CA1296113C - Sleeper sofa mattress - Google Patents
Sleeper sofa mattressInfo
- Publication number
- CA1296113C CA1296113C CA000541486A CA541486A CA1296113C CA 1296113 C CA1296113 C CA 1296113C CA 000541486 A CA000541486 A CA 000541486A CA 541486 A CA541486 A CA 541486A CA 1296113 C CA1296113 C CA 1296113C
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- mattress
- transverse
- lines
- top cushion
- flexure
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Abstract
SLEEPER SOFA MATTRESS
Abstract of the Invention A sofa bed mattress is disclosed. The mattress may be extended to provide a sleeping surface, and may be folded about transverse flexure lines for storage within a sofa or other configuration. The sofa bed mattress includes an inner spring unit and an overlying top cushion. The top cushion is secured to the inner spring unit substantially along the transverse flexure lines so that the position of the top cushion relative to the inner spring unit is substantially maintained when the mattress is folded.
Abstract of the Invention A sofa bed mattress is disclosed. The mattress may be extended to provide a sleeping surface, and may be folded about transverse flexure lines for storage within a sofa or other configuration. The sofa bed mattress includes an inner spring unit and an overlying top cushion. The top cushion is secured to the inner spring unit substantially along the transverse flexure lines so that the position of the top cushion relative to the inner spring unit is substantially maintained when the mattress is folded.
Description
129~
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Case No. 065-1058-00 SLEEPER SOFA MATTRESS
1 Backqround of the Invention This invention relates to mattresses, and more particularly to sleeper sofa mattre6ses of the type having an inner spring unit and an overlying top cushion. In conventional mattresses having inner spring units and top cushions, it has been known to secure the top cushion to the underlying inner ~pring through lin6s of trPnsverse titching. ~uch con~ructlon~ are lllustrated ln Unlted States Patents Numbers 3,110,043 and 2,168,037. As illustrated in these patents, h narrow strip or flange may be 6ecured to the inner face of the top cushlon at the lines of transverse stltching and secured to the spring construction by suitable means, such as hog rings. As illustrated in these patents, two lines of transverse stitching typically divide the mattress into three sections providing extra support i the center one-third of the mattress where body weight is concentrated.
In contrast to conventional mattresses, sleeper sofa mattresses are designed to be foldable and extendable.
Such mattresses may be extended to provide a flat sleeping surface and may be folded along transverse flexures for storage within the sofa. When folded, a part of the mattress may be doubled over, providing a flat surface for the 1296~i3 1 placement of sofa 6eat cushions, and part of the mattress any abe angled upwardly to fit within the back of the sofa. In many sleeper sofas, the head of the mattress and support frame are designed to be angled upwardly to provide a raised headrest for reading or television viewing. However, when the sleeper sofa mattress is of the type having an inner spring unit and an overlying top cushion, folding the mattress and raising the headrest may cause the top cushion to bunch and 6hift position. Thi~ bunching and shifting may make it more difficult to fold the mattress. When the mattress is folded with the sofa, the bunching and shifting may reduce the sofa's ~eating comfort. And, over time, the bunching and shifting may shorten the useful life of the ~attr~
Summary of the Invention The device of the present invention provides a sleeper sofa mattresæ that can be easily folded for storage without bunchiny or shifting of the top cushion. Bunching and shifting are also eliminated when the mattress's head re8t i8 rai8ed. To eliminate bunching and shifting, the mattresses top cushion is secured to the underlying inner spring unit along a plurality of transverse lines, spaced at predetermined intervals. This construction allows only limited movement of the top cushion with respect t~ the inner spring unit. This construction provides increased support at 1;~9~1i3 . . ~
1 the mattress's center section for sleep$ng comfort, and also enhances seating comfort when the mattress is folded into the sofa. Thus, the present invention provides a sleeper sofa mattress that i6 comfortable, durable, and easily folded.
Accordingly, the present invention provides a sleeper sofa mattress that i6 adapted to be extended flat to provide a sleeping surface, and to be folded about transverse flexure lines for storage within a sofa configuration. The sleeper sofa mattress includes an inner spring unit and an overlying top cushion. The mattress also includes means for securing the top cushion to the inner spring unit so that the position of the to cushion relative to the inner spring unit i8 substantially maintained when the mattress is folded. The ~ecuring means are disposed ~ubstantially along the transverse flexure lines so as to provide positive folding of the top cushion along with the spring at the appropriate location.
