CA2234839C - Mattress construction - Google Patents
Mattress construction Download PDFInfo
- Publication number
- CA2234839C CA2234839C CA 2234839 CA2234839A CA2234839C CA 2234839 C CA2234839 C CA 2234839C CA 2234839 CA2234839 CA 2234839 CA 2234839 A CA2234839 A CA 2234839A CA 2234839 C CA2234839 C CA 2234839C
- Authority
- CA
- Canada
- Prior art keywords
- springs
- edge region
- support member
- mattress
- border
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 238000010276 construction Methods 0.000 title claims abstract description 19
- 239000007779 soft material Substances 0.000 claims abstract description 4
- 238000007688 edging Methods 0.000 claims description 4
- 230000000284 resting effect Effects 0.000 claims description 3
- 239000000463 material Substances 0.000 claims description 2
- 230000002708 enhancing effect Effects 0.000 claims 1
- 239000002184 metal Substances 0.000 abstract description 11
- 238000000034 method Methods 0.000 description 6
- 230000002787 reinforcement Effects 0.000 description 3
- 230000007704 transition Effects 0.000 description 3
- 230000003247 decreasing effect Effects 0.000 description 1
- 239000006261 foam material Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 230000007958 sleep Effects 0.000 description 1
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/06—Spring inlays
- A47C27/063—Spring inlays wrapped or otherwise protected
- A47C27/064—Pocketed springs
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C23/00—Spring mattresses with rigid frame or forming part of the bedstead, e.g. box springs; Divan bases; Slatted bed bases
- A47C23/04—Spring mattresses with rigid frame or forming part of the bedstead, e.g. box springs; Divan bases; Slatted bed bases using springs in compression, e.g. coiled
- A47C23/043—Spring mattresses with rigid frame or forming part of the bedstead, e.g. box springs; Divan bases; Slatted bed bases using springs in compression, e.g. coiled using wound springs
- A47C23/0433—Spring mattresses with rigid frame or forming part of the bedstead, e.g. box springs; Divan bases; Slatted bed bases using springs in compression, e.g. coiled using wound springs of different resilience
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/06—Spring inlays
- A47C27/066—Edge stiffeners
Landscapes
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
- Springs (AREA)
Abstract
A mattress has a resilient internal construction formed by a border surrounding a larger interior region. The border comprises a plurality of rows of pocketed springs each of which consists of a metal coil contained within a pocket of soft material. In the border coils of adjacent pocketed springs are linked to one another such that each pocketed spring derives strength from an adjacent pocketed spring making the border more rigid than the interior region of the mattress.
Description
TITLE: MATTRESS CONSTRUCTION
FIELD OF THE INVENTION
The present invention relates to a support member such as a mattress or the like formed with a peripheral border of pocketed springs.
BACKGROUND OF THE INVENTION
Dating back to the early 1900's, Marshall Mattress of Toronto Canada developed and patented a pocket spring mattress. The pocketed springs in the mattress, which have become more and more popular since the advent of the Marshall Mattress, are designed to flex individually of one another and as such have extremely appealing flex properties. Accordingly, many companies, in addition to Marshall, make pocket spring mattresses.
The Marshall pocketed springs, which continue to be used in substantially the same form as they were nearly 100 years ago, do not provide a stiffening of the edge of the mattress. However, edge stiffening has become desirable in the mattress industry. To date such edge stiffening is provided with springs other than pocketed springs. These edge stiffening springs unlike pocketed springs, are used at discrete locations around the edge of the mattress and therefore undesirably produce intermittent harder and softer mattress edge regions.
Furthermore, these known stiffening springs do not provide a desired gradual transition to the softer interior region of the mattress, particularly when the interior region is made with pocketed springs.
SUMMARY OF THE INVENTION
The present invention relates to a support member such as a mattress and the like which has a perimeter trim in the form of reinforced pocket spring edge border using the same type of pocketed spring as can be used in the larger interior region of the mattress. More particularly, the border comprises a plurality of rows of pocketed springs each of which consists of a metal coil contained within a pocket of soft material. According to the present invention, the metal coils of adjacent springs in the border are linked to one another such that each spring derives strength from an adjacent spring. Accordingly, the border is more rigid than the internal region of the mattress.
BRIEF DESCRIPTION OF THE DRAWINGS
The above as well as other advantages and features of the present invention will be described in greater detail according to the preferred embodiments of the present invention in which:
Figure 1 is a perspective view of a mattress with the external covering removed to show the internal construction according to a preferred embodiment of the present invention.
