVA foam, 3D mesh, spacer mesh, polyurethane foam, and the
like.
[0052] As shown in this embodiment, the foam backing 650 may be
attached to the panel 600 and supporting surface 616 using glue,
Velcro, by over-molding, or any other fastening means. However, in
certain embodiments, the foam backing 650 may not be securely
attached to the panel 600, and instead may simply be positioned
over and supported by, or otherwise in contact with the panel 600
and/or supporting surfaces 616.
[0053] As shown in this embodiment, the foam backing 650 can
further comprise openings 652 positioned over the openings 618 of
the supporting surface 616, which in turn are positioned over the
non-structural components 608, thus forming a channel between the
upper and lower sides of the panel 600. As previously noted, this
maintains the breathability of the panel, allowing for both air
flow and drainage. As shown in this embodiment, the openings 652
match the size of the supporting surface 616, thus maximizing
breathability. However, in certain embodiments, the openings 652
can be sized smaller or larger than the supporting surface 616. For
example, in certain embodiments the soft material may be soft
enough such that a child or infant placed thereon would contact the
structural components 506. In these embodiments, it may be
preferable to reduce the size of the openings 652 to slightly
overlap the supporting surface 616 and structural components
606.
[0054] FIG. 8A illustrates a cross-sectional view of the panel 600
along line C-C' in FIG. 7A. As shown in this embodiment, the
supporting layer or surface 616 can be molded together as a
component of the structural components 606. The use of the
supporting surface 616 allows for the structural components 606 to
be thinner, thus further decreasing the weight of the panel 600.
Accordingly, the supporting surface 616 can be wider than the
structural components 606, thus presenting a larger contact surface
area for supporting or attaching the foam backing 650. In this
embodiment, the width of the structural components 606 is 1.8-2 mm,
the width of the non-structural components 608 is 25.4 mm, and the
width of the supporting surface 616 is 5-6 mm. The height or
thickness of the structural components 606 can be 10 mm, or even
less. For example, if the panel 600 comprises reinforced
polypropylene, the height of the rib can be 8 mm.
[0055] As shown in this embodiment, the combination of the
non-structural components 608, openings 618, and openings 652
create a channel between the top and bottom of the panel 600,
allowing fluid communication for gas and liquid. FIG. 8B
illustrates a cross-sectional view of the panel 600 of FIG. 7A with
the foam backing 650, and further comprising an outer layer 660. In
the embodiment shown, the outer layer 660 completely surrounds both
the panel 600 and foam backing 650. In certain embodiments, the
outer layer 660 may comprise a thin mesh material.
[0056] The outer layer 660 serves as an additional layer for
providing a soft surface for placing an infant or child.
Additionally, the outer layer 660 can also prevent foreign objects
or other materials from occupying or blocking the channel defined
by the non-structural components 608, openings 618, and openings
652. Further, in certain embodiments, the outer layer 660 may be
removable. In this way, the outer layer 660 may be removed to allow
for cleaning or replacement of either the outer layer 660 or the
panel 600. Further, in embodiments where the outer layer 660
comprises mesh or other breathable materials, the ventilation of
the channel defined by the non-structural components 608, openings
618, and openings 652 will not be severely impacted.
[0057] FIG. 8C illustrates a cross-sectional view of the panel 600
comprising another embodiment of a cushioning layer or foam backing
670 according to the disclosure. As shown in this embodiment, the
foam backing 670 may instead comprise a single continuous planar
sheet of a soft material, and thus lack openings 652, as compared
to the foam backing 650 of FIGS. 8A-B. In these embodiments, it may
be preferable to use materials having increased breathability, thus
continuing to allow the transfer of air and fluids between the
upper and lower portions of the panel 600 through the
non-structural components 608 and openings 618 of the supporting
surface 616.