Brief Description of the Drawings FIGURE 1 is a top view of a sleeper sofa mattress embodying the principles of the present invention, with a portion of the top cushion removed.
FIGURE 2 is an enlarged cross-section of the mattress, taken along line 2-2 of FIGURE ~.
FIGURE 3 is an enlarged partial cross-section of another embodiment of the mattress.
129~113 1 FIGURE 4 is a 6ide view of the mattress of FIGURE
1, folded for ~torage within a 60fa.
FIGURE 5 is a side view of the mattress of FIGURE
1, extended for use and with it6 head rest raised.
Detailed Description of the Illustrated Embodiment In the accompanying drawings, there is illustrated a sleeper sofa mattress embodying the principles of the present invention. The illustrated sleeper sofa mattress is designed to be extended to provide a sleeping ~urface, and to be folded about transverse flexure lines or positions for storage within a sofa configuration. When extended, the mattress also provides a headrest which may be raised for comfort in reading or television viewing. When folded within the sofa, a part of the mattress angles upwardly into the back of the sofa, and the remainder of Ihe mattress is doubled over, to provide a surface for the placement of the ~of~ ~eat cuehions. In both folding the mattress and in raising the headrest, the mattre6s's top cushion i6 arranqed 80 that it will not bunch or shift position because the top cushion is secured to the underlying inner spring unit along the line6 of fold. This construction facilitates folding the mattress, enhances the sofa's seating comfort because of the absence of bunched cushion material underlying the seat cushion, and enhances the mattress's support of the sleeper's lumbar region.
` ` 1~961:13 1 Referring to FIGURE 1, the illustrated sleeper sofa mattress, generally designated 10, is shown fully extended.
The mattress 10 has a top cushion 12 overlying an inner spring unit 14. The ~op cushion is a part of the overall cover 15 in which the spring is encased. The inner spring unit 14 extends between the mattress's longitudinal sides 16 and its head 18 and foot 20 ends.
To provide a head rest for reading or television viewing, the head end 18 of the mattress 10 may be raised to 1o provide a headrest, as shown in FIGURE 5~ Typically, the mattress 10 would be supported on a foldable frame (not shown) which can be locked into the head rsst position shown.
Suitable support frames and sofa constructions are known in the art and may be used with the mattress of the present invention. To raise the mattress's headrest, the head end 18 of the illustrated mattress must be angled upwardly about a transverse head rest flexure line 22.
To fold the mattress 10 for storage within the eofa, the lllu~trated mattres~ must be ~olded about a plurality of transverse storage flexure lines 24, 26, 28, as shown in FIGURE 4. As shown, the foot end 20 of the mattress is doubled over the center of the mattress about two flexure lines 26, 28 with the foot end overlying flexure line 22.
The head end 18 of the mattress i6 angled upwardly about flexure line 24. When the mattress is folded as shown in `` ` 1296113 FIGURE 4, the upwardly-angled head end 18 fits within the back of the sofa, and the sofa seat cushions are set upon the flat underside 30 of the foot end 20 of the mattress.
To prevent bunching or shifting of the top cushion 5 12 of the Dlattress 10 when the mattress is folded, as shown in FIGURE 4, or when the head rest i8 raised! as ~hown in FIGURE 5, the present invention provides means for securing the top cushion to the inner æpring unit. The securing means are disposed substantially along the transverse flexures 22, 24, 26, 28. The securing means provide positive fold hinges for folding and angling the mattress, and serve to substantially maintain the position of the top cushion 12 relative to the innar spring unit 14.
Suitable securing means for the top cushion 12 are illustrated in FIGURE 2. In the illustrated embodiment, the top cushion is layered. It has a top layer of ticking 32 o~erlying a layer of polyurethane foam 34, which overlies a quilt backin~ layer 36, these top three layers are ~uilted together, as indicated at 38. Under these top three layers 32, 34, 36, the top cushion 12 has another layer of polyurethane foan~ 40 and a polyester fiber pad 42. To secure the layered top cushion 12 to the inner spring unit 14, transverse flanges 44 are ~ecured to the top cushion 12 substantially at each flexure line 22, 24, 26, 28.
In the illustrated embodiment, each flange 44 comprises an elongated narrow sheet of material, such as 12~ 3 1 cloth, or non-woven flexible material secured to the top cushion 12 by transveræe lines of stitching 46, 48, 50, 52 which extend through all of the layers of the top cu6hion 12, as shown in FIGURE 2. As ~hown in FIGURE 1, each transverse line of stitching 46, 48, 50, 52 and each attached flange 44, extends 6ubstantially between the longitudinal sides 16 of the mattress 10, along the mattress's flexures 22, 24, 26, 28.