Figure 2 is an enlargement of the corner region of the mattress construction of Figure 1.
Figure 3 is a view similar to Figure 2 with the mattress having a slightly different construction according to another preferred embodiment of the present invention.
Figure 4 is a perspective view of a row of pocket coils showing the metal coil spring and soft pocket construction.
Figure 5 is a top view of the border and interior resting region formed with pocketed springs according to the mattress construction of Figure 1.
Figure 6 is a perspective view of a mattress construction according to still a further preferred embodiment of the present invention.
Figure 7 is a perspective view showing a method of assembling a pocketed spring mattress according to still another preferred embodiment of the present invention.
DETAILED DESCRIPTION ACCORDING TO THE PREFERRED
Figure 1 shows a mattress construction generally indicated at 1. This mattress construction is built around a plurality of pocketed springs generally indicated at 7 in Figure 4 of the drawings. Each pocketed spring comprises a metallic coil spring 9 contained within a pocket of soft material. This material is sewn at its opposite ends to trap the metal coil in a somewhat compressed condition within the pocket.
In the embodiment shown, a long line of pockets are sewn side by side with one another and each one loaded with a metal coil. This arrangement makes it very easy to assemble the overall mattress as will be described later in detail with respect to Figure 7 of the drawings.
Returning to Figure 1, mattress 1 is formed with a border region generally indicated at 3 which surrounds a larger interior region generally indicated at 5. Even though each of these regions is made up of the same or at least very similar pocketed springs, the border region is more rigid than the interior region of the mattress. The border region is reinforced to accept, for example, a concentrated load such as the weight of a person sitting on it without excessive collapsing while the larger interior region is specially designed to be softer for comfort conditions as required when a person sleeps on the mattress.
The border region is stiffened by linking the metal coils of adjacent pocketed springs across the border. More particularly, as best seen in Figures 1 and 2 of the drawings side by side pocketed springs in the border 3 are secured by metal staples 13. These staples are punched through the soft pocket to lock onto the metal coil of each pocketed spring. The staples are attached at opposite ends to adjacent springs sufficiently tightly to prevent the staples from releasing from the springs but not so tightly as to prevent some play between adjacent springs, i.e. each staple end is attached in a pivot like manner to its respective metal coil. The staples are a fixed length so that as any one of the springs is compressed so is an adjacent linked spring. However, because of the play allowed between the springs one spring will tend to compress before the next which provides a gradual transition between springs in the border and also between the border and the main sleeping or resting area of the mattress. This play also reduces stress on the staples substantially decreasing the likelihood that they might be damaged under load.
Referring specifically to Figure 2, the border 3 of the mattress is formed by the side edge border 3A and the end edge border 3B. In the embodiment shown, the staples 13 extend across rather than longitudinally of each border edge. However, additional staples could also be provided between side by side coils lengthwise of each border region to further enhance the strength or rigidity of the overall border.
Figure 5 of the drawings shows that the pocketed springs in the border 3 of the mattress are arranged as aligned rows, i.e. side by side pocketed springs are centrally aligned with one another. This is to be contrasted to the interior region in which the pocketed springs are nested in a honeycomb fashion.
The side by side spring configuration in the edge border makes it easy to mate the side edge with the end edge regions of the border because each region terminates with a flat end. In addition, it reduces the overall number of springs required in the border.
According to the specific set up shown in Figure 5, the side edge regions 3A of the mattress border are set up with two side by side linked pocketed springs while the end edge regions of the border 3B are set up with three side by side linked pocketed springs. However the border regions can either have more or fewer side by side springs depending upon the size of the mattress and the amount of reinforcement required.
In the embodiment of Figures 1 and 2, the border is further reinforced by means of metal edge wires 17 at the upper and lower sides of the mattress completely around the border. The outermost pocketed springs are secured by staples 14 to the wire edging 17.
Also provided to the top and bottom side of the mattress are a plurality of straps 15 which are also stapled to the edge wire. The entire internal construction of the mattress is then covered by covering layers 19 and 21 which are stapled at 23 as seen in Figure 2 of the drawings to the edge wire.
Figure 3 shows a slight modification to the mattress in which straps 15 are replaced by a plastic mesh 25 across the complete upper and lower surfaces of the mattress. In all other respects, the mattress shown in Figure 3 is identical to the mattress shown in Figures 1 and 2.
Figure 6 shows a further mattress generally indicated at 31 again employing a linked pocketed spring edge border generally indicated at 33. However, in this embodiment, the interior region generally indicated at 35 is made from a foam material rather than pocketed springs.