[0058] FIG. 8D illustrates a cross-sectional view of another
embodiment of a panel 700 comprising structural components 706 and
non-structural components 708, the structural components 706
further comprising a supporting surface 716 for a foam backing 760
that is thinner than the structural components 706. In particular,
as shown in this embodiment, the supporting surface 716 comprises a
protrusion extending from the structural components 706. Further,
in this embodiment, the foam backing 760 further comprises a groove
718 that securely fits over the supporting surface 716. In certain
embodiments, this feature helps to keep the foam backing 760 firmly
attached to the panel 700. However, compared to the panel 600 of
FIGS. 8A-C, the panel 700 requires structural components 706 that
are relatively wider, potentially increasing the weight of the
panel. In certain embodiments, the structural components 706 may
further comprise interior spaces (e.g., the interior spaces 412 of
FIGS. 4A-B) to decrease the weight of the panel 700
accordingly.
[0059] FIG. 8E illustrates a cross-sectional view of another
embodiment of a panel 720 comprising structural components 726 and
non-structural components 728, the structural components 726
further comprising a supporting surface 736 for a foam backing 770.
In this embodiment, the supporting surface 736 comprises a groove
sized to accommodate a protrusion 738 extending from the foam
backing 770. For example, the foam backing 770 may be prefabricated
and then pressed onto the supporting surface 736. In other
embodiments, the foam backing 770 may instead comprise rubber or
another moldable material, which may be over-molded directly into
the supporting surface 736. Various embodiments are considered to
be within the scope of the disclosure.
[0060] It should be noted that the individual features described
herein may be combined with one another to present various
embodiments of a mattress. For example, a mattress according to the
instant disclosure may comprise two panels stacked on one another,
and also feature ribs and a supporting surface to allow placement
of a foam backing or other soft material. In certain embodiments,
foam backings or other soft materials having openings or no
openings may be adhered to a variety of supporting surfaces, or
directly to a structural component or rib. Each of the above
described features may be combined with one another to form various
panels and mattress according to the disclosure.
[0061] FIG. 9 is a top view of a mattress 800 for a play yard,
crib, or bed according to an embodiment of the instant disclosure.
The mattress 800 can comprise four panels; in this embodiment, each
panel is the panel 100 as shown in FIG. 1A. However, mattresses
according to the disclosure may comprise various panels according
to the disclosure, including different embodiments or combinations
of panels. The panels are separated by a gap 810 and are connected
by an attachment mechanism 820 which allows the panels to pivot
with respect to one another.
[0062] The attachment mechanism 820 can comprise a hinge, allowing
the panels 100 to pivot with respect to one another such that the
mattress 800 may be folded. However, the attachment mechanism may
be any means of attaching panels to one another, such as a living
hinge, straps, snaps, movable joint, or other mechanism. The gap
810 and attachment mechanism 820 allow the panels to be folded
against each other, or to form a square tube. This aids
portability, as the panels may thus be wrapped around a folded play
yard and used as a box. Alternately, the panels may be stacked on
one another and stored with or adjacent to a folded play yard.
[0063] FIGS. 10A-B illustrate another embodiment of a mattress 900
according to the disclosure. Similar to the mattress 800, the
mattress 900 comprises four panels. In this embodiment, the panels
comprise the panel 600 of FIG. 7A, and accordingly comprise a foam
backing 650 secured to supporting surfaces 616 and surrounded by an
outer layer 660. The panels 600 serve as a rigid substructure for
the foam backing 650 and outer layer 660, thus resulting in a light
weight, breathable, yet soft, mattress 900. As previously noted,
the foam backing 650 can comprise breathable foam, 3D mesh, spacer
mesh, and the like to allow air flow and liquid drainage through
the non-structural components 608. Finally, the outer layer 660
surrounds the panel 600 and foam backing 650, providing a soft
surface for placing an infant or child thereon.