As shown in FIGURE 2, each flange 44 has a downwardly-extending portion 54, through which each flange is secured to the underlying innerspring unit 14. As shown in FIGURE 2, the downwardly-extending portion 54 of each flange 44 is 6ecured to the inner spring unit 14 by a plurality of clips 56, or hog rings. In the illustrated embodiment, the downwardly-extending portion 54 of each flange 44 i5 doubled over during manufacture, so that the flange is pierced twice by each hog ring 56. As shown, the connections between the hog rings 56 and the flanges 44 may be spaced below the stitching of the flange to the top cushion, to allow limited movement of the top cushion with respect to the inner spring unit.
As shown in FIGURE 2, each hog ring 56 is also secured to the inner spring unit 14. In the illustrated embodiment, the inner 6pring unit 14 comprises a plurality of transverse adjacent row 58 of spaced individual springs 60.
Each individual spring 60 is helical, and has an hourglass . `` ~2~13 1 6hape. The springs 60 in each row 58, and ad~acent rows of springs are connected by transver6ely-extending helical wires 62. The $nner spring unit 14 overlies a polyester fiber pad 64 and a bottom layer of ticking 66 which are part of the cover 15. Since the mattress must fold, the spring unit does not include a peripheral stiffener rod as would be found in a conventional non-folding mattre6s.
As shown in FIGURE 2, each hog ring 56 secures the flange 44 to two springs 60 on adjacent rows 58 of springs by encircling the tops of the two springs. As shown in FIGURE
1, the hog rings 56 are disposed at intervals across the mattress; in the illustrated embodiment, the hog rings are connected to alternate springs in each row. ~ach transverse line of stitching 46, 48, 50, 52 overlies the ~unction of two adjacent rows 58 of springs, along the mattress'6 flexure lines or positions. Thus, the top cushion 12 is secured to the inner spring unit 14 along the lines about which the mattress folds or angles. In effect, this construction provides positive hinges about which the mattress may fold or bend, without bunching or ~hifting of the top cushion, enhancing the 6eating comfort of the sofa as well as the appearance ~nd durablllty of the mattress. This construction also enhances the mattress's support of the sleeper, providing firmer support for the sleeper's lumbar region, where body weight is concentrated.
` ` 12~6113 1 The positions of the securing means in the present invention depend upon mattre6s thickness and the folding mechanism geometry. In the illustrated embodiment, with the folding and head rest po~ltions ~hown in ~IGURES 4 and 5, the mattre6s is about 5-1~4 inches thick, 59-1~2 inches wide, and 71 inches long. The distance from the head end 18 of the mattre6s to the first line of stitching 46 at storage line 24 iB about 13-1/2 inche~; from the first line 46 to the second line of stitching 48 at the head reRt flexure line 22 is about 6-1/4 inches; from the second line 48 to the third line of stitching 50 at storage flexure line 26 is about 17-1/2 inches: and from the third line 50 to the fourth line of 6titching 52 at storage flexure line 28, about 6-1/4 inches.
The illustrated inner spring unit 14 has 23 rows of springs, each row having 13 springs, each spring having a 3 inch diameter. The juncture of the fourth and fifth rows of springs, from the head end, underlies the first line of stitching 46; the juncture of the sixth and seventh rows of springs underlie~ the second line of stitching 48; the juncture of the eleventh and twelfth rows of springs underlies the third line of stitching 50; and the juncture of the thirteenth and fourteenth rows of springs underlies the fourth line of ~titching 52. Each line of stitching 46, 48, 50, 52 corresponds to a transverse flexure lines 22, 24, 26, 28 of the mattress, such that the top cushion 12 is secured to the inner spring unit 1~ along transverse lines at the 1 mattress 1 6 flexures. The top cushion 10 iB secured to the spring 12 by the hog rings 56 in portions 54 of flanges 44.
The transver6e flexure lines and hence the stitch lines 46, 48, 50, 52 are located at predetermined positions where the mattress i8 to fold for either raised head rest or storage positioning. The connection of the top cushion to the mattress at these positions necessarily requires the top cushion to fold at the juncture where the spring folds and provides positive folding of the top cushion.
