U.S. patent number 3,732,586 [Application Number 05/169,652] was granted by the patent office on 1973-05-15 for mattress construction.
Invention is credited to Louis Elliott Frey.
United States Patent |
3,732,586 |
Frey |
May 15, 1973 |
MATTRESS CONSTRUCTION
Abstract
A mattress formed of soft, low density resilient foam material
which conforms to the body weight and contour. The upper portion of
the mattress is divided into a plurality of separate portions which
are individually compressible in respect to body weight. A
plurality of partially compressed coil springs are mounted within
cylindrical slits formed in the lower part of the mattress beneath
each separate portion. The springs provide added strength for body
support and assure prompt return of the upper part of the resilient
material to its normal shape when weight is removed from it.
Inventors: |
Frey; Louis Elliott (Los
Angeles, CA) |
Family
ID: |
22616595 |
Appl.
No.: |
05/169,652 |
Filed: |
August 6, 1971 |
Current U.S.
Class: |
5/718; 5/727;
5/35 |
Current CPC
Class: |
A47C
27/20 (20130101) |
Current International
Class: |
A47C
27/14 (20060101); A47C 27/20 (20060101); A47c
023/00 () |
Field of
Search: |
;5/246,248,256,345,351,353,91,357 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: McCall; James T.
Assistant Examiner: Calvert; Andrew M.
Claims
I claim:
1. A mattress comprising a resilient member constructed of
substantially soft, low density foam material, the upper part of
said mattress being divided into a plurality of relatively thick
separate portions which are individually compressible in respect to
the weight placed thereon in use, the lower part of each of said
mattress portions having at least one vertically directed
cylindrical slit, and a plurality of coil springs mounted within
said slits, said coil springs being held within said mattress in
partially compressed condition.
2. The structure described in claim 1, said coil springs being
frusto-conical, with their larger ends disposed at the upper ends
of said slits.
3. The structure described in claim 2, said mattress having a
plurality of block-like portions of substantially square shape, one
of said coil springs being mounted beneath the center of each of
said portions.
4. The structure described in claim 2, said mattress having a
plurality of longitudinally extending elongated portions, and a
plurality of spaced coil springs mounted beneath each of said
elongated portions.
5. The structure described in claim 2, each of said coil springs
being completely surrounded by a substantial thickness of foam
material.
6. The structure described in claim 3, each of said coil springs
being completely surrounded by a substantial thickness of foam
material.
7. The structure described in claim 1, the area within each of said
slits comprising a cylindrical resilient core, the coils of said
springs engaging said cores to hold said springs in partially
compressed condition.
8. The structure described in claim 2, the area within each of said
slits comprising a cylindrical resilient core, the coils of said
springs engaging said cores to hold said springs in partially
compressed condition.
9. The structure described in claim 8, and a layer of backing
material extending across the bottom of said mattress to hold said
springs within said slits.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a new and improved construction for
mattresses.
2. Description of the Prior Art
The present invention relates to an improvement over the mattress
construction shown and described in my prior U.S. Pat. No.
3,191,197. The mattress shown in that patent was divided into a
plurality of separate block-like sections, each of which was
capable of limited independent vertical movement.
The most feasible material for use in constructing such a mattress
is resilient foam. It has been found, however, that resilient foam
which has sufficient density to support the weight of a person is
hard to the touch and does not provide the type and degree of
softness which is desirable for a mattress. Such material also has
a slow recovery due to its heavy density and it accordingly tends
to take and hold a set. This is an undesirable and unsatisfactory
characteristic in a mattress.
SUMMARY OF THE INVENTION
The invention comprises a mattress which is formed of relatively
low density resilient foam material which will substantially
conform to the contour of every part of the body and which provides
the degree of softness which is desirable in a mattress. The upper
portion of the mattress is divided into a plurality of separate
block-like sections of the type shown in my prior U.S. Pat. No.
3,191,197. Mounted beneath each of these block-like sections is a
compressed spring which provides the strength necessary to support
the body and which acts to prevent the foam material from taking a
set, as it is inherently inclined to do.
The spring is inserted and held in a compressed condition within
the lower portion of the mattress beneath each block, to provide
the necessary body support and strength when the upper portion of
the block is depressed by the weight of a portion of the body. This
construction provides the body-responding comfort of a soft light
form with strength and support equal to that of more dense and
rigid foam material.
The spring preferably comprises a substantially frusto-conical coil
spring which is mounted in a cylindrical slit cut or otherwise
formed beneath the center of each block-like section of the
mattress. A frusto-conical spring provides the desired amount of
progressively increased support as it is depressed in use.
It is accordingly among the objects of my invention to provide a
mattress construction having all of the advantages and benefits of
the structure set forth above and described in detail hereinafter
in this specification.
Another object of the invention is to provide a mattress having a
plurality of block-like sections which are capable of independent
vertical movement and which also have the desired softness and
comfort combined with the strength for proper body support.
A further object of the invention is to provide a mattress of the
type described which will not take a set and in which the upper
surface will return to a flat horizontal position as soon as the
weight of the body is removed from it.