This exemplifies the fact that the linked spring edge border can be used around many types of different interior regions.
In addition to the feature of providing a gradual transition from the perimeter trim to the main rest area of the mattress, the use of linked pocketed springs in the border eliminates noticeable intermittent hard and soft areas around the border. Each pocketed spring has a relatively small diameter so that there are no large gaps between reinforcements in the border producing an edge trim which has a very consistent or uniform feeling around the perimeter of the mattress.
Mattress 31 has a further and very unique feature.
More specifically, the edge wire shown in the embodiments of Figures 1, 2 and 3 has been replaced by a flexible and preferably plastic mesh edging 39 to which the coils in the outermost springs in the border are attached. This edging, which may have the same construction as the spring covering mesh used on the upper and lower sides of the mattress, enables the mattress to be flexed to the extent that it can be bent upon itself as is shown at the mattress corner generally indicated at 41. This feature has substantial benefits when attempting to get a relatively large mattress through a small opening. Unlike a conventional mattress which has very limited deflection, mattress 31 can be bent to almost any configuration for clearing through the opening. However the edge border 33 provided by the side by side linked springs still provides more than adequate reinforcement around the mattress.
Figure 7 of the drawings shows a unique method of assembling a pocketed spring mattress. According to this method, the edge border is first established with the end and side regions of the border being secured to one another and then the interior region pocketed springs are fitted within the border. This is achieved by arranging a plurality of rows of pocketed springs in their honeycombed pattern outside of the edge border and then, from one side of the mattress, pushing the arranged rows as a single unit into the edge border. The very nature of the pocketed springs allows them to be compressed to fit in the area defined by the edge border and to then rebound outwardly against the edge border.
The above method is substantially more efficient than attempting to fit the rows of pocketed springs within the border on an individual basis. Further, this method eliminates the difficult procedure of attempting to find sufficient space for the last row or two within the interior region of the mattress.
It is to be noted that, although the description above refers specifically to a mattress, the construction of the present invention is equally applicable to different types of support structures such as sofa cushions and the like.
Although various preferred embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that variations may be made without departing from the spirit of the invention or the scope of the appended claims.
FIELD OF THE INVENTION
The present invention relates to a support member such as a mattress or the like formed with a peripheral border of pocketed springs.
BACKGROUND OF THE INVENTION
Dating back to the early 1900's, Marshall Mattress of Toronto Canada developed and patented a pocket spring mattress. The pocketed springs in the mattress, which have become more and more popular since the advent of the Marshall Mattress, are designed to flex individually of one another and as such have extremely appealing flex properties. Accordingly, many companies, in addition to Marshall, make pocket spring mattresses.
The Marshall pocketed springs, which continue to be used in substantially the same form as they were nearly 100 years ago, do not provide a stiffening of the edge of the mattress. However, edge stiffening has become desirable in the mattress industry. To date such edge stiffening is provided with springs other than pocketed springs. These edge stiffening springs unlike pocketed springs, are used at discrete locations around the edge of the mattress and therefore undesirably produce intermittent harder and softer mattress edge regions.
Furthermore, these known stiffening springs do not provide a desired gradual transition to the softer interior region of the mattress, particularly when the interior region is made with pocketed springs.
SUMMARY OF THE INVENTION
The present invention relates to a support member such as a mattress and the like which has a perimeter trim in the form of reinforced pocket spring edge border using the same type of pocketed spring as can be used in the larger interior region of the mattress. More particularly, the border comprises a plurality of rows of pocketed springs each of which consists of a metal coil contained within a pocket of soft material. According to the present invention, the metal coils of adjacent springs in the border are linked to one another such that each spring derives strength from an adjacent spring. Accordingly, the border is more rigid than the internal region of the mattress.
BRIEF DESCRIPTION OF THE DRAWINGS
The above as well as other advantages and features of the present invention will be described in greater detail according to the preferred embodiments of the present invention in which:
Figure 1 is a perspective view of a mattress with the external covering removed to show the internal construction according to a preferred embodiment of the present invention.
Figure 2 is an enlargement of the corner region of the mattress construction of Figure 1.
Figure 3 is a view similar to Figure 2 with the mattress having a slightly different construction according to another preferred embodiment of the present invention.
Figure 4 is a perspective view of a row of pocket coils showing the metal coil spring and soft pocket construction.
Figure 5 is a top view of the border and interior resting region formed with pocketed springs according to the mattress construction of Figure 1.
Figure 6 is a perspective view of a mattress construction according to still a further preferred embodiment of the present invention.