In making the illustrated mattress 10, the top three layer6 32, 34, 36 may be quilted together using a multi-needle quilt machine. The flanges 44 may be secured to the top cushion 12 by 6titching the top cushion and the flanges together with the panel quilt machine. The top cushion 12, with the attached flanges 44, and the hog rings 56 successively attached to the springs 60 and the flanges 44. The remaining steps of manufacture may be accomplished by processes known in the art.
As an alternative to using one flange 44 at every flexure 22, 24, 26, 28 of the mattress, two wider flanges 44 may be used, as shown in FIGURE 3. As illustrated, one wide flange 44~may be 6ecured to the top cushion with tWQ lines of stitching 46, 48, corresponding to two flexures 22, 24. The flange 44~has two downwardly-extending portions 54, which may be secured to the inner 6pring unit as described above.
~296~i3 1 Although the invention has been described with respect to the illustrated embodiments it should be understood that the invention i6 not limited to those embodiments. Additional modifications and/or additions may be included by those skilled in the art without departing from the 8cope of the invention as defined by the claims.
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Case No. 065-1058-00 SLEEPER SOFA MATTRESS
1 Backqround of the Invention This invention relates to mattresses, and more particularly to sleeper sofa mattre6ses of the type having an inner spring unit and an overlying top cushion. In conventional mattresses having inner spring units and top cushions, it has been known to secure the top cushion to the underlying inner ~pring through lin6s of trPnsverse titching. ~uch con~ructlon~ are lllustrated ln Unlted States Patents Numbers 3,110,043 and 2,168,037. As illustrated in these patents, h narrow strip or flange may be 6ecured to the inner face of the top cushlon at the lines of transverse stltching and secured to the spring construction by suitable means, such as hog rings. As illustrated in these patents, two lines of transverse stitching typically divide the mattress into three sections providing extra support i the center one-third of the mattress where body weight is concentrated.
In contrast to conventional mattresses, sleeper sofa mattresses are designed to be foldable and extendable.
Such mattresses may be extended to provide a flat sleeping surface and may be folded along transverse flexures for storage within the sofa. When folded, a part of the mattress may be doubled over, providing a flat surface for the 1296~i3 1 placement of sofa 6eat cushions, and part of the mattress any abe angled upwardly to fit within the back of the sofa. In many sleeper sofas, the head of the mattress and support frame are designed to be angled upwardly to provide a raised headrest for reading or television viewing. However, when the sleeper sofa mattress is of the type having an inner spring unit and an overlying top cushion, folding the mattress and raising the headrest may cause the top cushion to bunch and 6hift position. Thi~ bunching and shifting may make it more difficult to fold the mattress. When the mattress is folded with the sofa, the bunching and shifting may reduce the sofa's ~eating comfort. And, over time, the bunching and shifting may shorten the useful life of the ~attr~
Summary of the Invention The device of the present invention provides a sleeper sofa mattresæ that can be easily folded for storage without bunchiny or shifting of the top cushion. Bunching and shifting are also eliminated when the mattress's head re8t i8 rai8ed. To eliminate bunching and shifting, the mattresses top cushion is secured to the underlying inner spring unit along a plurality of transverse lines, spaced at predetermined intervals. This construction allows only limited movement of the top cushion with respect t~ the inner spring unit. This construction provides increased support at 1;~9~1i3 . . ~
1 the mattress's center section for sleep$ng comfort, and also enhances seating comfort when the mattress is folded into the sofa. Thus, the present invention provides a sleeper sofa mattress that i6 comfortable, durable, and easily folded.
Accordingly, the present invention provides a sleeper sofa mattress that i6 adapted to be extended flat to provide a sleeping surface, and to be folded about transverse flexure lines for storage within a sofa configuration. The sleeper sofa mattress includes an inner spring unit and an overlying top cushion. The mattress also includes means for securing the top cushion to the inner spring unit so that the position of the to cushion relative to the inner spring unit i8 substantially maintained when the mattress is folded. The ~ecuring means are disposed ~ubstantially along the transverse flexure lines so as to provide positive folding of the top cushion along with the spring at the appropriate location.
Brief Description of the Drawings FIGURE 1 is a top view of a sleeper sofa mattress embodying the principles of the present invention, with a portion of the top cushion removed.
FIGURE 2 is an enlarged cross-section of the mattress, taken along line 2-2 of FIGURE ~.
FIGURE 3 is an enlarged partial cross-section of another embodiment of the mattress.
129~113 1 FIGURE 4 is a 6ide view of the mattress of FIGURE
1, folded for ~torage within a 60fa.