Still another object of the invention is to provide such a mattress
which is simple and economical to manufacture, so that it can be
manufactured and sold at a reasonable price. My invention also
comprises such other objects, advantages and capabilities as will
later more fully appear and which are inherently possessed by my
invention.
While I have shown in the accompanying drawings preferred
embodiments of my invention, it should be understood that the same
are susceptible of modification and change without departing from
the spirit of my invention.
DESCRIPTION OF THE DRAWINGS
FIG, 1 is an isometric view of a mattress constructed in accordance
with my invention, with the springs shown in phantom lines, the
upper portion of the left hand side of the mattress being divided
into block-like sections and the right hand side being divided into
elongated sections;
FIG. 2 is a partial sectional view of the same taken along line
2--2 of FIG. 1;
FIG. 3 is a bottom plan view of one of the block-like sections
shown on the left hand side of FIG. 1, showing the slit before the
spring is inserted.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment which has been selected to illustrate my
invention comprises a mattress 10, which is preferably formed of
suitable resilient foam material. The mattress 10 includes an
integral border 11, which extends around all four sides of the
mattress and an integral lower portion 12, which extends across the
bottom of the entire area defined by the border 11.
The central upper portion 23 of the mattress which is disposed
above the lower portion 12 is provided as shown on the left side of
FIG. 1 with a plurality of intersecting vertical and horizontal
slits 13, which preferably extend downwardly approximately half the
distance between the top of the mattress and the top of the lower
portion 12. The slits 13 divide the central portion 23 into a
plurality of adjacent block-like sections 14, each of which is
individually compressible in respect to a weight placed thereon in
use.
The block-like sections 14 may extend across the entire area
defined by the border 11. They may also cover only the major
portion of this area, as shown in FIG. 1 of the drawings, with a
pair of larger rectangular blocks 15 being disposed adjacent to the
head and foot of the mattress between the sections 14 and the
border 11.
The exposed surfaces of the mattress may be covered with suitable
cloth, flocking or other suitable covering means as desired.
Various methods of forming and covering such a mattress are shown
and described in my prior U.S. Pat. No. 3,191, 197, the contents of
which are incorporated herein by reference. The present invention
is directed toward the use of a spring member to reinforce the
independently movable block-like sections of a mattress such as
that shown in U.S. Pat. No. 3,191,197.
Beneath the center of each of the sections 14 a circular slit 16 is
provided by cutting, molding or other suitable means. The slit 16
extends inwardly to a point substantially aligned with the lower or
inner ends of the slits 13 which define the sections 14. The area
within each of the slits 16 comprises a cylindrical core 17 of
resilient foam material.
A frusto-conical coil spring 18 is inserted into each of the slits
16 with its larger diameter end disposed toward the inner or upper
end of the slit 16. The length of the slit 16 is preferably
approximately half the normal expanded length of the spring 18. The
spring 18 when it is disposed entirely within the slit 16 is
accordingly compressed to approximately half its normal expanded
length.
The bottom of the slit 16 is preferably covered by backing material
20 such as treated buckram or other suitahle material which is
adhered or otherwise secured to the bottom of the sections 14. The
backing material 20 may comprise a single piece of material which
extends across the bottom of the entire spring area 23.
The backing material 20 acts to prevent the springs 18 from coming
out of the slits 16. The previously mentioned engagement between
the coils of the springs 18 and the cores 17 prevents the springs
18 from exerting undue pressure against the backing material
20.
The same coil spring structure described above may also be used
with a mattress having a plurality of elongated longitudinal
sections 19 instead of block-like sections. Such a structure is
shown in FIG. 1 of the drawings on the right hand side. In such a
structure, a plurality of coil springs 18 are mounted in slits
spaced along the lower portion of each of the longitudinal
sections, with the springs and foam material inter-acting in the
same manner described above.
Coil springs 18 may also be used in part or all of the border 11
and/or the blocks 15.
In use, this structure provides all of the advantages and benefits
contemplated by my prior U.S. Pat. No. 3,191,197 with regard to the
independent movement of the mattress sections and their individual
response to body weight and movement. It also provides a definite
improvement in that a relatively soft foam material may be used to
provide the desired body comfort and easy resilient response while
the coil springs disposed within the mattress sections provide the
necessary support and return the foam material to its uncompressed
state.
It will be noted that the mattress has a relatively thick upper
portion which is formed entirely of substantially low density
resilient foam material which is divided into separate sections and
which is capable of adjusting to the natural contours of the body.
Beneath this relatively thick upper portion is a lower portion in
which the foam material is reinforced by a compressed coil spring
which serves the dual purpose of providing added strength to
support the body without requiring the use of undesirable and
unsatisfactory high density foam and of urging the upper portion of
the mattress back to its normal condition after the weight of the
body has been removed from it.
It will also be noted that the upper ends of the springs are
disposed so deeply within the foam material that they do not cause
discomfort to the mattress user, nor do they disturb the smooth
upper surface of the mattress.
The coil springs are preferably completely enclosed within the foam
material, so that they are securely held in place and the mattress
user is unaware of their existence or action.
* * * * *