[0064] FIGS. 10C-D illustrate the mattress 900 when folded. As the
mattress 900 comprises four panels 600, it may be folded along the
gaps 810 into a rectangular structure, creating a volume 910 for
receiving a collapsed play yard or other objects. Though the
mattresses 800, 900 in this embodiment comprises only four panels,
more or fewer panels may be used. For example, if the average panel
width is shorter, more panels may be required to create a
full-length mattress according to the disclosure. In some
embodiments, a play yard mattress uses five panels. Four- and
five-panel configurations are beneficial because they allow for
easy folding into a box-like structure to contain the folded play
yard. However, in certain embodiments, panels may simple be folded
over onto one another into order to form a compact structure for
storage or travel. However, in some embodiments the mattress may
comprise only a single panel.
[0065] In some embodiments, mattresses according to the disclosure
may be disassembled into individual panels for ease of storage, or
for panel replacement. Alternately, the panels may be permanently
attached.
[0066] As described above for panels according to the instant
disclosure, the mattresses 800, 900 may be covered in fabric and
soft material, thus making the contact surface soft and walkable.
Further, the hollow or open surface area of the panels (e.g., the
channel created by the non-structural components, openings in the
supporting surface, and opening in the foam backing) leads to the
unique property of increasing breathability for the mattresses 800,
900 thus providing for an air layer beneath the fabric and soft
batting. Breathability is desired as it provides more air to an
infant or child within the play yard, and also helps to prevent
mold, bacteria, or odors from settling within the mattresses 800,
900. Further, the combination of layers, i.e., a mesh outer layer
660, foam backing layer (e.g., foam backing layer 650), and a rigid
sublayer or structural layer (e.g., the panel 600), results in a
mattress 800, 900 this is also sturdy and light weight.
[0067] In use, the mattresses 800, 900 may be unfolded flat and
then placed within a play yard. As illustrated by FIG. 11, a
mattress according to the present disclosure may be used in various
locations of a play yard 1000. For example, infants who do not yet
have the ability to pull themselves up or to stand may sleep
comfortably on the mattress placed in the bassinet position 1010.
However, older children with increased mobility will be safely
contained if the mattress is placed in the floor position 1020
instead. Alternately, the mattresses 800, 900 may even be used
without a play yard to simply provide a clean and soft surface to
place an infant or child.
[0068] When not in use, mattresses according to embodiments of the
disclosure may be folded and wrapped around a folded play yard,
thus forming a convenient package for travel.
[0069] It should be noted that embodiments of panels according to
the instant disclosure may comprise any form of structural and
non-structural components in a panel. As discussed above, other
shapes in a pattern may be used. Multiple patterns and designs may
be used in a single panel. The panels may vary in their dimensions.
The ribs or structural components may comprise a variety of shapes
and configurations. Mattresses may be formed from a single panel or
from multiple panels. The panels may be connected by hinges or
other forms of attachment mechanisms.
[0070] Embodiments of the disclosure may be used in any kind of
mattress. For example, embodiments of panels according to the
disclosure may be used as a surface for resting by adults, such as
for camping. Further, while various layers or components of panels
are described hereinabove, these layers may be omitted or used in
combination with other layers or features to form embodiments of
panels according to the disclosure. Moreover, layers according to
the disclosure do not need to be formed of different materials or
manufactured separately; for example, a supporting layer or surface
and a structural component according to the disclosure may comprise
a single piece of molded plastic, metal, or other material.
[0071] The present disclosure is not to be limited in scope by the
specific embodiments described herein. Indeed, other various
embodiments of and modifications to the present disclosure, in
addition to those described herein, will be apparent to those of
ordinary skill in the art from the foregoing description and
accompanying drawings. Thus, such other embodiments and
modifications are intended to fall within the scope of the present
disclosure. Furthermore, although the present disclosure has been
described herein in the context of a particular implementation in a
particular environment for a particular purpose, those of ordinary
skill in the art will recognize that its usefulness is not limited
thereto and that the present disclosure may be beneficially
implemented in any number of environments for any number of
purposes. Accordingly, the claims set forth below should be
construed in view of the full breadth and spirit of the present
disclosure as described herein.
* * * * *