FIGURE 5 is a side view of the mattress of FIGURE
1, extended for use and with it6 head rest raised.
Detailed Description of the Illustrated Embodiment In the accompanying drawings, there is illustrated a sleeper sofa mattress embodying the principles of the present invention. The illustrated sleeper sofa mattress is designed to be extended to provide a sleeping ~urface, and to be folded about transverse flexure lines or positions for storage within a sofa configuration. When extended, the mattress also provides a headrest which may be raised for comfort in reading or television viewing. When folded within the sofa, a part of the mattress angles upwardly into the back of the sofa, and the remainder of Ihe mattress is doubled over, to provide a surface for the placement of the ~of~ ~eat cuehions. In both folding the mattress and in raising the headrest, the mattre6s's top cushion i6 arranqed 80 that it will not bunch or shift position because the top cushion is secured to the underlying inner spring unit along the line6 of fold. This construction facilitates folding the mattress, enhances the sofa's seating comfort because of the absence of bunched cushion material underlying the seat cushion, and enhances the mattress's support of the sleeper's lumbar region.
` ` 1~961:13 1 Referring to FIGURE 1, the illustrated sleeper sofa mattress, generally designated 10, is shown fully extended.
The mattress 10 has a top cushion 12 overlying an inner spring unit 14. The ~op cushion is a part of the overall cover 15 in which the spring is encased. The inner spring unit 14 extends between the mattress's longitudinal sides 16 and its head 18 and foot 20 ends.
To provide a head rest for reading or television viewing, the head end 18 of the mattress 10 may be raised to 1o provide a headrest, as shown in FIGURE 5~ Typically, the mattress 10 would be supported on a foldable frame (not shown) which can be locked into the head rsst position shown.
Suitable support frames and sofa constructions are known in the art and may be used with the mattress of the present invention. To raise the mattress's headrest, the head end 18 of the illustrated mattress must be angled upwardly about a transverse head rest flexure line 22.
To fold the mattress 10 for storage within the eofa, the lllu~trated mattres~ must be ~olded about a plurality of transverse storage flexure lines 24, 26, 28, as shown in FIGURE 4. As shown, the foot end 20 of the mattress is doubled over the center of the mattress about two flexure lines 26, 28 with the foot end overlying flexure line 22.
The head end 18 of the mattress i6 angled upwardly about flexure line 24. When the mattress is folded as shown in `` ` 1296113 FIGURE 4, the upwardly-angled head end 18 fits within the back of the sofa, and the sofa seat cushions are set upon the flat underside 30 of the foot end 20 of the mattress.
To prevent bunching or shifting of the top cushion 5 12 of the Dlattress 10 when the mattress is folded, as shown in FIGURE 4, or when the head rest i8 raised! as ~hown in FIGURE 5, the present invention provides means for securing the top cushion to the inner æpring unit. The securing means are disposed substantially along the transverse flexures 22, 24, 26, 28. The securing means provide positive fold hinges for folding and angling the mattress, and serve to substantially maintain the position of the top cushion 12 relative to the innar spring unit 14.
Suitable securing means for the top cushion 12 are illustrated in FIGURE 2. In the illustrated embodiment, the top cushion is layered. It has a top layer of ticking 32 o~erlying a layer of polyurethane foam 34, which overlies a quilt backin~ layer 36, these top three layers are ~uilted together, as indicated at 38. Under these top three layers 32, 34, 36, the top cushion 12 has another layer of polyurethane foan~ 40 and a polyester fiber pad 42. To secure the layered top cushion 12 to the inner spring unit 14, transverse flanges 44 are ~ecured to the top cushion 12 substantially at each flexure line 22, 24, 26, 28.
In the illustrated embodiment, each flange 44 comprises an elongated narrow sheet of material, such as 12~ 3 1 cloth, or non-woven flexible material secured to the top cushion 12 by transveræe lines of stitching 46, 48, 50, 52 which extend through all of the layers of the top cu6hion 12, as shown in FIGURE 2. As ~hown in FIGURE 1, each transverse line of stitching 46, 48, 50, 52 and each attached flange 44, extends 6ubstantially between the longitudinal sides 16 of the mattress 10, along the mattress's flexures 22, 24, 26, 28.
