U.S. patent number 3,604,025 [Application Number 04/817,478] was granted by the patent office on 1971-09-14 for foam bedding.
This patent grant is currently assigned to Sears, Roebuck and Co.. Invention is credited to Billy P. Mims.
United States Patent |
3,604,025 |
Mims |
September 14, 1971 |
FOAM BEDDING
Abstract
Foam resin bedding for use a box spring and mattress, both
having areas of differential resistance to weight, the middle area
having greater resistance than the end areas. This is accomplished
in the box spring by forming on one side integral tapered
protuberances extending normally from the face thereof, the
protuberances in the midportion being smaller and closer spaced
than those at the ends. In the mattress element the differential
resistance is obtained by varying the size and or number of the
pins extending through the foam body in the mold, as regards the
midportion and end portions of the molded body.
Inventors: |
Mims; Billy P. (Oak Park,
IL) |
Assignee: |
Sears, Roebuck and Co.
(Chicago, IL)
|
Family
ID: |
25223181 |
Appl.
No.: |
04/817,478 |
Filed: |
April 18, 1969 |
Current U.S.
Class: |
5/730 |
Current CPC
Class: |
A47C
27/144 (20130101); A47C 27/148 (20130101); A47C
27/15 (20130101); A47C 23/00 (20130101); A47C
27/146 (20130101) |
Current International
Class: |
A47C
27/14 (20060101); A47C 23/00 (20060101); A47c
023/00 (); A47c 025/00 () |
Field of
Search: |
;5/345X,361X |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
370,544 |
|
Aug 1963 |
|
CH |
|
863,343 |
|
Mar 1961 |
|
GB |
|
1,324,907 |
|
Dec 1963 |
|
FR |
|
978,951 |
|
Jan 1965 |
|
GB |
|
1,440,284 |
|
Apr 1966 |
|
FR |
|
Primary Examiner: Gilliam; Paul R.
Claims
I claim:
1. In combination, a first bedding element and a second bedding
element superposed on said first bedding element, said bedding
elements each comprising a slab of substantial but minor thickness
relative to its length and breadth and formed essentially of a
resin foam, each of said elements having end portions and a middle
portion with said middle portions generally underlying the
midportion of the human body disposed thereon, said first element
having a flat upper planar face and a plurality of generally
conical protuberances projecting in a direction opposite from said
face, the protuberances in the middle portion thereof being smaller
and more closely spaced than the protuberances in the end portions
and thus offering greater resistance to weight disposed thereon
than the protuberances in the end portions, said second element
having upper and lower flat planar faces and having a plurality of
transverse vertical passages extending through its thickness, the
passages being so varied as to size and number in the middle
portion as compared to the end portions as to offer greater
resistance to weight disposed thereon than in said end portions and
a substantially rigid supporting panel underlying said first
bedding element.
Description
My invention relates to bedding, and has to do more particularly
with box springs and mattresses formed of foamed resinous
material.
It has long been customary to provide such items in combination on
a bed, the spring normally being disposed at the bottom and the
mattress on top, the sheets, blankets, coverlets and the like being
"made" or arranged over the mattress.
BACKGROUND AND PRIOR ART
For many years it was customary to provide a box spring containing
a large number of coil springs secured within a fabric casing for
resilient support of the mattress. The latter was usually a solid
pack of hair, cotton-wool or similar material enclosed within a
fabric casing or ticking.
Comparatively recently it has been proposed to employ for bedding a
block of foamed resin, such as natural or artificial rubber,
polyurethane or other synthetic resin. Such material has been found
to have certain desirable qualities such as durability, resistance
to packing and lumping, and the desired resilience.
Also, it has been recognized that the human body, because of its
nonuniform weight distribution, rests more comfortably on a
mattress wherein the resistance to body pressure is differentially
disposed according to the weight variation in different parts of
the body. That is to say, greater resistance is provided in the
midportion of the mattress than in the end portions thereof. An
example of prior art of this character is Robell U.S. Pat. No.
2,504,352 Apr. 18, 1950. Also of interest is Adler U.S. Pat. No.
3,083,380, Apr. 2, 1963; Pollock U.S. Pat. No. 3,210,781, Oct. 12,
1965, and Trogdon et al. U.S. Pat. No. 3,287,748, Nov. 29,
1966.
I am also aware that the prior art has proposed molded resilient
cushions and the like wherein resilience is provided by a plurality
of spaced protuberances projecting normally from one face of the
molded body. Examples of such art are Berman U.S. Pat. No.
2,659,418, Nov. 17, 1953, and Unger U.S. Pat. No. 3,205,515, Sept.
14, 1965.
BRIEF OUTLINE OF THE INVENTION
An object of my invention is to provide new and improved bedding of
resilient resinous foam material which will have a number of
advantages over products of this type heretofore known.
More particularly, one object of my invention is to provide a new
and improved so-called box spring comprising a slab or block of
foamed resinous material having differential areas of resistance,
with greater resistance in its midportion, supporting the heavier
parts of the human body, and less resistance in its end
portions.
Another object is to provide an article of the class described
characterized by a plurality of spaced protuberances on one face
thereof, usually disposed on the bottom of the slab, said
protuberances in the midportion of the slab being of such size and
so spaced, as compared with the protuberances in the end portions
of the slab, as to provide greater resistance, i.e. less
resilience, in the midportion as compared with the end
portions.