Figure 7 is a perspective view showing a method of assembling a pocketed spring mattress according to still another preferred embodiment of the present invention.
DETAILED DESCRIPTION ACCORDING TO THE PREFERRED
Figure 1 shows a mattress construction generally indicated at 1. This mattress construction is built around a plurality of pocketed springs generally indicated at 7 in Figure 4 of the drawings. Each pocketed spring comprises a metallic coil spring 9 contained within a pocket of soft material. This material is sewn at its opposite ends to trap the metal coil in a somewhat compressed condition within the pocket.
In the embodiment shown, a long line of pockets are sewn side by side with one another and each one loaded with a metal coil. This arrangement makes it very easy to assemble the overall mattress as will be described later in detail with respect to Figure 7 of the drawings.
Returning to Figure 1, mattress 1 is formed with a border region generally indicated at 3 which surrounds a larger interior region generally indicated at 5. Even though each of these regions is made up of the same or at least very similar pocketed springs, the border region is more rigid than the interior region of the mattress. The border region is reinforced to accept, for example, a concentrated load such as the weight of a person sitting on it without excessive collapsing while the larger interior region is specially designed to be softer for comfort conditions as required when a person sleeps on the mattress.
The border region is stiffened by linking the metal coils of adjacent pocketed springs across the border. More particularly, as best seen in Figures 1 and 2 of the drawings side by side pocketed springs in the border 3 are secured by metal staples 13. These staples are punched through the soft pocket to lock onto the metal coil of each pocketed spring. The staples are attached at opposite ends to adjacent springs sufficiently tightly to prevent the staples from releasing from the springs but not so tightly as to prevent some play between adjacent springs, i.e. each staple end is attached in a pivot like manner to its respective metal coil. The staples are a fixed length so that as any one of the springs is compressed so is an adjacent linked spring. However, because of the play allowed between the springs one spring will tend to compress before the next which provides a gradual transition between springs in the border and also between the border and the main sleeping or resting area of the mattress. This play also reduces stress on the staples substantially decreasing the likelihood that they might be damaged under load.
Referring specifically to Figure 2, the border 3 of the mattress is formed by the side edge border 3A and the end edge border 3B. In the embodiment shown, the staples 13 extend across rather than longitudinally of each border edge. However, additional staples could also be provided between side by side coils lengthwise of each border region to further enhance the strength or rigidity of the overall border.
Figure 5 of the drawings shows that the pocketed springs in the border 3 of the mattress are arranged as aligned rows, i.e. side by side pocketed springs are centrally aligned with one another. This is to be contrasted to the interior region in which the pocketed springs are nested in a honeycomb fashion.
The side by side spring configuration in the edge border makes it easy to mate the side edge with the end edge regions of the border because each region terminates with a flat end. In addition, it reduces the overall number of springs required in the border.
According to the specific set up shown in Figure 5, the side edge regions 3A of the mattress border are set up with two side by side linked pocketed springs while the end edge regions of the border 3B are set up with three side by side linked pocketed springs. However the border regions can either have more or fewer side by side springs depending upon the size of the mattress and the amount of reinforcement required.
In the embodiment of Figures 1 and 2, the border is further reinforced by means of metal edge wires 17 at the upper and lower sides of the mattress completely around the border. The outermost pocketed springs are secured by staples 14 to the wire edging 17.
Also provided to the top and bottom side of the mattress are a plurality of straps 15 which are also stapled to the edge wire. The entire internal construction of the mattress is then covered by covering layers 19 and 21 which are stapled at 23 as seen in Figure 2 of the drawings to the edge wire.
Figure 3 shows a slight modification to the mattress in which straps 15 are replaced by a plastic mesh 25 across the complete upper and lower surfaces of the mattress. In all other respects, the mattress shown in Figure 3 is identical to the mattress shown in Figures 1 and 2.
Figure 6 shows a further mattress generally indicated at 31 again employing a linked pocketed spring edge border generally indicated at 33. However, in this embodiment, the interior region generally indicated at 35 is made from a foam material rather than pocketed springs.
This exemplifies the fact that the linked spring edge border can be used around many types of different interior regions.
In addition to the feature of providing a gradual transition from the perimeter trim to the main rest area of the mattress, the use of linked pocketed springs in the border eliminates noticeable intermittent hard and soft areas around the border. Each pocketed spring has a relatively small diameter so that there are no large gaps between reinforcements in the border producing an edge trim which has a very consistent or uniform feeling around the perimeter of the mattress.