As shown in FIGURE 2, each flange 44 has a downwardly-extending portion 54, through which each flange is secured to the underlying innerspring unit 14. As shown in FIGURE 2, the downwardly-extending portion 54 of each flange 44 is 6ecured to the inner spring unit 14 by a plurality of clips 56, or hog rings. In the illustrated embodiment, the downwardly-extending portion 54 of each flange 44 i5 doubled over during manufacture, so that the flange is pierced twice by each hog ring 56. As shown, the connections between the hog rings 56 and the flanges 44 may be spaced below the stitching of the flange to the top cushion, to allow limited movement of the top cushion with respect to the inner spring unit.
As shown in FIGURE 2, each hog ring 56 is also secured to the inner spring unit 14. In the illustrated embodiment, the inner 6pring unit 14 comprises a plurality of transverse adjacent row 58 of spaced individual springs 60.
Each individual spring 60 is helical, and has an hourglass . `` ~2~13 1 6hape. The springs 60 in each row 58, and ad~acent rows of springs are connected by transver6ely-extending helical wires 62. The $nner spring unit 14 overlies a polyester fiber pad 64 and a bottom layer of ticking 66 which are part of the cover 15. Since the mattress must fold, the spring unit does not include a peripheral stiffener rod as would be found in a conventional non-folding mattre6s.
As shown in FIGURE 2, each hog ring 56 secures the flange 44 to two springs 60 on adjacent rows 58 of springs by encircling the tops of the two springs. As shown in FIGURE
1, the hog rings 56 are disposed at intervals across the mattress; in the illustrated embodiment, the hog rings are connected to alternate springs in each row. ~ach transverse line of stitching 46, 48, 50, 52 overlies the ~unction of two adjacent rows 58 of springs, along the mattress'6 flexure lines or positions. Thus, the top cushion 12 is secured to the inner spring unit 14 along the lines about which the mattress folds or angles. In effect, this construction provides positive hinges about which the mattress may fold or bend, without bunching or ~hifting of the top cushion, enhancing the 6eating comfort of the sofa as well as the appearance ~nd durablllty of the mattress. This construction also enhances the mattress's support of the sleeper, providing firmer support for the sleeper's lumbar region, where body weight is concentrated.
` ` 12~6113 1 The positions of the securing means in the present invention depend upon mattre6s thickness and the folding mechanism geometry. In the illustrated embodiment, with the folding and head rest po~ltions ~hown in ~IGURES 4 and 5, the mattre6s is about 5-1~4 inches thick, 59-1~2 inches wide, and 71 inches long. The distance from the head end 18 of the mattre6s to the first line of stitching 46 at storage line 24 iB about 13-1/2 inche~; from the first line 46 to the second line of stitching 48 at the head reRt flexure line 22 is about 6-1/4 inches; from the second line 48 to the third line of stitching 50 at storage flexure line 26 is about 17-1/2 inches: and from the third line 50 to the fourth line of 6titching 52 at storage flexure line 28, about 6-1/4 inches.
The illustrated inner spring unit 14 has 23 rows of springs, each row having 13 springs, each spring having a 3 inch diameter. The juncture of the fourth and fifth rows of springs, from the head end, underlies the first line of stitching 46; the juncture of the sixth and seventh rows of springs underlie~ the second line of stitching 48; the juncture of the eleventh and twelfth rows of springs underlies the third line of stitching 50; and the juncture of the thirteenth and fourteenth rows of springs underlies the fourth line of ~titching 52. Each line of stitching 46, 48, 50, 52 corresponds to a transverse flexure lines 22, 24, 26, 28 of the mattress, such that the top cushion 12 is secured to the inner spring unit 1~ along transverse lines at the 1 mattress 1 6 flexures. The top cushion 10 iB secured to the spring 12 by the hog rings 56 in portions 54 of flanges 44.
The transver6e flexure lines and hence the stitch lines 46, 48, 50, 52 are located at predetermined positions where the mattress i8 to fold for either raised head rest or storage positioning. The connection of the top cushion to the mattress at these positions necessarily requires the top cushion to fold at the juncture where the spring folds and provides positive folding of the top cushion.
In making the illustrated mattress 10, the top three layer6 32, 34, 36 may be quilted together using a multi-needle quilt machine. The flanges 44 may be secured to the top cushion 12 by 6titching the top cushion and the flanges together with the panel quilt machine. The top cushion 12, with the attached flanges 44, and the hog rings 56 successively attached to the springs 60 and the flanges 44. The remaining steps of manufacture may be accomplished by processes known in the art.