Still another object is to provide, in combination with a box
spring of the type described, a mattress also comprising a slab of
foamed resin, said mattress being characterized in that it is less
resilient in the midportion thereof than in the end portions, said
variations in resistance being accomplished by varying the size and
number of voids in the midportion as compared with the end
portions.
Still another object is to provide a combination of box spring and
mattress having the characteristics hereinabove described
Various other objects and advantages will doubtless suggest
themselves to those skilled in the art as the description
proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a combined perspective and longitudinal section showing a
combination of a box spring and mattress embodying my invention,
parts being broken away for added clearness;
FIG. 2 is a fragmentary sectional view on an enlarged scale of the
mattress portion of the combination, said section being taken
through one of the end portions of the article;
FIG. 3 is a view similar to FIG. 2 but taken through the midportion
of the article, and
FIG. 4 is a fragmentary vertical section on an enlarged scale of
the "spring" portion of the combination.
DETAILED DESCRIPTION
Reference character M designates a mattress which comprises a slab
or block of plastic foam, production of which is well known in the
art. It may be molded or otherwise produced, preferably as a single
unit, or in a plurality of sections, as desired. Said mattress will
be covered in the usual way with a fabric ticking T.
Said mattress M comprises a plurality of sections, viz, a
midsection 10, which may be approximately one-third of the mattress
measured length wise. The other two sections, 10 a and 10 b which
may likewise each constitute approximately one-third of the unit,
may be referred to as the end sections or the upper and lower
sections, respectively, again referring to the length of the
mattress.
In order to provide maximum support and resistance where desired,
namely to the heavier midportion of the sleeper's body, midsection
10 will be of maximum density as compared with end sections 10 a
and 10 b. This objective may readily be accomplished by varying the
size and number of the voids 12 a, 12 b formed within the foam.
These vertical passages or voids 12 a, 12 b are formed in the foam
body by pins, usually present in the mold for thermal conduction in
the curing operation, and usually of metal. While such pins have
been so employed for some time, I believe I am the first to suggest
varying the size thereof for the purpose here described.
I have found a density of about 33 pounds p.s.i. RMA (Rubber
Manufacturing Association Test Standards) or a range of about 30 to
36 pounds RMA, to be satisfactory for midsection 10, while a
density of about 28 pounds RMA, or a range between about 26 and 31
pounds, to be satisfactory for end sections 10 a and 10 b.
The slab constituting the mattress M may have a thickness of
approximately 5 1/2 inches, more or less, it being understood that
this dimension is not critical. It will also be understood by those
skilled in the art that such items as a quilted tranquilizer pad,
etc., may be superimposed on the core M and attached thereto as by
stitching; also, that the sides and ends may be finished in the
usual manner, as with strips or slabs of foam material, ticking,
etc.
Underlying the mattress or core M and corresponding to the usual
box spring is a block or slab S, which may also be encased in
fabric ticking. Said slab S will also vary longitudinally thereof
to provide maximum resistance in the midsection 20, which may be
roughly one-third of the length, the end sections 20 a and 20 b,
each also approximately one-third of the length, providing less
resistance than said midsection 20.
I preferably accomplish this differential in resistance by
providing on the lower face of slab S a plurality of spaced
protuberances 25 (FIG. 4). Said protuberances extend generally
normally from the bottom face of slab S and are preferably of
generally conical configuration, the apices of said protuberances
being at the outer free ends thereof. Said protuberances may be
arranged in any convenient or suitable manner, being preferably
produced by suitable mechanical equipment or molds well known in
the art.
In the embodiment shown the protuberances are arranged in staggered
rows, as seen best in FIG. 4, but such arrangement is merely
exemplary and is in no sense critical.
In midsection 20 the protuberances 25 are relatively shorter than
those in end sections 20 a and 20 b, are smaller in cross sectional
area and more numerous than in the end sections, in order that said
protuberances in midsection 20 may provide more resistance to the
greater weight of the body midportions.
While I do not consider the dimension, arrangement or spacing of
the protuberances 25 to be critical, it will be noted from FIG. 1
that in the end sections said protuberances may extend outwardly
for a distance of from one-fifth to one-third of the overall
thickness of the slab (including the protuberances), and are spaced
apart a distance approximately equal to the median diameter of said
protuberances; in midsection 20 said protuberances may extend
outwardly approximately for a distance between one-sixth to
one-eighth of the overall thickness of the slab.
In the case of "spring" S, as in the core M, the physical character
of the foam in the respective mid- and end sections may be
essentially similar to the sections 10, 10 a and 10 b,
respectively.
Spring S may likewise be encased in a fabric casing or ticking and
be underlaid by an insulation board 30 formed of corrugated fiber
board, preferably of about 200 p.s.i. test, under which may be
arranged a hardwood panel 35.
The combination of bedding elements described above has been
thoroughly tested and found to be highly satisfactory from the
standpoint of comfort. The desired maximum firmness is provided
where needed, under the heaviest portions of the sleeper's body.
Furthermore, products embodying my invention may be manufactured
most economically by mass production methods at relatively low
cost. Said products have great durability and may be used over a
long period of time without deterioration. Because of ventilation
means built into the structure, there is little or no tendency for
the absorption of body odor.
Various changes coming within the spirit of my invention may
suggest themselves to those skilled in the art; hence, I do not
wish to be limited to the specific embodiment shown and described
or uses mentioned, but intend the same to be merely exemplary, the
scope of my invention being limited only by the appended
claims.
* * * * *