Mattress 31 has a further and very unique feature.
More specifically, the edge wire shown in the embodiments of Figures 1, 2 and 3 has been replaced by a flexible and preferably plastic mesh edging 39 to which the coils in the outermost springs in the border are attached. This edging, which may have the same construction as the spring covering mesh used on the upper and lower sides of the mattress, enables the mattress to be flexed to the extent that it can be bent upon itself as is shown at the mattress corner generally indicated at 41. This feature has substantial benefits when attempting to get a relatively large mattress through a small opening. Unlike a conventional mattress which has very limited deflection, mattress 31 can be bent to almost any configuration for clearing through the opening. However the edge border 33 provided by the side by side linked springs still provides more than adequate reinforcement around the mattress.
Figure 7 of the drawings shows a unique method of assembling a pocketed spring mattress. According to this method, the edge border is first established with the end and side regions of the border being secured to one another and then the interior region pocketed springs are fitted within the border. This is achieved by arranging a plurality of rows of pocketed springs in their honeycombed pattern outside of the edge border and then, from one side of the mattress, pushing the arranged rows as a single unit into the edge border. The very nature of the pocketed springs allows them to be compressed to fit in the area defined by the edge border and to then rebound outwardly against the edge border.
The above method is substantially more efficient than attempting to fit the rows of pocketed springs within the border on an individual basis. Further, this method eliminates the difficult procedure of attempting to find sufficient space for the last row or two within the interior region of the mattress.
It is to be noted that, although the description above refers specifically to a mattress, the construction of the present invention is equally applicable to different types of support structures such as sofa cushions and the like.
Although various preferred embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that variations may be made without departing from the spirit of the invention or the scope of the appended claims.
Claims (6)
1. A support member for receiving a resting body, said support member having a resilient internal construction formed by a large interior region bordered by a narrower edge region, said edge region comprising a plurality of side by side rows of pocketed springs each of said pocketed springs comprising a wire coil compressed in a pocket of soft material, said edge region being made more rigid than said interior region by coil link members which loosely link only to the springs in the edge region, in a direction thereacross for enhancing strength of the springs in the edge region of the support member.
2. A support member as claimed in Claim 1 wherein said plurality of rows of pocketed springs in said edge region includes an outer row of springs separated from said interior region of said internal construction by at least one further row of pocketed springs, said edge region including top and bottom edge wires connected by staples to the outer row of springs in said edge region.
3. A support member as claimed in Claim 2 having a gradual reduction of rigidity from said outer row of springs, across said at least one row of further springs to said interior region of said internal construction of said member.
4. A support member as claimed in Claim 1 wherein said edge region is completely free of rigid wires such that said support member is foldable upon itself.
5. A support member as claimed in Claim 1 wherein said plurality of rows of pocketed springs in said edge region includes an outer row of springs separated from said interior region of said internal construction by at least one further row of springs, said support member including upper and lower edging of plastic mesh material secured to the springs in the outer row of springs in the edge region of the internal construction of the member.
6. A support member as claimed in Claim 1 wherein said interior region is formed by rows of pocketed springs which are nested in a honeycomb pattern off centred relative to one another, the rows of springs in the edge region being arranged in a non honeycomb pattern centred relative to one another.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2234839 CA2234839C (en) | 1998-04-15 | 1998-04-15 | Mattress construction |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2234839 CA2234839C (en) | 1998-04-15 | 1998-04-15 | Mattress construction |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2234839A1 CA2234839A1 (en) | 1999-10-15 |
| CA2234839C true CA2234839C (en) | 2003-12-16 |
Family
ID=29275552
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2234839 Expired - Lifetime CA2234839C (en) | 1998-04-15 | 1998-04-15 | Mattress construction |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2234839C (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105747678A (en) * | 2014-12-15 | 2016-07-13 | 焦伽 | Hard-edge independent bagged spring mattress |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102008024529A1 (en) * | 2008-05-21 | 2009-11-26 | Agro Holding Gmbh | Spring core with edge reinforcement |
| IT202000032123A1 (en) * | 2020-12-23 | 2022-06-23 | Margot S R L | ARMCHAIR WITH IMPROVED COMFORT |
-
1998
- 1998-04-15 CA CA 2234839 patent/CA2234839C/en not_active Expired - Lifetime
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105747678A (en) * | 2014-12-15 | 2016-07-13 | 焦伽 | Hard-edge independent bagged spring mattress |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2234839A1 (en) | 1999-10-15 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKEX | Expiry |
Effective date: 20180416 |