As an alternative to using one flange 44 at every flexure 22, 24, 26, 28 of the mattress, two wider flanges 44 may be used, as shown in FIGURE 3. As illustrated, one wide flange 44~may be 6ecured to the top cushion with tWQ lines of stitching 46, 48, corresponding to two flexures 22, 24. The flange 44~has two downwardly-extending portions 54, which may be secured to the inner 6pring unit as described above.
~296~i3 1 Although the invention has been described with respect to the illustrated embodiments it should be understood that the invention i6 not limited to those embodiments. Additional modifications and/or additions may be included by those skilled in the art without departing from the 8cope of the invention as defined by the claims.
Claims (16)
1. A sofa bed mattress adapted to be extended flat to provide a sleeping surface and to be folded about transverse flexure lines for storage within a sofa, the sofa bed mattress comprising:
a foldable inner spring unit including a plurality of uniformly-spaced rows of coil springs extending transversely across said mattress with adjacent rows of springs being connected by transversely-extending wires such that the flexure lines may be defined between any two rows of springs;
a cover encasing the spring unit and including a continuous top cushion overlying the inner spring unit to provide a sleeping surface;
each of said inner spring and said top cushion being of substantially uniform thickness;
means for securing the top cushion to the inner spring unit along at least one line extending transversely of said mattress such that the position of the top cushion relative to the inner spring unit is substantially maintained when the mattress is folded, said connection of said top cushion to said inner spring unit overlying the junction of two adjacent rows of springs to define one of said transverse flexure lines.
a foldable inner spring unit including a plurality of uniformly-spaced rows of coil springs extending transversely across said mattress with adjacent rows of springs being connected by transversely-extending wires such that the flexure lines may be defined between any two rows of springs;
a cover encasing the spring unit and including a continuous top cushion overlying the inner spring unit to provide a sleeping surface;
each of said inner spring and said top cushion being of substantially uniform thickness;
means for securing the top cushion to the inner spring unit along at least one line extending transversely of said mattress such that the position of the top cushion relative to the inner spring unit is substantially maintained when the mattress is folded, said connection of said top cushion to said inner spring unit overlying the junction of two adjacent rows of springs to define one of said transverse flexure lines.
2. A sofa bed mattress as claimed in claim 1 wherein the extended sofa bed mattress is adapted to provide a head rest by angling a portion of the mattress upwardly about a transverse head rest flexure line, the sofa bed mattress further comprising means for securing the top cushion to the inner spring unit so that the position of the top cushion relative to the inner spring unit is substan-tially maintained when the head rest portion of the mattress is angled upwardly, said securing means being disposed substantially along the transverse head rest flexure line.
3. A sofa bed mattress as claimed in claim 1 wherein each securing means comprises:
an elongated flange under the top cushion;
a transverse line of stitching extending through the top cushion and the flange to secure the flange to the top cushion while leaving a portion of the flange extending downwardly; and a plurality of clips securing the downwardly-extending portion of the flange to the inner spring unit.
an elongated flange under the top cushion;
a transverse line of stitching extending through the top cushion and the flange to secure the flange to the top cushion while leaving a portion of the flange extending downwardly; and a plurality of clips securing the downwardly-extending portion of the flange to the inner spring unit.
4. A sofa bed mattress as claimed in claim 3 wherein the top cushion is secured to the inner spring unit along at least three spaced transverse flexure lines disposed substantially along the mattress, said flexure lines disposed so that the mattress can be folded for storage within a sofa configuration.
5. A sofa bed mattress as claimed in claim 3 wherein each flange and each transverse line of stitching extends substantially across the width of the mattress, and wherein the clips are disposed at intervals substantially across the width of the mattress.
6. A sofa bed mattress as claimed in claim 1 wherein the securing means comprises:
an elongated flange disposed under the top cushion and associated with two transverse flexure lines;
a pair of transverse lines of stitching extending through the top cushion and through the flange to secure the flange to the top cushion, at each line of stitching while leaving a portion of the flange extending downwardly at each line of stitching, the pair of transverse lines of stitching being disposed substantially along the two associated flexure lines; and a plurality of clips securing the downwardly extending portions of the flange to the inner spring unit.
an elongated flange disposed under the top cushion and associated with two transverse flexure lines;
a pair of transverse lines of stitching extending through the top cushion and through the flange to secure the flange to the top cushion, at each line of stitching while leaving a portion of the flange extending downwardly at each line of stitching, the pair of transverse lines of stitching being disposed substantially along the two associated flexure lines; and a plurality of clips securing the downwardly extending portions of the flange to the inner spring unit.
7. A sofa bed mattress as claimed in claim 6 wherein the top cushion is secured to the inner spring unit along four spaced lines through two flanges, the four spaced lines being disposed substantially along the flexure lines of the mattress, one of the flexure lines being a head rest flexure line so that a portion of the mattress can be angled upwardly about the head rest flexure to provide a head rest when the mattress is extended; the remaining flexure lines being storage flexure lines for folding the mattress into a sofa configuration.
8. A sofa bed mattress having a head end and being foldable for storage within a sofa, the sofa bed mattress comprising:
a foldable inner spring unit including a plurality of uniformly-spaced rows of coil springs extending transversely across said mattress with adjacent rows of springs being connected by transversely-extending wires such that flexure lines may be defined between any two rows of springs;
a cover including a top cushion overlying the inner spring unit;
elongated flanges disposed transversely to the top cushion and secured to the top cushion at transverse lines of stitching, each line of stitching extending through the top cushion, said flanges having downwardly-extending portions; and a plurality of clips securing the downwardly-extending portions of the flanges to the inner spring unit along transverse lines so that the position of the top cushion relative to the inner spring unit is substantially maintained when the mattress is folded, the connection of said downwardly-extending portions of the flanges to said inner spring unit overlying the junction of two adjacent rows of springs to define a trans-verse flexure line.
a foldable inner spring unit including a plurality of uniformly-spaced rows of coil springs extending transversely across said mattress with adjacent rows of springs being connected by transversely-extending wires such that flexure lines may be defined between any two rows of springs;
a cover including a top cushion overlying the inner spring unit;
elongated flanges disposed transversely to the top cushion and secured to the top cushion at transverse lines of stitching, each line of stitching extending through the top cushion, said flanges having downwardly-extending portions; and a plurality of clips securing the downwardly-extending portions of the flanges to the inner spring unit along transverse lines so that the position of the top cushion relative to the inner spring unit is substantially maintained when the mattress is folded, the connection of said downwardly-extending portions of the flanges to said inner spring unit overlying the junction of two adjacent rows of springs to define a trans-verse flexure line.
9. A sofa bed mattress as claimed in claim 8 having three transverse lines of stitching, and a downward portion of a flange extending from each such line, each such flange being secured to said spring along a line transverse of the mattress to provide a transverse fold line to allow said spring and said top cushion to fold therealong upon folding said mattress to said storage configuration.
10. A sofa bed mattress as claimed in claim 9 having four transverse lines of stitching and a downward portion of a flange extending therefrom each said flange having secured to said spring along a line transverse of the mattress to provide a transverse fold line to allow said spring and said top cushion to fold therealong when said mattress is urged to fold along one of said transverse lines.
11. A sofa bed mattress as claimed in claim 1 wherein said inner spring unit includes a plurality of rows of coil springs extending transversely across said mattress, said mattress including two transverse flexure lines spaced apart a distance equal to at least two adjacent transverse rows of coil springs providing a positive hinge about which a portion of said mattress may be folded upon the remainder thereof.
12. A sofa bed mattress as claimed in claim 11 wherein said transverse flexure lines forming said hinge are spaced apart a distance equal to two adjacent transverse rows of said coil springs.
13.. A sofa bed as claimed in claim 11 wherein said transverse flexure lines are positioned between adjacent rows of said coil springs.
14. A sofa bed mattress as claimed in claim 12 wherein said transverse flexure lines are positioned between adjacent rows of said coil springs.
15. A sofa bed mattress as claimed in claim 11 wherein said mattress includes two additional transverse flexure lines spaced apart a distance equal to a least two adjacent rows of said coil springs, said additional transverse flexure lines being spaced from said other transverse flexure lines a distance greater than two adjacent rows of said coil springs.
16. A sofa bed mattress as claimed in claim 15 wherein all said transverse flexure lines are positioned between adjacent rows of said coil springs.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US91772886A | 1986-10-10 | 1986-10-10 | |
| US917,728 | 1986-10-10 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1296113C true CA1296113C (en) | 1992-02-18 |
Family
ID=25439240
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000541486A Expired - Lifetime CA1296113C (en) | 1986-10-10 | 1987-07-07 | Sleeper sofa mattress |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1296113C (en) |
-
1987
- 1987-07-07 CA CA000541486A patent/CA1296113C/en not_active Expired - Lifetime
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKLA | Lapsed | ||
| MKEC | Expiry (correction) |
Effective date: 20121205 |